OM-05465-01
Contents
1. wi pega aay a usada LUBRIGATION asics pa CREARE Oe ERA Ca A Oe Caan Seal Assembly i ea ep ai Engine PAGE E PAGE E PAGE E PAGE E PAGE E PAGE E PAGE E PAGE E PAGE E PAGE E PAGE E PAGE E PAGE E PAGE E PAGE E PAGE E 35 6 6 6 6 7 7 7 8 9 9 9 9 9 9 9 10 SERIES OM 05465 INTRODUCTION Thank You for purchasing a Gorman Rupp pump Read this manual carefully to learn how to safely install and operate your pump Failure to do so could result in personal injury or damage to the pump This Installation Operation and Maintenance manual is designed to help you achieve the best performance and longest life from your Gorman Rupp pump This pump is a 10 Series semi open impeller self priming centrifugal model with a suction check valve It is close coupled to a four cycle air cooled Yanmar diesel engine model LABEE DP The pump is designed for handling most non volatile non flammable liquids containing specified entrained solids The basic material of construction for wetted parts is gray iron with ductile iron impeller and steel wearing parts If there are any questions regarding the pump or its application which are not covered in this man ual or in other literature accompanying this unit please contact your Gorman Rupp distributor or write The Gorman Rupp Company P O Box 1217 Mansfield Ohio 44901 1217 Phone2. OM 05465 tance equal to atleast 3 times the diameter ofthe suction pipe Suction Line Positioning The depth of submergence of the suction line is critical to efficient pump operation Figure 2 shows recommended minimum submergence vs veloc ity 10 SERIES NOTE The pipe submergence required may be reduced by installing a standard pipe increaser fitting atthe end ofthe 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 SUBMERGENCE MIN ala 0 2 245678 9 H 12 13 t4 1s 16 QUAN G PM x 321 G PM x 4085 VELOCITY FT SEC REA FLOW M MIN x21 22 D FLOW M SEC VELOCITY DIAMETER IN MV AREA IN M Figure 2 Recommended Minimum Suction Line Submergence vs Velocity DISCHARGE LINES Siphoning Do notterminate the discharge line ata level lower than that of the liquid being pumped unless a si phon breaker is used in the line Otherwise a si phoning action causing damage to the pump could result Valves If a throttling valve is desired in the discharge line use a valve as large as the largestpipe to minimize friction losses Never install a throttling valve in a suction line PAGE B 4 A check va
3. ITEM PART MAT L NO PART NAME NUMBER CODE QTY 1 PUMP PARTS ONLY 12D1 L48EE 1 2 PRIMING STICKER 6588AH 1 3 DISCHARGE STICKER 6588 1 4 STREETELBOW RS32 11999 1 5 YANMAR L48EE ENGINE 29239 041 1 6 WARNING DECAL 2613FE 1 7 ROLLOVER BASE 41583 316 24150 1 8 HAND CARRY DECAL 2613FT 2 9 RUBBER FOOT MOUNTING KIT 48152 607 1 10 MOUNTING 24631 401 4 11 FLANGED HEX NUT 21765 312 4 12 HEX HD CAPSCREW B0506 15991 4 13 FLAT WASHER 06 15991 2 14 FLANGED HEX NUT 21765 314 2 15 HEX HD CAPSCREW B0606 15991 2 16 SPACER 31141 029 13000 2 17 FLAT WASHER 06 15991 2 18 HEX HD CAPSCREW B0607 15991 2 19 FLANGED HEX NUT 21765 314 2 20 SUCTION STICKER 6588AG 1 SHOWN CAUTION OIL LABEL 45 011 1 Above Serial Numbers Do Not Apply To Pumps Made In Canada Items shipped loose with the pump MAINTENANCE amp REPAIR PAGE E 3 OM 05465 10 SERIES SECTION DRAWING SEAL AREA DETAIL 56 323 31 Sp EN Oe 50 29 28 21 26 25 DAE 21 18 20 19 13 12 11 1f 16 15 14 Figure 2 12D1 L48EE Pump Parts Only PAGE E 4 MAINTENANCE amp REPAIR 10 SERIES ITEM NO NOT SHOWN PARTS LIST 12D1 L48EE Pump Parts Only PART NAME PUMP CASING IMPELLER SEAL ASSY IMP ADJ SHIM SE
4. 419 755 1011 or Gorman Rupp of Canada Limited 70 Burwell Road St Thomas Ontario N5P 3R7 Phone 519 631 2870 As described on the following page this manual will alert personnel to known procedures which re quire special attention to those which could dam age equipment and to those which could be dan gerous to personnel However this manual cannot possibly anticipate and provide detailed precau tions for every situation that might occur during maintenance ofthe unit Therefore itis the respon sibility ofthe owner maintenance personnel to en INTRODUCTION sure that only safe established maintenance pro cedures are used and thatany procedures notad dressed in this manualare performed only afteres tablishing that neither personal safety nor pump in tegrity are compromised by such practices The following are used to alert maintenance per sonnel to procedures which require special atten tion to those which could damage equipment and to those which could be dangerous to personnel Immediate hazards which WILL resultin severe personal injury or death These instructions describe the procedure re quired and the injury which will result from failure to follow the procedure WARNING 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 CAUTION Haz
5. Bearings Bearing Housing Piping Driver Lubrication See Mfgr s Literature Legend Inspect Clean Adjust Repair or Replace as Necessary C Clean 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 10 SERIES OM 05465 PUMP MAINTENANCE AND REPAIR SECTION E MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE TOTAL HEAD YANMAR DIESEL ENGINE L48EE GOVERNOR ET SETTING 3600 RPM e SHUT OFF PERFORMANCE CURVE 1 19 L30 2 MMI DIA MAX SPHERICAL SOLIDS VOLUTE _38224 205 curve 12D L48EE 1 44 14 IMPELLER 38615 066 120 48 Pe SIZE 2 2 4 97 40 56 1130 SP GR 10 RPM 3600 36 52120 48 10 324 44 MAXIMUM CONTINUOUS 100 PERFORMANCE 28 40 go 24 36 ao 32 204 28 24 55 16 28 50 12
6. Riad th acta tend de reete ruere deri Sealing ER Suction Lines In 5 Suction Line Positioning DISCHARGE LINES 27 eed As pert braun ed eed rs SPIO MING ms kutu n pease Bypass Lines cds onis atat ek eder adis e dde dabat adr 8 OPERATION SECTION C PRIMING i ROV ee STARTING cec oe oed eoe ace cce doe OPERATION dtd on Ca ual ede Or era Lines With a Bypass sei ee E CHEER ERE ee ud Lines Without a Bypass leakage ber BERE EOE EA eee ETE Liquid Temperature And Overheating Strainer Check e Pup eae ey enc Pump VACUUM CHECK onec Le reo e IER et n att e ONSE Cold Weather Preservation TROUBLESHOOTING SECTION D PREVENTIVE vhi eR ob x Res capa e u eka iS PUMP MAINTENANCE AND REPAIR SECTIONE 5 STANDARD PERFORMANCE CURVE PARTS LISTS Pump Model s Ga edt
7. STATIONARY ROTATING SEAT ELEMENT Figure 3 25285 853 Seal Assembly CAUTION This seal is not designed for operation at temperatures above 160 F 71 C Do not use at higher operating temperatures Press the stationary subassembly into the interme diate until fully seated After installation wipe the sealing face lightly in a concentric pattern with a clean lint free tissue Position the intermediate 8 and stationary subas sembly over the shaft and againstthe engine Se cure the intermediate to the engine with the hard ware 9 and 10 Slide the rotating subassembly consisting of the element bellows and retainer over the lubricated shaft sleeve until the rotating element is just flush with the chamfered end of the sleeve Slide the PAGE E 8 sleeve over the shaft until the sealing faces con tact Continue to press the shaftsleeve through the seal assembly until it seats squarely against the shaft shoulder Install the seal spring and spring retainer 5 Impeller Installation And Adjustment Figure 2 Inspect the impeller and replace it if cracked or badly worn Install the same thickness of impeller shims 4 as previously removed and screw the im peller onto the shaft until tight A clearance of 015 to 040 inch 0 38 to 1 02 mm between the impeller and the intermediate is nec essary for maximum pump efficiency Measure this clearance and add or remove impeller shims until this clearance i
8. a two man carry han dle The total pump weight is approximately 108 pounds 49 kg not including accessories or en gine fuel Customer installed equipment such as suction hose with foot valve mustbe removed be fore attempting to lift Mounting Locate the pump in an accessible place as close as practical to the liquid being pumped Level mount ing is essential for proper operation PAGE B 2 10 SERIES The pump may have to be supported or shimmed to provide for level operation or to eliminate vibra tion If the pump has been mounted on a moveable base make certain the base is stationary by setting the brake and blocking the wheels before attempt ing to operate the pump To ensure sufficient lubrication and fuel supply to the engine do not position the pump and engine more than 15 off horizontal for continuous opera tion The pump and engine may be positioned up to 30 off horizontal for intermittent operation only however the engine manufacturer should be consulted for continuous operation at angles greater than 15 Clearance When positioning the pump allow a minimum clearance of 18 inches 457 2 mm in front of the back cover to permit removal of the cover and easy access to the pump interior SUCTION AND DISCHARGE PIPING Pump performance is adversely effected by in creased suction lift discharge elevation and fric tion losses See the performance curve and notes on Page E 1 to be sure your overal
9. information pertains to a standard static liftapplication where the pump is positioned above the free level of liquid to be pumped Ifinstalled in a flooded suction application where the liquid is supplied to the pump under pressure some of the information such as mounting line configuration and priming must be tailored to the specific application Since the pressure supplied to the pump is critical to performance and safety besureto limitthe incoming pressure to 5096 ofthe maximum permissible operating pressure as shown on the pump performance curve see Sec tion E Page 1 Forfurther assistance contact your Gorman Rupp distributor or the Gorman Rupp Company Pump Dimensions See Figure 1 for the approximate physical dimen sions of this pump OUTLINE DRAWING 18 00 125 41 RECOMMENDED FOR REMOVAL OF BACK COVER PLATE 5 75 146 0 REQUIRED FOR REMOVAL OF BACK COVER PLATE f DISCHARGE 2 00 11 5 NPT SUCTION 2 00 11 5 NPT YANMAR DIESEL 41583 316 18 00 457 21 ksi DIMENSIONS INCHES 5 00 96 127 01 24 41 12 00 304 81 22 00 558 81 MILLIMETERS POWERED BY YANMAR L48EE DP DIESEL ENGINE Figure 1 Pump Model 12D1 L48EE PREINSTALLATION INSPECTION The pump assembly was inspected and tested be fore shipment from the factory Before installati
10. the Gorman Rupp Company Record keeping is an essential componentofa 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 indi cate thata certain part such as the seal fails atapproximately the same duty cycle the partcan 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 Daily Weekly Monthly Semi Annually Annually General Condition Temperature Unusual Noises or Vibrations Cracks Leaks Loose Hardware Etc Pump Performance Gauges Speed Flow Bearing Lubrication Seal Lubrication And Packing Adjustment If So Equipped V Belts If So Equipped Air Release Valve Plunger Rod If So Equipped C Front Impeller Clearance Wear Plate Rear Impeller Clearance Seal Plate Check Valve Pressure Relief Valve If So Equipped Pump and Driver Alignment Shaft Deflection
11. 4 16 40 gl 12 30 8120 STATICH 25 20 15 10 5 4 LIFT 6M 6 1M 4 6M 3 1 4 1 5 U S GALLONS am AQ Un 016 po QN om WD 5m Or PER MINUTE X 10 GR gees o e N m wo o az N Sus ox m B m xo Ron STANDARD PERFORMANCE FOR PUMP MODEL 12D1 L48EE 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 dif ferent due to such factors as viscosity specific gravity elevation temperature and impeller trim If your pump serial number is followed by an N your pump is NOT a standard production model Contactthe Gorman Rupp Company to verify per formance or part numbers MAINTENANCE amp REPAIR WARNING Never tamper with the governor to gain more power The governor establishes safe operating limits that should not be exceeded The maximum continuous operating speed for this pump is 3600 RPM PAGEE 1 OM 05465 10 SERIES SECTION DRAWING YANMAR DI 12 11 10 5 Figure 1 Pump Model 12D1 L48EE PAGE E 2 MAINTENANCE amp REPAIR 10 SERIES OM 05465 PARTS LIST Pump Model 12D1 L48EE From S N 1255241 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
12. ACEGU OM 05465 OEO01 November 13 2002 INSTALLATION OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST 6 GORMAN RUPP PUMPS 10 SERIES PUMP MODEL 1201 148 THE GORMAN RUPP COMPANY e MANSFIELD OHIO GORMAN RUPP OF CANADA LIMITED ST THOMAS ONTARIO CANADA Printed in U S A Copyright by the Gorman Rupp Company The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm TABLE OF CONTENTS INTRODUCTION orsa eer nam ru rrr n rea One ti SAFETY SECTION A INSTALLATION SECTION B Pump DIMENSIONS pv rer PC du en CR GRIS ER RR DDR PREINSTALLATION INSPECTION POSITIONING PUMP erect te ean tet aa UR Mounting Side s aqhaq ka ahay S ancl a Clearance s yr tps yy ei vies es SUCTION AND DISCHARGE PIPING Materials usca Up Mies ean UNE Lu en nei eee Line Configuration x rro nte t eer dta Connections t PUMP icon pner bx Sa teed Ae Ee Reps kayka oe tette d ede leat aeta SUCTION LINES eren DUREE C Fittings a essen
13. T SPRING RETAINER SHAFT SLEEVE STREET ELBOW INTERMEDIATE HEX HD CAPSCREW LOCKWASHER STUD HEX NUT CASING GASKET SET WEAR PLATE LOCKWASHER HEX NUT CASING DRAIN PLUG BACK COVER PLATE WARNING PLATE COVER PLATE DRIVE SCREW STUD FLAT WASHER WING NUT NAME PLATE DRIVE SCREW COVER PLATE GSKT STUD HEX NUT SUCTION FLANGE CHECK VALVE ASSY VALVE WEIGHT VALVE WEIGHT LOCKWASHER RD HD MACH SCREW CHECK VALVE FILL PLUG ASSY STRAINER INDICATES PARTS RECOMMENDED FOR STOCK MAINTENANCE amp REPAIR PART NUMBER 38224 205 38615 066 25285 853 513A 31161 041 31411 267 RS32 6732A 22645 130 21171 510 C0605 1 2 D06 504G 46451 018 104 D04 P06 42111 919 261 NOT AVAILABLE 404 03 C0808 KE08 08 38818 021 404 03 123696 0606 D06 38645 024 46413 028 19B 1354 104 0403 38671 630 48271 063 90260 05465 MAT L CODE QTY 13040 11060 17090 17000 17020 11999 10010 15991 15991 18000 24150 15991 15991 15079 13990 17000 15991 15991 15991 13990 17000 20000 15991 15991 13040 10010 15160 17090 17090 19070 24001 R mu Ea pa NIIS NJ NJ N A HIS H3 NJ N HIS 5 S S US HI HI HB EP m m Hd PH PAGEE 5 OM 05465 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Review all SAFETY information in Section A Follow the instructions on all tags labels and decals att
14. ached to the pump This pump requires little service due to its rugged minimum maintenance design However if it be comes necessary to inspectorreplace 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 re quire special attention to those which could dam age equipment and to those which could be dan gerous to personnel However this manual cannot possibly anticipate and provide detailed precau tions for every situation that might occur during maintenance ofthe unit Therefore itis the respon sibility ofthe owner maintenance personnel to en sure that only safe established maintenance pro cedures are used and thatany procedures notad dressed in this manualare performed only afteres tablishing that neither personal safety nor pump in tegrity are compromised by such practices Before attempting to service the pump shutdown the engine and take precautions 7to ensure that it will remain inoperative Close all valves in the suc tion and discharge lines For engine disassembly and repair consultthe lit erature supplied with the engine or contact your local Yanmar engine representative WARNING Before attempting to open orservice the pump 1 Familiarize yourself with this man ual 2 Shut down the engine and take precautions to e
15. aid Wee dec Eee ati vlt ane PAGEI 1 PAGEA 1 1 PAGEB 1 PAGEB 1 PAGE B 2 PAGE B 2 PAGE B 2 PAGE B 2 PAGE B 2 PAGE B 2 PAGEB 2 PAGEB 3 PAGEB 3 PAGE B 3 PAGE B 3 PAGE B 3 PAGE B 3 PAGE B 3 PAGEB 4 PAGEB 4 PAGEB 4 PAGEB 4 PAGEB 5 C 1 PAGE C 1 PAGE C 1 PAGE C 1 PAGE C 1 PAGE C 2 PAGE C 2 PAGE C 2 PAGE C 2 PAGE C 2 PAGE C 2 PAGE C 3 PAGE D 1 PAGED 3 1 PAGE E 1 3 TABLE OF CONTENTS continued PUMP ENJ ASSY amana eene Dent s PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Suction Check Valve Back over Removal ea eddies eoe nih hand bet aaa Pump Casing Removal serere ence ees Impeller Removal eR Se ea RR ROMS Seal Removal and Seal Reassembly and Installation Impeller Installation And Pump Casing 22 2222222222 2 2 Back Cover Installation Suction Check Valve Installation Final Pump Assembly cce teret i
16. ards orunsafe practices which COULD result in minor personal injury or product or property damage These instructions describe the requirements and the possi ble damage which could result from failure to follow the procedure NOTE Instructions to aid in installation operation and maintenance or which clarify a procedure PAGE I 1 10 SERIES OM 05465 SAFETY SECTION A This information applies to 10 Series en gine driven pumps Refer to the manual accompanying the engine before at tempting to begin operation This manual will alert personnel to known procedures which require spe cial attention to those which could damage equipment and to those which could be dangerous to personnel How ever this manual cannot possibly pro vide detailed instructions and precau tions for each specific application orfor every situation that might occur during maintenance of the unit Therefore it is the responsibility of the owner installer and or maintenance personnel to en sure that applications and or mainte nance procedures notaddressed in this manual are performed only after estab lishing that neither personal safety nor pump integrity are compromised by such applications or procedures Before attempting to open orservice the pump 1 Familiarize yourself with this man ual 2 Shut down the engine and take precautions to ensure that the pump will remain inoperative 3 Allow the pump to completely cool if ove
17. eezing conditions drain the pump to OPERATION OM 05465 prevent damage from freezing Also clean outany solids by flushing with a hose Operate the pump for approximately one minute this will remove any remaining liquid that could freeze the pump rotat ing parts If the pump will be idle for more than a few hours or if it has been pumping liquids con taining a large amount of solids drain the pump and flush itthoroughly with clean water To prevent large solids from clogging the drain port and pre venting the pump from completely draining insert a rod or stiff wire in the drain port and agitate the liquid during the draining process Clean out any remaining solids by flushing with a hose PAGE C 3 10 SERIES OM 05465 TROUBLESHOOTING SECTION D Review all SAFETY information in Section A WARNING Before attempting to open orservice the pump 1 Familiarize yourself with this manual 2 Shut down the engine and discon nect the spark plug wire to ensure that the pump will remain inopera tive 3 Allow the pump to completely cool if overheated 4 Check the temperature before open ing any covers plates or plugs 5 Close the suction and discharge valves 6 Ventthe pump slowly and cautiously 7 Drain the pump Not enough liquid in casing Suction check valve contaminated or damaged Air leak in suction line Lining of suction hose collapsed Leaking or worn seal or pump
18. es gauges or plugs 5 Vent the pump slowly and cau tiously 6 Referto instructions in this manual before restarting the pump Do not remove plates covers gauges pipe plugs or fittings from an over heated pump Vapor pressure within the pump can cause parts being disen gaged to be ejected with great force Al low the pump to cool before servicing Do not operate an internal combustion engine in an explosive atmosphere When operating internal combustion engines in an enclosed area make cer tain that exhaust fumes are piped to the outside These fumes contain carbon monoxide a deadly gas that is color less tasteless and odorless PAGE A 2 10 SERIES Fuel used by internal combustion en gines presents an extreme explosion and fire hazard Make certain that all fuel lines are securely connected and free of leaks Never refuel a hot or run ning engine Avoid overfilling the fuel tank Always use the correcttype of fuel Never tamper with the governor to gain more power The governor establishes safe operating limits that should not be exceeded The maximum continuous operating speed for this pump is 3600 RPM SAFETY 10 SERIES OM 05465 INSTALLATION SECTION B Review all SAFETY information in Section A Since pump installations are seldom identical this section offers only general recommendations and practices required to inspect position and ar range the pump and piping Most of the
19. eve To remove the stationary seat and O ring remove the hardware 9 and 10 and slide the stationary portion ofthe seal and intermediate 8 off the shaft asaunit Position the intermediate on a flatsurface with the impeller side down Use thumb pressure to press the stationary seatand O ring from the in termediate If no further disassembly is required see Seal Reassembly and Installation MAINTENANCE amp REPAIR OM 05465 Seal Reassembly and Installation Figures 2 and 3 Inspect the engine crankshaft for damage Small scratches or nicks may be removed with a fine file or emery cloth If excessive wear exists the shaft will have to be replaced in the engine refer to the engine service manual Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent WARNING Most cleaning solvents are toxic and flammable Use them only in a well ven tilated area free from excessive heat sparks and flame Read and follow all precautions printed on solventcontain ers Inspect the engine shaft for damage Small scratches or nicks may be removed with a fine file or emery cloth If excessive wear exists the shaft will have to be replaced referto the engine service manual The seal is not normally reused because wear pat terns on the finished faces cannot be realigned during reassembly This could result in premature failure If necessary to reuse an old sealin an emer gency carefully wash all me
20. gasket Suction check valve or foot valve clogged or binding Suction lift or discharge head too high Strainer clogged TROUBLESHOOTING Add liquid to casing See PRIMING Clean or replace check valve Correct leak Replace suction hose Check pump vacuum Replace leaking or worn seal or gasket Clean valve Check piping installation and install bypass line if needed See INSTAL LATION Check strainer and clean if neces Sary PAGE D OM 05465 TROUBLE PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE PUMP REQUIRES TOO MUCH POWER PUMP CLOGS FREQUENTLY EXCESSIVE NOISE PAGE D 2 10 SERIES POSSIBLE CAUSE PROBABLE REMEDY Air leak in suction line Suction intake not submerged at proper level or sump too small Lining of suction hose collapsed Impeller or other wearing parts worn or damaged Impeller clogged Pump speed too slow Suction lift or discharge head too high Leaking or worn seal or pump gasket Strainer clogged Pump speed too high Discharge head too low Liquid solution too thick Discharge flow too slow Suction check valve or foot valve clogged or binding Discharge line clogged or restricted hose kinked Cavitation in pump Pumping entrained air Pump or drive notsecurely mounted Impeller clogged or damaged Correct leak Check installation and correct submergence as needed Replace suction hose Replace wor
21. ing Removal Figure 1 To service the impeller or seal assembly discon nect the discharge piping Remove the hardware MAINTENANCE amp REPAIR 10 SERIES 16 17 18 and 19 securing the pump casing to the rollover base 7 Figure 2 Support the pump casing using a suitable hoist and sling Remove the nuts 12 and separate the pump casing 1 from the intermediate 8 by pull ing the casing straight away For ease of reas sembly tie and tag any leveling shims used under the casing mounting feet Remove the casing gaskets 13 Clean the mating surfaces of the intermediate and pump casing Impeller Removal Figure 2 To loosen the impeller 2 tap the vanes ofthe im pellerin a counterclockwise direction when facing the impeller with a block of wood or a soft faced mallet Be careful not to damage the vane Un screw the impellerand replace itif cracked orbadly worn Use caution when removing the impeller tension on the seal spring will be released as the impeller is unscrewed Slide the impeller adjusting shims 4 offthe impel ler shaft Tie and tag the shims or measure and re cord their thickness for ease of reassembly Seal Removal and Disassembly Figure 2 and 3 Remove the spring retainer 5 and seal spring Slide shaft sleeve 6 and rotating portion of the seal off the shaft as a unit Apply oil to the sleeve and work it under the bellows Slide the rotating portion of the seal off the sle
22. l application al lows 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 mustbe the rigid wall rein forced type to prevent collapse under suction Us ing piping couplings in suction lines is not recom mended Line Configuration Keep suction and discharge lines as straight as possible to minimize friction losses Make mini mum use of elbows and fittings which substan tially increase friction loss If elbows are necessary use the long radius type to minimize friction loss INSTALLATION 10 SERIES Connections to Pump Before tightening a connecting flange align it ex actly with the pump port Never pull a pipe line into place by tightening the flange bolts and or cou plings Lines near the pump must be independently sup ported to avoid strain on the pump which could cause excessive vibration decreased bearing life and increased shaft and seal wear If hose type lines are used they should have adequate support to secure them when filled with liquid and under pressure Gauges Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges If these gauges are desired for pumps that are not tapped drill and tap the suction and discharge lines not less than 18 inches 457 2 mm from the suction and di
23. lve in the discharge line is normally rec ommended but it is not necessary in low dis charge head applications With high discharge heads itis recommended that a throttling valve and a system check valve be in stalled in the discharge line to protect the pump from excessive shock pressure and reverse rota tion when itis stopped CAUTION Ifthe application involves a high discharge head gradually close the discharge throttling valve before stopping the pump INSTALLATION 10 SERIES Bypass Lines If a system check valve is used due to high dis charge head it may be necessary to vent trapped air from the top of the pump during the priming process This may be accomplished by installing a INSTALLATION OM 05465 bypass line from the top ofthe pump back to the source ofliquid The end ofthe bypass line mustbe submerged The line mustbe large enough to pre vent clogging but not so large as to affect pump discharge capacity PAGE B 5 10 SERIES OM 05465 OPERATION SECTION C Review all SAFETY information in Section A Follow the instructions on all tags labels and decals attached to the pump WARNING This pump is designed to pump most non volatile non flammable liquids containing specified entrained solids Do not attempt to pump volatile corro sive or flammable liquids which may damage the pump or endanger person nel as a result of pump failure WARNING Never tamper with the gove
24. n Refer to OPERATION Section C before putting the pump back into service LUBRICATION Seal Assembly The seal assembly is lubricated by the medium be ing pumped and no additional lubrication is re quired Engine Consult the literature supplied with the engine or contact your local Yanmar engine representative PAGE E 9 J uly 18 1979 WARRANTY Pumping units manufactured by The Gorman Rupp Company Mansfield Ohio are guaranteed to be free from defects in mate rial and workmanship for one year from date of shipment from factory in Mansfield Ohio The obligation under this Warranty statutory or otherwise is limited to replacement or repair at Mansfield Ohio factory or at a point designated by Gorman Rupp ofsuch partas shall appearto us upon inspection atsuch point to have been defective in material or workmanship This Warranty does notobligate The Gorman Rupp Company to bear the cost of labor or transportation charges in connection with replacement or repair of defective parts nor shall itapply to a pump upon which repairs or alterations have been made un less authorized by Gorman Rupp No warranty is made in respect to engines motors or trade ac cessories such being subject to warranties of their respective manufacturers In Submersible Pumps pump and motor are integral and Sub mersibles are warranted as a unit Since motor is subject to an important degree upon quality and performance of elect
25. n or damaged parts Check that impeller is properly centered and rotates freely Free impeller of debris Check engine output consult en gine operation manual Check piping installation and install bypass line if needed See INSTAL LATION Check pump vacuum Replace leaking or worn seal or gasket Check strainer and clean if neces Sary Check engine output Adjust discharge valve Dilute if possible Open discharge valve fully to in crease flow rate and run engine at maximum governed speed Clean valve Check discharge lines straighten hose Reduce suction lift and or friction losses in suction line Record vac uum and pressure gauge readings and consult local representative or factory Locate and eliminate source of air bubble Secure mounting hardware Clean out debris replace damaged parts TROUBLESHOOTING 10 SERIES OM 05465 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 ofthe 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 Gorman Rupp distributor or
26. nsure that the pump will remain inoperative 3 Allow the pump to completely cool if overheated PAGE E 6 10 SERIES 4 Check the temperature before opening any covers plates or plugs 5 Close the suction and discharge valves 6 Vent the pump slowly and cau tiously 7 Drain the pump Suction Check Valve Disassembly Figure 2 Before attempting to service the pump remove the pump casing drain plug 19 and drain the pump Clean and reinstall the drain plug To service the suction check valve remove the suc tion piping Remove the hex nuts 29 securing the suction flange 30 to the pump casing 1 Pull the check valve assembly 31 from the suction port Inspect the check valve assembly for wear or dam age Remove the hardware 34 and 35 securing the check valve weights 32 and 33 to the check valve 36 Replace parts as required If no further disassembly is required see Suction Check Valve Installation Back Cover Removal Figure 2 The wear plate 14 can be serviced after the back cover assembly 18 has been removed Remove the wing nuts and washers 23 and 24 se curing the back cover to the casing Pull the back cover and assembled wear plate from the pump casing Inspect the wear plate for excessive wear or scoring If replacement is required remove the hardware 15 and 16 securing itto the back cover Remove the cover plate gasket 27 and clean the mating surfaces Pump Cas
27. on inspect the pump for damage which may have oc curred during shipment Check as follows INSTALLATION a Inspect the pump and engine for cracks dents damaged threads and other obvious damage b Check for and tighten loose attaching hard ware Since gaskets tend to shrink after dry PAGE B 1 OM 05465 ing check for loose hardware at mating sur faces c Carefully read all tags decals and markings on pump assembly and perform all duties indicated d Check levels and lubricate as necessary Re fer to LUBRICATION in the MAINTENANCE AND REPAIR section ofthis manual and per form duties as instructed e Ifthe pump and engine have been stored for more than 12 months some of the compo nents or lubricants may have exceeded their maximum shelflife These mustbe inspected or replaced to ensure maximum pump serv ice f The rubber mounting kitand discharge elbow see the Parts List pages E 3 and E 5 were shipped loose with the pump Refer to Figure 1 page E 2 and install the parts as shown If the maximum shelf life has been exceeded or if anything appears to be abnormal contact your Gorman Rupp distributor or the factory to deter mine the repair or updating policy Do not putthe pump into service until appropriate action has been taken POSITIONING PUMP Lifting This pump is designed to be lightweight and porta ble The pump is protected by the wrap around roll cage which also serves as
28. or fill plug before operating the pump STARTING Consult the operations manual furnished with the engine OPERATION Lines With a Bypass Close the discharge throttling valve if so equipped so that the pump will not have to prime against the weight of the liquid in the discharge line Air from the suction line will be discharged through the bypass line back to the wet well during the priming cycle When the pump is fully primed and liquid is flowing steadily from the bypass line PAGE C 1 OM 05465 open the discharge throttling valve Liquid will then continue to circulate through the bypass line while the pump is in operation Lines Without a Bypass Open all valves in the discharge line and start the engine Priming is indicated by a positive reading on the discharge pressure gauge or by a quieter operation The pump may not prime immediately because the suction line must first fill with liquid If the pump fails to prime within five minutes stop it and check the suction line for leaks Afterthe pump has been primed partially close the discharge line throttling valve in order to fill the line slowly and guard against excessive shock pres sure which could damage pipe ends gaskets sprinkler heads and any other fixtures connected to the line When the discharge line is completely filled adjustthe throttling valve to the required flow rate Leakage No leakage should be visible at pump mating sur faces or a
29. rheated 4 Check the temperature before opening any covers plates or plugs 5 Close the suction and discharge valves 6 Vent the pump slowly and cau tiously 7 Drain the pump SAFETY WARNING This pump is designed to handle most non volatile non flammable liquids containing specified entrained solids Do not attempt to pump volatile corro sive or flammable liquids which may damage the pump or endanger person nel as a result of pump failure WARNING Use lifting and moving equipment in good repair and with adequate capacity to preventinjuries to personnel or dam age to equipment Suction and dis charge hoses and piping must be re moved from the pump before lifting WARNING Afterthe pump has been installed make certain that the pump and all piping or hose connections are tight properly supported and secure before operation WARNING Do not operate the pump against a closed discharge valve forlong periods of time If operated againsta closed dis charge valve pump components will deteriorate and the liquid could come to a boil build pressure and cause the pump casing to rupture or explode WARNING Overheated pumps can cause severe burns and injuries If overheating of the pump occurs 1 Stop the pump immediately ji PAGE A 1 OM 05465 2 Ventilate the area 3 Allow the pump completely to cool 4 Check the temperature before opening covers plat
30. rical controls unit warranty is valid only when controls have been specified and provided by Gorman Rupp No express implied or statutory warranty other than herein set forth is made or authorized to be made by Gorman Rupp In no eventshall The Gorman Rupp Company be liable for con sequential damages orcontingentliabilities arising outofthe fail ure ofany Gorman Rupp pump or parts thereofto operate prop erly THE GORMAN RUPP COMPANY Mansfield Ohio NOTE In Canada all above references to The Gorman Rupp Company Mansfield Ohio is understood to mean Gorman Rupp of Canada Limited St Thomas Ontario THE GORMAN RUPP COMPANY OHIO GORMAN RUPP OF CANADA LIMITED e ST THOMAS ONTARIO CANADA printed in U S A Copyright by the Gorman Rupp Company
31. rnor to gain more power The governor establishes safe operating limits that should not be exceeded The maximum continuous operating speed for this pump is 3600 RPM PRIMING Install the pump and piping as described in IN STALLATION Make sure that the piping connec tions are tight and that the pump is securely mounted Check that the pump is properly lubri cated see LUBRICATION in MAINTENANCE AND REPAIR This pump is self priming but the pump should never be operated unless there is liquid in the pump casing CAUTION Never operate this pump unless there is liquid in the pump casing The pump will OPERATION notprime when dry Extended operation of a dry pump will destroy the seal assembly Add liquid to the pump casing when 1 The pump is being put into service for the first time 2 The pump has notbeen used fora consider able length of time 3 The liquid in the pump casing has evapo rated Once the pump casing has been filled the pump will prime and reprime as necessary WARNING After filling the pump casing reinstall and tighten the fill plug Do not attempt to operate the pump unless all connect ing piping is securely installed Other wise liquid in the pump forced out un der pressure could cause injury to per sonnel To fill the pump remove the pump casing fill cover or fill plug in the top of the casing and add clean liquid until the casing is filled Replace the fill cover
32. s reached MAINTENANCE amp REPAIR 10 SERIES Pump Casing Installation Figure 2 Install the same thickness of pump casing gaskets 13 as previously removed and secure the pump casing 1 to the intermediate 8 with the nuts 12 Do not fully tighten the nuts at this time A clearance of 010 to 020 inch 0 25 to 0 51 mm between the impeller and the wear plate is also rec ommended for maximum pump efficiency This clearance must be set after installing the back cov erby adding orremoving pump casing gaskets un tilthe impellerscrapes againstthe wear plate when the shaftis turned After the impeller scrapes add approximately 010 inch 0 25 mm of gaskets After the face clearance has been set tighten the nuts 12 securing the pump casing to the interme diate See Figure 1 and secure the pump casing to the base 7 with the hardware 16 17 18 and 19 Be sure to reinstall any leveling shims used underthe mounting feet of the pump casing Back Cover Installation Figure 2 Inspect the wear plate 14 and replace it if badly worn orgrooved Carefully center the wear plate on the back cover 20 and secure itwith the hardware 15 and 16 The wear plate must be concentric to prevent binding when the back cover is installed Clean any scale or debris from the back cover shoulder and pump casing which might prevent a good seal NOTE Apply a film of Never Seez or equivalent com pound on the back cover sho
33. scharge ports and install the lines Installation closerto the pump may result in erratic readings SUCTION LINES To avoid air pockets which could affect pump prim ing the suction line mustbe as shortand directas 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 The maximum vertical suction lift for this pump is 25 ft 7 6 m Itis not designed to be operated ata 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 in stalled with the flat part ofthe reducers uppermost to avoid creating air pockets Valves are not nor mally used in suction lines but if a valve is used install it with the stem horizontal to avoid air pock ets INSTALLATION OM 05465 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
34. t pump connections or fittings Keep all line connections and fittings tightto maintain maxi mum pump efficiency Liquid Temperature And Overheating The maximum liquid temperature for this pump is 110 F 43 C Do notapply itata higher operating temperature Overheating can occur if operated with the valves in the suction or discharge lines closed Operating against closed valves could bring the liquid to a boil build pressure and cause the pump to rup ture or explode If overheating occurs stop the pump and allow itto cool before servicing it Refill the pump casing with cool liquid WARNING Do not remove plates covers gauges pipe plugs or fittings from an over heated pump Vapor pressure within the pump can cause parts being disen PAGE C 2 10 SERIES gaged to be ejected with great force Al low the pump to cool before servicing Strainer Check If a suction strainer has been shipped with the pump or installed by the user check the strainer regularly and clean it as necessary The strainer should also be checked if pump flow rate begins to drop If a vacuum suction gauge has been in stalled monitor and record the readings regularly to detect strainer blockage Never introduce air or steam pressure into the pump casing or piping to remove a blockage This could result in personal injury or damage to the equipment If backflushing is absolutely neces sary liquid pressure mustbe limited to 5096 of
35. tallic 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 pattem to avoid scratching the faces Inspect the seal components for wear scoring grooves and other damage that might cause leak age Clean and polish the shaft sleeve or replace it ifthere are nicks or cuts on either end If any com ponents 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 PAGEE 7 OM 05465 faces to ensure that they are free of any foreign matter To ease installation ofthe seal lubricate the O ring RETAINER SPRING SPRING RETAINER 10 SERIES and shaft sleeve with water or a very small amount ofoil and apply a drop oflight lubricating oil on the finished faces Assemble the seal as follows see Figure 3 INTERMEDIATE IMPELLER 2 BELLOWS IMPELLER SHAFT SHAFT SLEEVE IMPELLER SHIMS 2 g DRIVE BAND
36. the maximum permissible operating pressure shown on the pump performance curve See Section E Page 1 Pump Vacuum Check With the pump inoperative installa vacuum gauge in the system using pipe dope on the threads Block the suction line and startthe pump Atoper ating speed the pump should pull a vacuum of 20 inches 508 mm or more of mercury If it does not check for airleaks in the seal gasket ordischarge valve Open the suction line and read the vacuum gauge with the pump primed and at operation speed Shutoffthe pump The vacuum gauge reading will immediately drop proportionate to static suction lift and should then stabilize 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 Never halt the flow of liquid suddenly If the liquid being pumped is stopped abruptly damaging shock waves can be transmitted to the pump and piping system Close all connecting valves slowly On engine driven pumps reduce the throttle speed slowly and allow the engine to idle briefly be fore stopping OPERATION 10 SERIES CAUTION Ifthe application involves a high discharge head gradually close the discharge throttling valve before stopping the pump After stopping the pump remove the spark plug wire to ensure that the pump will remain inopera tive Cold Weather Preservation In below fr
37. the solids handling capability of the pump This pump is designed to handle up to 1 3 16 inch 30 mm diameter spherical solids Sealing Since even a slight leak will affect priming head and capacity especially when operating with a high suction lift all connections in the suction line should be sealed with pipe dope to ensure an air tight seal Follow the sealant manufacturer s rec ommendations when selecting and applying the pipe dope The pipe dope should be compatible with the liquid being pumped Suction Lines In Sumps If a single suction line is installed in a sump it should be positioned away from the wall of the sump ata distance equalto 1 1 2 times the diame ter of the suction line If there is a liquid flow from an open pipe into the sump the flow should be kept away from the suc tion inlet because the inflow will carry air down into the sump and air entering the suction line will re duce pump efficiency If itis necessary to position inflow close to the suc tion inlet install a baffle between the inflow and the suction inlet at a distance 1 1 2 times the diameter of the suction pipe The baffle will allow entrained air to escape from the liquid before itis drawn into the suction inlet If two suction lines are installed in a single sump the flow paths may interact reducing the efficiency of one or both pumps To avoid this position the suction inlets so that they are separated by a dis PAGE B 3
38. ulder or any surface which contacts the pump casing to ease future dis assembly and to reduce rust and scale build up Replace the back cover gasket 27 and slide the back cover assembly 18 into the pump casing Be sure the wear plate does not bind against the pump casing MAINTENANCE amp REPAIR OM 05465 Secure the back cover assembly using the hard ware 23 and 24 Do not over tighten the wing nuts they should be just tight enough to ensure a good seal atthe back cover shoulder Suction Check Valve Installation Figure 2 Inspectthe check valve components and replace as required Assemble the check valve weights 32 and 33 to each side ofthe check valve 36 and se cure with the hardware 34 and 35 Position the check valve assembly 31 in the suc tion port with the large weighttoward the impeller and the small weighttoward the suction flange In stall the suction flange 30 and secure it with the nuts 29 Check the operation ofthe check valve to ensure proper seating and free movement Final Pump Assembly Figure 1 Be sure the pump and engine are securely mounted to the base Install the suction and discharge lines and open all valves Make certain thatall piping connections are tight properly supported and secure Be sure the pump and engine have been properly lubricated see LUBRICATION Remove the fill plug 37 and fill the pump casing with clean liquid Reinstall the fill plug and tighte
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