82D1-9-X - mascottec.com
Contents
1. Suction Line Positioning DISGHARGE EINES edili n pia Siphoning s oerte EA e Rude upra i ees ValVves aee rernm e EE I ebat Bypass Lines eere eun AR RR eae a eia GROUNDING z nes Vogt tends et Sinton eid bate thee YE REUS VERAM OPERATION SECTION wie aco aca d dn na a a Robes e iod PRIMING QR MERERI AO el eee Pee ie ee IE RES STARTING xia ERU A ee i OPERATION Sela xe s ERE EE et Lines With a Bypass Lines Without a Bypass beakage ihre np tu Dre didtur A edt et eis Liquid Temperature And Overheating Strainer Check coe Yan wee ee Yee a RR x DN S ids Pump Vacuum Check SIOPPINGQ teni b E o ILL esL bi Cold Weather Preservation TROUBLESHOOTING SECTIOND PREVENTIVE MAINTENANCE PUMP MAINTENANCE AND REPAIR SECTIONE STANDARD PERFORMANCE CURVE PAGE I 1 PAGE A 1 PAGE B 1 PAGE B 1 PAGE B 1 PAGE 2 PAGE B 2 PAGE2. 2 The pump has not been used for a consider able length of time 3 The liquid in the pump casing has evapo rated Once the pump casing has been filled the pump will prime and reprime as necessary 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 or fill plug before operating the pump STARTING Consult the operations manual furnished with the engine Be sure the pump unit is properly grounded before operation See GROUNDING Section B 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 03873 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 th
3. creased suction lift discharge elevation and fric tion losses See the performance curve and notes on Page E 1 to be sure your overall 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 must be the rigid wall rein forced type to prevent collapse under suction Us ing piping couplings in suction lines is not recom mended Line Configuration Keep suction and discharge lines as straight as possible to minimize friction losses Make mini mum use of elbows and fittings which substan tially increase friction loss If elbows are necessary use the long radius type to minimize friction loss Connections to Pump Before tightening a connecting flange align it ex actly with the pump port Never pull a pipe line into INSTALLATION 80 SERIES 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 desi
4. Do not put the pump into service until appropriate action has been taken POSITIONING PUMP Lifting This pump is designed to be light weight and por table with a two man carry handle provided The total pump weight is approximately 60 pounds 27 kg not including accessories or engine fuel Cus tomer installed equipment such as suction and dis charge hoses must be removed before attempting to lift CAUTION The pump assembly can be seriously damaged if the cables or chains used to lift and move the unit are improperly wrapped around the pump PAGE B 2 80 SERIES Mounting Locate the pump in an accessible place as close as practical to the liquid being pumped Level mount ing is essential for proper operation The pump may have to be supported or shimmed to provide for level operation or to eliminate vibra tion If the pump has been mounted on a moveable base make certain the base is stationary by setting the brake and blocking the wheels before attempt ing to operate the pump To ensure sufficient lubrication and fuel supply to the engine do not position the pump and engine more than 15 off horizontal for continuous opera tion The pump and engine may be positioned up to 30 off horizontal for intermittent operation only however the engine manufacturer should be consulted for continuous operation at angles greater than 15 SUCTION AND DISCHARGE PIPING Pump performance is adversely effected by in
5. seal until the chamtered end seats firmly against the shaft shoulder Install the seal spring and spring centering washer 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 8 as previously removed and screw the impeller onto the shaft until tight A clearance of 010 to 020 inch 0 25 to 0 51 mm between the impeller and the intermediate is rec ommended for maximum pump efficiency Mea sure this clearance and add or remove impeller shims until the proper clearance is obtained Pump Casing Installation Figure 2 If the wear plate assembly 14 was removed for re placement secure the new wear ring to the pump casing using the attaching hardware 15 16 20 and 21 Replace the fiber washer 19 if badly worn or compressed Install the same thickness of pump casing gaskets 13 as previously removed and secure the pump MAINTENANCE amp REPAIR 03873 casing to the intermediate with the nuts 7 Do not fully tighten the nuts at this time A clearance of 008 to 015 inch 0 20 to 0 38 mm between the impeller and the wear plate is also rec ommended for maximum pump efficiency This clearance can be obtained by adding or removing gaskets in the pump casing gasket set until the im peller scrapes against the wear plate when the shaft is turned by hand After the impeller scrapes add approxima
6. EXCESSIVE NOISE PAGE D 2 Air leak in suction line Lining of suction hose collapsed Suction intake not submerged at proper level or sump too small Impeller or other wearing parts worn or damaged Impeller clogged Pump speed too slow Discharge head too high Suction lift 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 Cavitation in pump Pumping entrained air Pump or drive not securely mounted Impeller clogged or damaged Correct leak Replace suction hose Check installation and correct submergence as needed Replace worn or damaged parts Check that impeller is properly centered and rotates freely Free impeller of debris Check engine output consult en gine operation manual Install bypass line Measure lift w vacuum gauge Re duce lift and or friction losses in suction line Check pump vacuum Replace leaking or worn seal or gasket Check strainer and clean if neces Sary Check driver output check that sheaves or couplings are correctly sized Adjust discharge valve Dilute if possible Open discharge valve fully to in crease flow rate and run engine at maximum governed speed Clean valve Reduce suction lift and or friction losses in suction line Record vac uum and pre
7. How ever most petroleum products such as gasoline are more efficiently handled at ambient temperatures Do not use at high er operating temperatures PAGE E 10 If the intermediate was removed lay it on a flat sur face with the impeller side facing up Subassemble the O ring into the groove in the sta tionary seat and press this subassembly into the in termediate bore until it seats squarely against the shoulder Slide the assembled intermediate and stationary seat over the shaft and secure the inter mediate to the engine with the hardware 10 and 11 When installing the intermediate use caution not to damage the stationary seat on the shaft threads MAINTENANCE amp REPAIR 80 SERIES NOTE If the intermediate was not separated from the en gine during disassembly subassemble the O ring into the stationary seat and use a piece of plastic tubing to press the seat into the intermediate bore until fully seated The O D of the tubing should be approximately the same as the O D of the seal spring Lubricate the shaft sleeve with light oil then slide the rotating portion ofthe seal consisting of the ro tating element bellows and retainer onto the lubri cated shaft sleeve until the face of the rotating ele ment is just flush with the chamfered end of the sleeve Slide the subassembled sleeve and rotating por tion of the seal onto the shaft until the seal faces contact Continue to push the sleeve through the
8. primed and at operation speed Shut off the pump The vacuum gauge reading will immediately drop proportionate to static suction lift and should then stabilize If the vacuum reading falls off rapidly after stabilization an air leak exists Before checking for the source of the leak check the point of installation of the vacuum gauge STOPPING Never halt the flow of liquid suddenly If the liquid being pumped is stopped abruptly damaging OPERATION 80 SERIES 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 CAUTION If the application involves a high discharge head gradually close the discharge throttling valve before stopping the pump OPERATION 03873 After stopping the pump remove the spark plug wire to ensure that the pump will remain inopera tive Cold Weather Preservation Since the application of this pump is limited to pe troleum products normal freezing conditions should not damage the pump However during ex tremely severe conditions care should be exer cized during start up especially if the pump has been idle for more than a few hours PAGE C 80 SERIES 03873 TROUBLESHOOTING SECTION D Review all SAFETY information in Section A WARNING Before attempting to open or service the pump 1 F
9. 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 antici pate and provide detailed instructions and precautions for every situation that might occur during maintenance of the unit Therefore it is the responsibility of the owner maintenance personnel to ensure that only safe established main tenance procedures are used and that any procedures not addressed in this manual are performed only after estab lishing that neither personal safety nor pump integrity are compromised by such practices A WARNING The engine used in this pump is not standard It has been modified for use in handling gasoline and other petroleum products in a well ventilated non flam mable atmosphere free of combustible hazards It cannot be further modified without affecting performance and safe ty factors The shield and spark arrest ing modifications must be inspected and maintained regularly while the unit is in use Refer to the manual accompa nying the engine before attempting to start the engine A WARNING Before attempting to open or service the pump SAFETY 1 Familiarize yourself with this man ual 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 opening any covers plates o
10. throttling valve in a suction line A check valve in the discharge line is normally rec ommended but it is not necessary in low dis charge head applications With high discharge heads it is recommended that a throttling valve and a system check valve be in 4 stalled in the discharge line to protect the pump from excessive shock pressure and reverse rota tion when it is stopped CAUTION If the application involves a high discharge head gradually close the discharge throttling valve before stopping the pump Bypass Lines If a system check valve is used due to high dis charge head it may be necessary to vent trapped air from the top of the pump during the priming process This may be accomplished by installing a bypass line from the top of the pump back to the source of liquid The end of the bypass line must be submerged The line must be large enough to pre vent clogging but not so large as to affect pump discharge capacity INSTALLATION 80 SERIES 03873 GROUNDING To eliminate electrostatic build up by the liquid be CAUTI O N ing pumped the unit must be grounded by attach ing the ground wire assembly to a ground rod In Inspect and test the ground wire assembly stall the ground rod in accordance with the Nation for conductivity replace broken or frayed al Electrical Codes and all local codes Be sure the wire before resuming operation clamp or fastener has made a tight electric
11. 232 ENGINE GOVERNOR SETTING 3600 RPM M PSI FT SHUT OFF PERFORMANCE CURVE vorute 6846C curve 820 9 2 444 50 T IMPELLER 2912F MODEL 820 9 SIZE 2X wp pia 497 454130 SP GR 80 RPM__NOTED 120 367 40 3 5 2800 32 bes INTERMITTENT DUTY PERFORMANCE 35 100 E 3600 WITH GOVERNOR BY PASSED NO ENGINE 28 WARRANTY AT THESE SPEEDS 90 30 AL 80 24 2 MAXIMUM CONTINOUS m rer PERFORMANCE 60 20 EN 16 50 124 5 40 30 g 10 20 a io STATICHE25 20 2150105 LIFT 7 6 6 1M t4 6MH3M HH1 5M Os cal Lon E E AE E sen PER MINUTE X 10 n LITRES o N m wo N o o N m GR PER SECOND A E et PUMPS CUBIC METRES PER HOUR NNN NM MM TTI 7 393 STANDARD PERFORMANCE FOR PUMP MODEL 82D1 9 X Based on 70 F 21 C clear water or corrected to 80 specific gravity at sea level with minimu
12. A 17090 1 Be CHECKVAIVE ASSY ISSE 9 SEAL SLEEVE 31411 267 17020 1 26 5 VALVE WEIGHT 1354 15160 1 10 HEX HD CAPSCREW B0503 1 28 15991 4 27 K CHECK VALVE IS i LOO RWASHER 405 19991 54 28 LARGE VALVE WEIGHT 19B 100010 1 12 INTERMEDIATE 6732A 190107 1 29 MACH SCREW 0403 17090 1 13 CASING GASKET SET 504G 18000 1 30 LOCKWASHER 104 17090 1 14 WEAR PLATE ASSY 2643A 15990 1 31 SUCTION STICKER 6588AB 1 15 LOCKWASHER 04 15991 1 32 FILL PLUG ASSY 48271 062 1 16 HEX NUT D04 15991 1 33 DISCHARGE STICKER 6588BJ mem c INDICATES PARTS RECOMMENDED FOR STOCK MAINTENANCE amp REPAIR 5 03873 80 SERIES SECTION DRAWING 17 18 23 SECTION ROTATED AS SHOWN FOR CLARITY 1 2 3 4 22 19 20 21 E A i Q OE mt gt pa a 16 5 Oe 9 10 RUN Ln 88 i IR j a 11 0 12 Figure 2 Pump Modification Assembly PAGE E 6 MAINTENANCE amp REPAIR 80 SERIES ITEM NO ONOaARWN N lm O 0 N DU
13. ABCEG OM 03873 OE01 January 14 1993 Rev C 08 01 03 INSTALLATION OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST GR GORMAN RUPP 80 SERIES PUMP MODEL 82D1 9 X COURTESY OF MASCOTT EQUIPMENT COMPANY Portland Seattle Tri Cities www masco ttec com 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 n SAFETY SECTION A eee INSTALLATION SECTION 25222052454 da swe awa ie Pump DIM NSIONS edge Oe dee peeked Aenea ieee ened PREINSTALLATION INSPECTION POSITIONING coer dada ae Se pepe ava EA ira peace cod dent eat DI aper Eu SUCTION AND DISCHARGE PIPING Materials i iaia EE idu raid natalia en S Line Connections to PUMP evita rigen ve needed dE ERG ede an x GAUGES d AES AA qc IRA A ier d atate SUCTION LINES 3 05 rr A it pta ER Ee EE RIOS mm ie COVER ent en ees eae eek UU ERE siii x CU eden pe t dte ERE MY oa Suction Lines In
14. B 2 PAGE B 2 PAGE B 2 PAGE B 2 PAGE B 2 PAGE B 3 PAGE B 3 PAGE B 3 PAGE B 3 PAGE B 3 PAGE B 3 PAGE B 3 PAGE B 4 PAGE 4 4 PAGE B 4 PAGE 5 1 PAGE 1 1 PAGE 1 PAGE 1 2 2 PAGE C 2 PAGE C 2 PAGE C 2 PAGE C 2 PAGE C 3 PAGE D 1 PAGE D 3 PAGE E 1 PAGE E 1 TABLE OF CONTENTS continued PARTS LISTS Model vorra CE REM RI vere E PAGE E 3 Pump End ASSy i sss nc A O A A PAGE E 5 Engine Modification Assembly PAGE E 7 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E 8 Suction Check Valve PAGE E 8 Pump Casing Removal PAGE E 9 Impeller Removal 2 2 22 eee eee PAGE E 9 Seal Removal and PAGE E 9 Seal Reassembly and Installation PAGE E 9 Impeller Installation And PAGE E 11 Pump Casing Installation PAGE E 11 Suction Check Valve Installation PAGE E 11 Fin
15. KRWNH O 21 22 23 PART NAME PARTS LIST BRIGGS amp STRATTON 3 5 H P ENGINE AIR CLEANER MOUNTING ASSY AIR CLEANER T TYPE LOCKWASHER SUPPORT SHIELD SPARK PLUG SPARK PLUG SHIELD KIT TERMINAL RUN DECAL TOGGLE SWITCH ON OFF DECAL GROUND WIRE ASSY PIPE NIPPLE PIPE COUPLING MUFFLER MUFFLER SHIELD SHIELD A SPARK PLATE POP RIVET SPACER HEX HD CAPSCREW FLAT WASHER RD HD MACH SCREW U L METAL CAL MAINTENANCE amp REPAIR Pump Modification Assembly PART NUMBER 29112 501 29334 031 29334 084 AK 10 34851 169 51809 51810 52067 38816 034 51961 38815 009 47311 052 08 AE08 29334 202 34851 162 38816 146 11703D 31411 252 0509 KO5 10 01 1 25 38811 383 03873 CODE QTY 15079 15079 15120 13990 15070 15991 15991 15991 PO N N A H H H H do do dd HS do dd SF S yy A PAGE E 7 03873 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Review all SAFETY information in Section A Follow the instructions on all tags label and de cals attached to the pump This pump requires little service due to its rugged minimum maintenance design However if it be comes necessary to inspect or replace the wearing parts follow these instructions which are keyed to the sectional views Figures 1 2 and 3 and the ac companying parts lists This manual will alert personnel to known proce dures which require special attention to t
16. NUT GROUND WIRE ASSY ENGINE MOD ASSY SEE FIGURE 3 ROLL CAGE W BASE RUBBER FOOT MOUNTING KIT FLANGED HEX NUT HEX HD CAPSCREW RUBBER MOUNTING FOOT HEX HD CAPSCREW FLAT WASHER FLANGED HEX NUT HEX HD CAPSCREW FLAT WASHER FLANGED HEX NUT HAND CARRY DECAL FLAT WASHER OIL CAUTION LABEL WHEEL KIT INDICATES PARTS RECOMMENDED FOR STOCK MAINTENANCE amp REPAIR PART NUMBER 82D1 9 X 34165 002 0402 1 2 K04 404 D04 13830 GRP41 17 41583 316 48152 607 21765 312 0506 24631 401 0506 5 21765 312 B0604 06 21765 314 2613FT 06 45 011 GRP30 52 03873 CODE QTY 2 py Aaa PAGE E 3 03873 80 SERIES SECTION DRAWING SEAL AREA DETAIL 19 18 17 16 15 14 La dei 18 10 Figure 2 Pump End Assembly 82D1 9 X PAGE E 4 MAINTENANCE amp REPAIR 80 SERIES 03873 PARTS LIST Pump End Assembly 82D1 9 X ITEM PART NAME PART ITEM PART NAME PART QTY NO NUMBER NO NUMBER CODE 1 PUMP CASING 6846C 13040 1 17 NAME PLATE 38812 041 13990 1 2 X IMPELLER 2912F 13040 1 18 DRIVE SCREW BM 04 03 17000 4 3 SEAL ASSY ESE 19 CASINGDRAINPLUG 15079 1 ie SEE DOW Eds 20 HEXHDCAPSCREW B0414 15991 1 5 SPRING CTR WASHER 12658 17100 1 21 FIBER WASHER REOS 18040 1 SUD Cube COE o 7 HEX NUT DO6 15991 4 24 SUCTION FLANGE 1361 10010 1 8 IMP ADJ SHIM SET 513
17. al Pump Assembly PAGE E 11 LUBRICATION 3 525235 A LIRE RUE RU E E ME epist PAGE E 12 Seal Assembly eo RR ee Ee RE Ee pe pra wed ston LOLA PAGE E 12 ENgirie LL othe eine PAGE E 12 ENGINE MODIFICATIONS PAGE E 12 80 SERIES 03873 INTRODUCTION This Installation Operation and Maintenance manual is designed to help you achieve the best performance and longest life from your Gorman Rupp pump Thank You for purchasing a Gorman Rupp pump Read this manual carefully to learn how to safely install and operate your pump Failure to do so could result in personal injury or damage to the pump This pump is a 80 Series semi open impeller self priming centrifugal model with a suction check valve It is close coupled to a single cylinder Briggs and Stratton gasoline engine incorporating such safety features as splash guards grounding wire and spark arresting muffler The pump is designed for pumping water gaso line or other petroleum products in a non flam mable atmosphere The basic material of construc tion aluminum with an aluminum 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 distribu
18. al con nection with the rod INSTALLATION PAGE B 5 80 SERIES 03873 OPERATION SECTION 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 handle water gasoline and other petroleum products in a non flammable atmosphere Do not attempt to pump corrosive materials or any liquids which may damage the pump or endanger personnel as a result of pump failure WARNING If this pump is used with volatile and or flammable liquids be certain proper safety practices are followed before op erating or servicing the pump Provide adequate ventilation prohibit smoking wear Static resistant clothing and shoes Clean up all fuel spills immedi ately after occurrence 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 not prime when dry Extended operation of a dry pump will destroy the seal assembly Add liquid to the pump casing when 1 The pump is being put into service for the first time
19. amiliarize yourself with this manual 2 Shut down the engine and take pre cautions to ensure that the pump will remain inoperative 3 Allow the pump to completely cool if overheated 4 Check the temperature before open ing any covers plates or plugs 5 Close the suction and discharge valves 6 Vent the pump slowly and cautiously 7 Drain the pump TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP FAILS TO PRIME TROUBLESHOOTING Not enough liquid in casing Suction check valve contaminated or damaged Air leak in suction line Product vapor pressure too high Lining of suction hose collapsed Leaking or worn seal or pump gasket Suction check valve or foot valve clogged or binding Pump speed too slow Discharge head too high Suction lift too high Strainer clogged Add liquid to casing See PRIMING Clean or replace check valve Correct leak Cool pump and product suction line Replace suction hose Check pump vacuum Replace leaking or worn seal or gasket Clean valve Check engine output consult en gine operation manual Install bypass line Measure lift w vacuum gauge Re duce lift and or friction losses in suction line Check strainer and clean if neces PAGE D 1 03873 80 SERIES TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE cont PUMP REQUIRES TOO MUCH POWER PUMP CLOGS FREQUENTLY
20. curing the pump casing to the roll cage 9 Figure 2 Remove the nuts 7 securing the pump casing to the intermediate Separate the parts by pulling the casing straight away from the intermediate If shims have been used under the mounting feet to level the pump casing tie and tag these shims Remove the casing gasket set 13 Record the thickness of the gaskets for future reference Clean the mating surfaces of the intermediate and pump casing Inspect the wear plate assembly 14 and replace if badly scored or worn To remove the wear plate as sembly disengage the hardware 15 16 20 and 21 and pull the wear plate from the pump casing Impeller Removal Figure 2 To loosen the impeller 2 tap the vanes of the im peller in a counterclockwise direction when facing the impeller with a block of wood or a soft faced mallet Unscrew the impeller from the engine crankshaft Use caution when removing the impel ler tension on the seal spring will be released as the impeller is unscrewed Slide the impeller adjusting shims 8 off the shaft Tie and tag the shims or measure and record their thickness for ease of reassembly MAINTENANCE amp REPAIR 03873 Seal Removal and Disassembly Figures 2 and 4 Carefully remove the spring centering washer 5 and seal spring Slide the shaft sleeve 9 and rotat ing portion of the seal off the shaft as a unit Apply oil to the sleeve and work it up under the bel
21. e 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 After the pump has been primed partially close the discharge line throttling valve in order to fill the line slowly and guard against excessive shock pres sure which could damage pipe ends gaskets sprinkler heads and any other fixtures connected to the line When the discharge line is completely filled adjust the throttling valve to the required flow rate Leakage No leakage should be visible at pump mating sur faces or at pump connections or fittings Keep all line connections and fittings tight to maintain maxi mum pump efficiency Liquid Temperature And Overheating The maximum liquid temperature for this pump is 160 F 71 C Do not apply it at a higher operating temperature Overheating can occur if operated with the valves in the suction or discharge lines closed Operating against closed valves could bring the liquid to a boil build pressure and cause the pump to rup ture or explode If overheating occurs stop the pump and allow it to 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 wi
22. eparated by a dis tance equal to at least 3 times the diameter of the suction pipe Suction Line Positioning The depth of submergence of the suction line is critical to efficient pump operation Figure 2 shows recommended minimum submergence vs veloc ity PAGE B 3 03873 pipe submergence required be reduced by installing a standard pipe increaser fitting at the end of the suction line The larger opening size will 80 SERIES reduce the inlet velocity Calculate the required submergence using the following formula based on the increased opening size area or diameter SUBMERGENCE x 0 1 2 245678 9101112191415 16 VII VSI OS QUAN G PM x 321 G PM x 4085 VELOCITY FT SEC REA FLOW M MIN x21 22 D2 FLOW 2 5 VELOCITY M SEC DIAMETER IN AREA IN M Figure 2 Recommended Minimum Suction Line Submergence vs Velocity DISCHARGE LINES Siphoning Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a si phon breaker is used in the line Otherwise a si phoning action causing damage to the pump could result Valves If a throttling valve is desired in the discharge line use a valve as large as the largest pipe to minimize friction losses Never install a
23. for and tighten loose attaching hard ware Since gaskets tend to shrink after dry PAGE B 1 POWERED BY 6 97 BRIGGS amp STRATTON 91232 2 NPT DISCHARGE 177 01 SPARK ARRESTED ENGINE 3 5 HP 2 NPT SUCTON lt 2 25 u 2 57 21 ET ON ESA 0 EA X 18 13 14 25 460 2 362 0 APPROX PS APPROX N 25 lo PA 6 38 q 162 0 Se Cu APPROX Sp 1 y Y Lj Y 6 12 10 88 63 4 2 69 155 41 276 4 68 51 adi 2 00 5 00 DES SENOS 304 8 127 0 18 00 558 8 457 2 MILLIMETERS 03873 ing check for loose hardware at mating sur faces c Carefully read all tags decals and markings on the pump assembly and perform all duties indicated d Check levels and lubricate as necessary Re fer to LUBRICATION in the MAINTENANCE AND REPAIR section of this manual and per form duties as instructed e If the pump and engine have been stored for more than 12 months some of the compo nents or lubricants may have exceeded their maximum shelf life These must be inspected or replaced to ensure maximum pump serv ice f Check all special engine modifications such as spark arresting muffler fuel guard and han dle assembly for loose mounting hardware 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
24. hose which could damage equipment and to those which could be dangerous to personnel However this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit Therefore it is the responsibility of the owner maintenance per sonnel to ensure that only safe established shop 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 Before attempting to service the pump remove the spark plug wire to ensure that it will remain inopera tive Close all valves in the suction and discharge lines For engine disassembly and repair consult the lit erature supplied with the engine or contact your local Briggs and Stratton engine representative WARNING The engine used in this pump is not standard It has been modified for use in handling gasoline and other petroleum products in a well ventilated non flam mable atmosphere free of combustible hazards It cannot be further modified without affecting performance and safe ty factors The shield and spark arrest ing modifications must be inspected and maintained regularly while the unit PAGE E 8 80 SERIES is in use Refer to the manual accompa nying the engine before attempting to start the engine WARNING If this pump is used with volatile and or flammable liq
25. ired Engine Consult the literature supplied with the engine or contact your local Briggs and Stratton engine rep resentative PAGE E 12 80 SERIES ENGINE MODIFICATIONS The engine used on this pump is not a standard commercial model It has been specially modified by Gorman Rupp for pumping gasoline and other petroleum products in a well ventilated non flam mable atmosphere free of combustible hazards The ground strap shield and spark arresting modi fications to the engine must be maintained when ever the unit is serviced or replaced otherwise fire or explosion could occur Further modifications to the engine may not be made without jeopardizing the integrity of these safety features MAINTENANCE amp REPAIR July 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 of such part as shall appear to us upon inspection at such point to have been defective in material or workmanship This Warranty does not obligate The Gorman Rupp Company to bear the cost of labor or transportation charges in connection with replacement or repair of defective parts nor shall it apply to a pump u
26. lows Slide the rotating portion of the seal off the sleeve Slide a pair of stiff wires with hooked ends along the shaft and use them to pull the stationary seat from the intermediate bore NOTE An alternate method of removing the stationary seat is to remove the hardware 10 and 11 and separate the intermediate 12 from the engine Use a wood en dowel or other suitable tool to press the station ary seat from the back side of the intermediate bore If no further disassembly is required see Seal Reassembly and Installation Seal Reassembly and Installation Figures 2 and 4 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 engine shaft will have to be replaced 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 solvent contain ers The seal is not normally reused because wear pat terns on the finished faces cannot be realigned during reassembly This could result in premature failure If necessary to reuse old seal in an emer gency carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly PAGE E 9 03873 Handle the seal pa
27. m suction lift Since pump installations are seldom identical your performance may be different due to such factors as viscosity specific gravity eleva tion temperature and impeller trim If your pump serial number is followed by an your pump is NOT a standard production model Contact the 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 PAGE E 1 03873 80 SERIES SECTION DRAWING 17 18 19 21 14 15 16 13 11 12 J 10 Figure 1 Pump Model 82D1 9 X PAGE E 2 MAINTENANCE amp REPAIR 80 SERIES ITEM NO SHOWN OPTIONAL PARTS LIST 82D1 9 X Pump Model From S N 1010740 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 PART NAME PUMP END ASSY ENGINE SHIELD HEX HD CAPSCREW FLAT WASHER LOCKWASHER HEX
28. manual before restarting the pump A WARNING 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 PAGE A 2 80 SERIES outside These fumes contain carbon monoxide a deadly gas that is color less tasteless and odorless A WARNING Fuel used by internal combustion en gines presents an extreme explosion and fire hazard Make certain that all fuel lines are securely connected and free of leaks Never refuel a hot or run ning engine Avoid overfilling the fuel tank always use the correct type of fuel A WARNING If this pump is used with volatile and or flammable liquids be certain proper safety practices are followed before op erating or servicing the pump Provide adequate ventilation prohibit smoking wear static resistant clothing and shoes Clean up all fuel spills immedi ately after occurrence A 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 SAFETY 80 SERIES 03873 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 pum
29. p and piping Most of the information pertains to a standard static lift application where the pump is positioned above the free level of liquid to be pumped If installed 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 be sure to limit the incoming pressure to 50 of the maximum permissible operating pressure as shown on the pump performance curve For further assistance contact your Gorman Rupp distributor or the Gorman Rupp Company Pump Dimensions See Figure 1 for the approximate physical dimen sions of this pump OUTLINE DRAWING Figure 1 Pump Model 8201 9 PREINSTALLATION INSPECTION The pump assembly was inspected and tested be fore shipment from the factory Before installation inspect the pump for damage which may have oc curred during shipment Check as follows INSTALLATION a Inspect the pump and engine for cracks dents damaged threads and other obvious damage b Check
30. pection of wearing parts at 250 hours will give insight into the wear rate for your particular application Subsequent inspec tions should be performed at the intervals shown on the chart below Critical applications should be inspected more frequently Preventive Maintenance Schedule Service Interval Daily Weekly Monthly Semi Annually Annuall 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 Front Impeller Clearance Wear Plate Rear Impeller Clearance Seal Plate Check Valve Pressure Relief Valve If So Equipped Pump and Driver Alignment Shaft Deflection Bearings Bearing Housing Piping Driver Lubrication See Mfgr s Literature Legend 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 80 SERIES 03873 PUMP MAINTENANCE AND REPAIR SECTION E MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE TOTAL HEAD BRIGGS amp STRATTON 91
31. pon 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 electrical 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 event shall The Gorman Rupp Company be liable for con sequential damages or contingent liabilities arising out of the fail ure of any Gorman Rupp pump or parts thereof to 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 COURTESY OF MASCOTT EQUIPMENT COMPANY Portland Seattle Tri Cities www mascottec com Copyright by the Gorman Rupp Company
32. r plugs 5 Close the suction and discharge valves 6 Vent the pump slowly and cau tiously 7 Drain the pump A WARNING This pump is designed to handle water gasoline and other petroleum products in a non flammable atmosphere Do not attempt to pump corrosive materials or any liquids which may damage the pump or endanger personnel as a result of pump failure A WARNING After the pump has been installed make certain that the pump and all piping or hose connections are tight properly supported and secure before operation A WARNING Do not operate the pump against a closed discharge valve for long periods of time If operated against a closed dis charge valve pump components will deteriorate and the liquid could come to a boil build pressure and cause the pump casing to rupture or explode PAGE A 1 03873 A 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 gaged to be ejected with great force al low the pump to cool before servicing A WARNING Overheated pumps can cause severe burns and injuries If overheating of the pump occurs 1 Stop the pump immediately 2 Ventilate the area 3 Allow the pump to completely cool 4 Check the temperature before opening covers plates gauges or plugs 5 Vent the pump slowly and cau tiously 6 Refer to instructions in this
33. red for pumps that are not tapped drill and tap the suction and discharge lines not less than 18 inches 457 2 mm from the suction and discharge ports and install the lines Installation closer to the pump may result in erratic readings SUCTION LINES To avoid air pockets which could affect pump prim ing the suction line must be as short and direct as possible When operation involves a suction lift the line must always slope upward to the pump from the source of the liquid being pumped if the line slopes down to the pump at any point along the suction run air pockets will be created Fittings Suction lines should be the same size as the pump inlet If reducers are used in suction lines they should be the eccentric type and should be in stalled with the flat part of the reducers uppermost to avoid creating air pockets Valves are not nor mally used in suction lines but if a valve is used install it with the stem horizontal to avoid air pock ets 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 INSTALLATION 03873 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 pas
34. rts with extreme care to prevent damage Be careful not to contaminate precision finished faces even fingerprints on the faces can shorten seal life If necessary clean the faces with a non oil based solvent and a clean lint free tissue Wipe lightly in a concentric pattern to avoid scratching the faces Inspect the seal components for wear scoring grooves and other damage that might cause leak age If any components are worn replace the com plete seal never mix old and new seal parts 80 SERIES If a replacement seal is being used remove it from the container and inspect the precision finished faces to ensure that they are free of any foreign matter To ease installation of the seal lubricate the bel lows and O rings with water or a very small amount of light lubricating oil and apply a drop of light lubricating oil on the finished faces Assemble the seal as follows see Figure 4 SPRING PRING CENTERIN RETAINER INTERMEDIATE S ROTATING ELEMENT O RING N ENGINE CRANKSHAFT Ar SLEEVE IMPELLER C SHIMS A M STATIONARY DRIVE BAND BELLOWS SEAT Figure 4 25271 841 Seal Assembly CAUTION This seal is not designed for operation at temperatures above 160 F 71 C
35. sage of solids larger than the solids handling capability of the pump This pump is designed to handle up to 5 8 inch 15 9 mm diameter spherical solids Sealing Since even a slight leak will affect priming head and capacity especially when operating with a high suction lift all connections in the suction line should be sealed with pipe dope to ensure an 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 at a distance equal to 1 1 2 times the diame ter of the suction line If there is a liquid flow from an open pipe into the sump the flow should be kept away from the suc tion inlet because the inflow will carry air down into the sump and air entering the suction line will re duce pump efficiency If it is necessary to position inflow close to the suc tion inlet install a baffle between the inflow and the suction inlet at a distance 1 1 2 times the diameter of the suction pipe The baffle will allow entrained air to escape from the liquid before it is drawn into the suction inlet If two suction lines are installed in a single sump the flow paths may interact reducing the efficiency of one or both pumps To avoid this position the suction inlets so that they are s
36. ssure 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 80 SERIES PREVENTIVE MAINTENANCE Since pump applications are seldom identical and pump wear is directly affected by such things as the abrasive qualities pressure and temperature of the liquid being pumped this section is intended only to provide general recommendations and practices for preventive maintenance Regardless of the application however following a routine pre ventive maintenance schedule will help assure trouble free performance and long life from your Gorman Rupp pump For specific questions con cerning your application contact your Gorman Rupp distributor or the Gorman Rupp Company Record keeping is an essential component of a good preventive maintenance program Changes in suction and discharge gauge readings if so 03873 equipped between regularly scheduled inspec tions can indicate problems that can be corrected before system damage or catastrophic failure oc curs The appearance of wearing parts should also be documented at each inspection for comparison as well Also if records indicate that a certain part such as the seal fails at approximately the same duty cycle the part can be checked and replaced before failure occurs reducing unscheduled down time For new applications a first ins
37. tely 008 inch 0 20 mm of gaskets After the face clearance has been set tighten the nuts 7 securing the pump casing to the intermedi ate See Figure 1 and secure the pump casing to the roll cage 9 with the hardware 17 18 and 19 Be sure to reinstall any leveling shims used under the mounting feet of the pump casing Suction Check Valve Installation Figure 2 Inspect the check valve components and replace as required Subassemble the check valve weights 26 and 28 and check valve 27 with the hardware 29 and 30 Position the check valve assembly 25 in the suc tion port with the large weight 28 toward the in side of the pump Install the suction flange 24 and secure with the nuts 23 Check the operation of the 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 roll cage Install the suction and discharge lines and open all valves Make certain that all piping connections are tight properly supported and secure Be sure the engine have been properly lubricated see the literature supplied with the engine Fillthe pump casing with clean liquid Reinstall the fill plug and tighten it Refer to OPERATION Section C before putting the pump back into service PAGE E 11 03873 LUBRICATION Seal Assembly The seal is lubricated by the medium being pumped No additional lubrication is requ
38. thin the pump can cause parts being disen PAGE C 2 80 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 must be limited to 50 of the maximum permissible operating pressure shown on the pump performance curve Pump Vacuum Check NOTE Petroleum products are very sensitive to changes in temperature Warmer temperatures elevate the product vapor pressure resulting in low vacuum readings Do not mistake temperature problems for faulty pump installation or performance With the pump inoperative install a vacuum gauge in the system using pipe dope on the threads Block the suction line and start the pump At oper ating speed the pump should pull a vacuum of 20 inches 508 0 mm or more of mercury If it does not check for air leaks in the seal gasket or dis charge valve Open the suction line and read the vacuum gauge with the pump
39. tor or write The Gorman Rupp Company P O Box 1217 Mansfield Ohio 44901 1217 Phone 419 755 1011 or Gorman Rupp of Canada Limited 70 Burwell Road St Thomas Ontario N5P 3R7 Phone 519 631 2870 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 Immediate hazards which WILL result in severe personal injury or death These instructions describe the procedure re quired and the injury which will result from failure to follow the procedure 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 INTRODUCTION CAUTION Hazards or unsafe practices which COULD result in minor personal injury or product or property damage These instructions describe the requirements and the possi ble damage which could result from failure to follow the procedure NOTE Instructions to aid in installation operation and maintenance or which clarify a procedure PAGE 1 80 SERIES 03873 SAFETY SECTION A This information applies to 80 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
40. uids be certain proper safety practices are followed before op erating or servicing the pump Provide adequate ventilation prohibit smoking wear Static resistant clothing shoes Clean up all fuel spills immedi ately after occurrence WARNING Before attempting to open or service the pump 1 Familiarize yourself with this man ual 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 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 nuts 23 securing the suc tion flange 24 to the pump casing 1 Pull the check valve assembly 25 from the suction port MAINTENANCE 8 REPAIR 80 SERIES Remove the hardware 29 and 30 securing the check valve weights 26 and 28 to the check valve 27 If no further disassembly is required see Suction Check Valve Installation Pump Casing Removal Figure 1 To service the impeller or seal assembly discon nect the discharge piping Remove the hardware 17 18 and 19 se
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