82D1EX13-X
Contents
1. Ces teni be e o BL A eL bi Cold Weather Preservation TROUBLESHOOTING SECTION D 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 PAGEB 2 PAGE 2 PAGE B 2 PAGE 2 PAGE 2 PAGE B 3 PAGE B 3 PAGE B 3 PAGE B 3 PAGE B 3 PAGE B 3 PAGE B 3 PAGEB 4 PAGE 4 PAGE 4 PAGE 4 PAGE 5 PAGE 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 PAGE D 3 PAGE E 1 PAGE E 1 TABLE OF CONTENTS continued PARTS LISTS Pump Model PAGE 3 ee ai PAGE E 5 Engine Modification Assembly PAGE 7 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE 8 Suction Check Valve PAGE 8 Pump C2. Line Connections to PUMP ences ve needed dE s ERG qnx GAUGES erbe d AES Di eh Sains qc Roo en i Bia ead ier d atate SUCTION EINES 33 05 rr ERE RUE pe Ret ER EE uper m Strainers COME caer gente ees eae IDEA UU SOR Sealitig eC E eden pe t dte RES a Suction Lines In Suction Line Positioning DISCHARGE FINES urere uei red aeree Sula miedo bulmus aa wees qe upra eb us uui etes 5 tex e ape kehrt eu EE I ebat Bypass L NES eere RR AR NA GROUNDING z nes v EPIRI bade E ra pe YE ERES ERAN OPERATION SECTION viis acad a es PRIMING ixi rA ER rere we MEER IDEO ER ES STARTING A DLE iR A HERD te i OPERATION op eis xe Ripa REN et Lines With a Bypass Lines Without a Bypass 1 beakage ihr deli Dried univer Gaudet His Liquid Temperature And Overheating Strainer Check coo Cain wee ee IE DAD E NR READER RR X DN S inu Pump Vacuum Check ave EKME idik FEN
3. existing installed units 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 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 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 s
4. 152 607 1 HEX HD CAPSCREW 0402 1 2 15991 1 FLAT WASHER K04 15991 1 T TYPE LOCK WASHER BLO4 15991 1 HEX NUT 004 15991 1 NAME PLATE 38812 040 13990 1 DRIVE SCREW BM 04 03 17000 4 FLAT WASHER 6 15991 4 FLANGED HEX NUT 21765 314 2 HEX HD CAPSCREW 0604 15991 2 HAND CARRY DECAL 2613FT 2 CAUTION PLATE 38816 146 13990 1 NOT USED POP RIVET 11703D 13990 4 ENGINE STARTUP TAG 38816 269 1 GROUND WIRE ASSEMBLY 13830 1 OIL CAUTION LABEL 38816 341 1 WHEEL KIT GRP30 52 1 MAINTENANCE amp REPAIR PAGE 3 06106 80 SERIES SECTION DRAWING Figure 2 82D1 EX13 X Pump Parts PAGE 4 MAINTENANCE 8 REPAIR 80 SERIES ITEM NO DO BEM a EN XX 3 19 20 21 22 NOT SHOWN PRIMING STICKER SUCTION STICKER PART NAME PUMP CASING STREET ELBOW STUD IMPELLER HEX HD CAPSCREW LOCK WASHER HEX NUT INTERMEDIATE BRACKET SHAFT SLEEVE SEAL ASSEMBLY PARTS LIST SPRING CENTERING WASHER IMPELLER ADJUSTING SHIM SET CASING GASKET SET WEAR PLATE ASSY PIPE PLUG FLAT WASHER SUCTION FLANGE FLAP VALVE ASSEMBLY SMALL VALVE WEIGHT CHECK VALVE LARGE VALVE WEIGHT RD HD MACH SCREW LOCKWASHER HEX HD CAPSCREW HEX NUT LOCK WASHER FILL PLUG ASSY G R DECAL DISCHARGE STICKER PAPER INSTRUCTION TAG WARNING TAG INDICATES PARTS RECOMMEND
5. 5 1280 International 1 419 755 1352 For Canadian Warranty Information Please Visit www grcanada com warranty or call 519 631 2870 THE GORMAN RUPP COMPANY MANSFIELD OHIO GORMAN RUPP OF CANADA LIMITED ST THOMAS ONTARIO CANADA
6. ABCEG OM 06106 01 January 22 2008 Rev A 10 29 09 INSTALLATION OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST GR GORMAN RUPP 80 SERIES PUMP MODEL 82D1 EX13 X THE GORMAN RUPP COMPANY e MANSFIELD OHIO GORMAN RUPP OF CANADA UTED e ST THOMAS ONTARIO CANADA Printed in U S A Register your new Gorman Rupp pump online at www grpumps com Valid serial number and e mail address required The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm RECORD YOUR PUMP MODEL AND SERIAL NUMBER Please record your pump model and serial number in the spaces provided below Your Gorman Rupp distributor needs this information when you require parts or service Pump Model Serial Number TABLE OF CONTENTS INTRODUCTION Ya SAFETY SECTION A a vie ne eee ERECTA M C pt INSTALLATION SECTION ea ar n xn e Pump Dimensions crire bee RR ke peeked Ae ee Geym PREINSTALLATION INSPECTION POSITIONING PUMP ERE ER ei ERA ese sce arses REID CREER EM e Hier MOUNTING eter en ala O ume SUCTION AND DISCHARGE PIPING Materials nette elm ELLE li idu qam vala ii
7. ED FOR STOCK MAINTENANCE amp REPAIR 82D1 EX13 X Pump Parts PART NUMBER 6846C RS32 C0606 2912F 0503 1 25 405 006 6732A 31411 267 25271 841 12658 513A 504GA 2643A P08 KF04 1361 1361E 1354 1361GC 19B X0403 J04 B0414 D04 J04 48271 062 6588AH 6588AG GR O3 6588BJ 38817 085 6588BG OM 06106 MAT L CODE QTY 13040 11999 15991 13040 15991 15991 15991 10010 17020 17100 17090 20000 15990 15079 18040 10010 15160 19550 10010 17090 17090 15991 15991 15991 ee mc On 00 ao 5 80 SERIES 06106 SECTION DRAWING Ih A ay ASSEMBLY REMOVED AIR CLEANE Figure 3 Engine Modification Assembly MAINTENANCE amp REPAIR PAGE E 6 80 SERIES 06106 PARTS LIST Engine Modification Assembly ITEM PART MAT L NO PART NAME NUMBER CODE QTY 1 ROBIN EX13 ENGINE 29124 001 1 2 SHIELDED LEAD ASSEMBLY 29184 001 1 3 SHIELDED SPARK PLUG 29331 076 1 4 GROUND WIRE ASSEMBLLY 47311 069 1 5 HEX NUT D 08 17000 1 6 SPRING PLUNGER 29184 003 1 7 INSULATOR 29184 002 1 8 ENGINE OPERATION DECAL 38815 026 1 INDICATES PARTS RECOMMENDED
8. ENTLY 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
9. FOR STOCK MAINTENANCE amp REPAIR PAGE 7 06106 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 those which could damage equipment and to those which could be dangerous to personnel However this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit Therefore it is the responsibility of the owner maintenance per sonnel to ensure that only safe established 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 represent
10. INE GOVERNOR SETTING 3800 RPM SHUT OFF M PSI 62 115 8 MMJ DIA MAX SPHERICAL SOLIDS 444 50 140 VOLUTE IMPELLER PERFORMANCE CURVE 68466 curve 820 13 1 2912F 820 13 s ze 2 X2 IMP DIA 4 97 40 1 45 130 80 RPM 3800 SP GR 120 36 40 110 32 35 100 28 90 30 80 24 251 20 60 20 16 50 15 12 40 30 10 8 20 15 10 SN 6M 1 3 1M 44 5 10 0 0 U S GALLONS PER MINUTE 10 LITRES PER SECOND CUBIC METRES PER HOUR 16 17 N GORMAN RUPP PUMPS T 11 07 1 wo 36 10 STANDARD PERFORMANCE FOR PUMP MODEL 82D1 EX13 X Based on 70 F 21 C clear water corrected to 80 specific gravity at sea level with minimum suc tion lift Since pump installations are seldom identi cal your performance may be different due to such factors as viscosity specific gravity elev
11. RNING 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 3800 RPM SAFETY 80 SERIES 06106 INSTALLATION SECTION B Review all SAFETY information in Section A Since pump installations are seldom identical this section offers only general recommendations and practices required to inspect position and ar range the pump and piping Most of the information pertains to a standard static lift application where the pump is positioned above the free level of liquid to be pumped If installed 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 appl
12. 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 06106 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 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 2 80 SERIES outside These fumes contain carbon monoxide a deadly gas that is color less tasteless and odorless A WA
13. 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 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 06106 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 fi
14. asing Removal PAGE 9 Impeller Removal ise RR RR bee E ER RE PAGE E 9 Seal Removal and PAGE E 9 Seal Reassembly and Installation PAGE E 9 Impeller PAGE 11 Pump Casing Installation PAGE E 11 Suction Check Valve Installation PAGE E 11 Final Pump Assembly PAGE E 11 LUBRICATION e ae on Ba eels Pa ala aa PAGE 12 Seal Assembly Cok epi Ee pe pra Hal ston PAGE 12 Engine s LL PAGE E 12 ENGINE MODIFICATIONS PAGE E 12 80 SERIES 06106 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 manual will alert personnel to known proce dures which require special attention to those which could damage equipment and to those which could be dangerous to personnel However this manual cannot possibly anticipate and provide deta
15. ation tem perature 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 3800 RPM PAGE 1 PAGE E 2 06106 15 6 17 Wy e 22 Figure 1 Pump Model 82D1 EX13 X SECTION DRAWING 13414 SN 9 15 80 SERIES 4 18111 12 19 4 20X 21 MAINTENANCE amp REPAIR 80 SERIES PARTS LIST 82D1 EX13 X Pump Model From S N 1390156 Up 06106 If your pump serial number is followed by your pump is a standard production model Contact the Gorman Rupp Company to verify part numbers ITEM NO DO BEM NOT SHOWN OPTIONAL PART MAT L PART NAME NUMBER CODE QTY PUMP PARTS 8201 13 PPO 1 ENGINE SHIELD 34335 160 1 ENGINE MODIFICATION KIT 44311 020 1 ROLLOVER BASE 41583 316 24150 1 FLANGED HEX NUT 21765 312 2 FLAT WASHER 05 15991 2 HEX HD CAPSCREW 0506 15991 2 RUBBER FOOT MOUNTING KIT 48
16. ation 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 06106 total area of the openings in the strainer is at least three or four times the cross section of the suction line and that the openings will not permit passage of solids larger than the solids handling capability of the pump This pump is designed to handle up to 5 8 inch 15 8 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 s
17. ative 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 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 liquids 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 15 and drain the pump Clea
18. ber washer 16 if badly worn or compressed Install the same thickness of pump casing gaskets 13 as previously removed and secure the pump MAINTENANCE amp REPAIR 06106 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 approximately 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 4 with the hardware 15 16 and 17 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 and check valve with the previously removed hard ware Position the check valve assembly 18 in the suc tion port with the large weight toward the inside of the pump Install the suction flange 17 and se cure with the nuts 7 Check the operation of the check valve to ensure proper seating and free movement Final Pump Assembly Fi
19. blished 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 This pump is designed to handle water gasoline and other petroleum products in a non flammable atmosphere Do not SAFETY attempt to pump corrosive materials or any liquids which may damage the pump or endanger personnel as a result of pump failure A 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 A
20. ced 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 12 off the shaft Tie and tag the shims or measure and record their thickness for ease of reassembly MAINTENANCE amp REPAIR 06106 Seal Removal and Disassembly Figures 2 and 4 Carefully remove the spring centering washer 11 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 bellows 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 5 and 6 and separate the intermediate 8 from the engine Use a wooden dowel or other suitable tool to press the stationary 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 w
21. 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 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 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 d
22. 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 PAGE C 2 80 SERIES 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 within the pump can cause parts bei
23. eads and other obvious damage b Check for and tighten loose attaching hard ware Since gaskets tend to shrink after dry PAGE 1 12 06106 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 shielded spark plug fuel spill guard and ground wire 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 Do not put the pump into service until appropriate action has been taken POSITIONING PUMP Lifting Pump unit weights will vary depending on the mounting and drive provided Check the shipping tag on the unit packaging for the actual weight and use lifting equipment with appropriate capacity Drain the pump and remove all customer installed equipment such as suction and discharge hoses or piping before attempting to lift
24. eal 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 separated 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 3 06106 pipe submergence required be reduced by installing a standard p
25. er 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 The engine used on the pump is not standard The manual ON OFF switch which is referred to in the engine operation manual has been removed To start the engine move the speed control lever to the position indicated in the engine operation manual and pull the start rope When the engine starts adjust the speed control as indicated in the engine operation manual PAGE C 1 06106 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 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
26. g to open or service the pump 1 Familiarize 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 Not enough liquid in casing Add liquid to casing See PRIMING Suction check valve contaminated or Clean or replace check valve damaged Air leak in suction line Correct leak Product vapor pressure too high Cool pump and product suction line Lining of suction hose collapsed Replace suction hose Leaking or worn seal or pump gasket Check pump vacuum Replace leaking or worn seal or gasket Suction check valve or foot valve Clean valve clogged or binding Pump speed too slow Check engine output consult en gine operation manual Discharge head too high Install bypass line Suction lift too high Measure lift w vacuum gauge Re duce lift and or friction losses in suction line Strainer clogged Check strainer and clean if neces TROUBLESHOOTING PAGE D 1 06106 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 FREQU
27. gure 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 has been properly lubricated see the literature supplied with the engine Fill the 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 06106 LUBRICATION Seal Assembly The seal is lubricated by the medium being pumped No additional lubrication is required Engine Consult the literature supplied with the engine or contact your local engine representative 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 For U S and International Warranty Information Please Visit www grpumps com warranty or call U S 419 75
28. ication 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 2 NPT DISCHARGE 2 NPT SUCTION 6 97 1177 0 4 2 25 57 2 14 28 362 6 m 163 21 Ke Eh M W 41583 316 18 1460 4 APPROX 6 12 FS 155 4 B2 15 91 17 00 APPROX 1431 81 DIMENSIONS 18 00 457 2 INCHES MILLIMETERS 2 73 69 3 Las 12 00 5 51 304 8 140 07 APPROX 22 51 571 8 POWERED BY ROBIN EX13 SPARK ARREST ENGINE 3 0 HP Figure 1 Pump Model 82D1 EX13 X 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 thr
29. iled precautions for every situation that might occur during maintenance of the unit Therefore it is the responsibility of the owner maintenance per sonnel to ensure that only safe established main tenance procedures are used and that any proce dures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such prac tices 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 Robin gasoline engine incorporating such safety features as splash guards grounding wire and shielded spark plug The pump is designed for pumping water gasoline or other petroleum products in a non flammable at mosphere The basic material of construction alu minum with an aluminum impeller and steel wear ing 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 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 INTRODUCTION 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 cou
30. ipe 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 MIN LI eee e eee FLOW G PM 321 FLOW G PM x 4085 VELOCITY FT SEC AREA IN IN DIAMETER IN IN _ FLOW L SEO x 001 FLOW M HR 353 7 ee OES AREA IN M On DIAMETER IN MM 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 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 PAGE B 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 a
31. ith 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 9 06106 Handle the seal parts with extreme care to prevent damage Be careful not to contaminate precision finished faces even fingerprints on the faces can shorten seal life If necessary clean the faces with a non oil based solvent and a clean lint free tissue Wipe lightly in a concentric pattern to avoid scratching the faces Inspect the seal components for wear scoring grooves and other damage that might cause leak age 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 o
32. ld 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 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 06106 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 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 esta
33. n and reinstall the drain plug To service the suction check valve remove the suc tion piping Remove the nuts 7 securing the suc tion flange 17 to the pump casing 1 Pull the check valve assembly 18 from the suction port MAINTENANCE amp REPAIR 80 SERIES To disassemble the check valve remove the hard ware securing the check valve weights to the check valve 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 15 16 and 17 securing the pump casing to the roll cage 4 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 16 19 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 fa
34. n the finished faces Assemble the seal as follows see Figure 4 SPRING PRING CENTERIN RETAINER INTERMEDIATE AERE ROTATING ELEMENT O RING MP Q ENGINE CRANKSHAFT SEAT SLEEVE IMPELLER H C SHIMS vx SS 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 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 5 and 6 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 int
35. ng disen 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 primed and at operation speed Shut off the pump The vacuum ga
36. o 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 of the 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 seal until the chamfered end seats firmly against the shaft shoulder Install the seal spring and spring centering washer 11 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 plate to the pump casing using the attaching hardware 16 19 20 and 21 Replace the fi
37. pplication 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 06106 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 a broken or al Electrical Code and all local codes Be sure the frayed wire before resuming operation clamp or fastener has made a tight electrical con nection with the rod INSTALLATION PAGE 5 80 SERIES 06106 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
38. rst inspection of wearing parts at 250 hours will give insight into the wear rate for your particular application Subsequent inspec tions should be performed at the intervals shown on the chart below Critical applications should be inspected more frequently Preventive Maintenance Schedule Service Interval 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 06106 PUMP MAINTENANCE AND REPAIR SECTION MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE TOTAL HEAD ROBIN EX13 ENG
39. uction 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 desired for pumps that are not tapped drill and tap the suction and discharge lines not less than 18 inches 457 2 mm from the suction and discharge ports and install the lines 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 oper
40. uge reading will OPERATION 80 SERIES immediately drop proportionate to static suction lift and should then stabilize If the vacuum reading falls off rapidly after stabilization an air leak exists Before checking for the source of the leak check the point of installation of the vacuum gauge STOPPING Never halt the flow of liquid suddenly If the liquid being pumped is stopped abruptly damaging shock waves can be transmitted to the pump and piping system Close all connecting valves slowly On engine driven pumps reduce the throttle speed slowly and allow the engine to idle briefly be fore stopping 06106 CAUTION If the application involves a high discharge head gradually close the discharge throttling valve before stopping the pump The engine used on the pump is not standard The manual ON OFF switch which is referred to in the engine operation manual has been removed To stop the engine move the speed control lever to the lowest setting 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 OPERATION PAGE C 3 80 SERIES 06106 TROUBLESHOOTING SECTION D Review all SAFETY information in Section A WARNING Before attemptin
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