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OM-02164-01
April 9, 1984
Rev. D 08‐30‐13
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
80 SERIES PUMP
MODEL
81 1/2P47A-E2 1P
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA
Printed in U.S.A.
1984 The Gorman‐Rupp Company
Register your new
Gorman‐Rupp pump online at www.grpumps.com
Valid serial number and e‐mail address required.
RECORD YOUR PUMP MODEL AND SERIAL NUMBER
Please record your pump model and serial number in the spaces provided below. Your Gorman‐Rupp distributor needs this information when you require parts or service.
Pump Model:
Serial Number:
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE I - 1
SAFETY ‐ SECTION A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE A - 1
INSTALLATION - SECTION B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREINSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POSITIONING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUCTION AND DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections to Pump
Gauges
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUCTION LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fittings
Strainers
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Lines In Sumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Line Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Siphoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE B - 1
PAGE B - 1
PAGE B - 1
PAGE B - 2
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PAGE B - 2
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PAGE B - 3
PAGE B - 3
PAGE B - 3
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PAGE B - 4
PAGE B - 5
PAGE B - 5
PAGE B - 5
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PAGE B - 5
OPERATION - SECTION C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE C - 1
PRIMING
STARTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lines With a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lines Without a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Temperature And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strainer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 - 2
PAGE C - 3
PAGE C - 3
TROUBLESHOOTING - SECTION D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE D - 1
PAGE D - 3
PUMP MAINTENANCE AND REPAIR ‐ SECTION E . . . . . . . . . . . . . . . . .
STANDARD PERFORMANCE CURVE
PARTS LIST:
Pump Model
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE E - 1
PAGE E - 1
PAGE E - 3 i
TABLE OF CONTENTS
(continued)
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Casing and Vane Plate Removal
Impeller Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vane Plate and Pump Casing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE E - 4
PAGE E - 4
PAGE E - 4
PAGE E - 5
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PAGE E - 6
PAGE E - 7
PAGE E - 7
PAGE E - 7
PAGE E - 7 ii
80 SERIES OM-02164
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 pump is an 80 Series, semi‐open impeller, self‐ priming centrifugal model without a suction check valve. It is close‐coupled to a 2 H.P., single phase, totally enclosed, fan‐cooled electric motor. The ba sic material of construction for wetted parts is fiber glass reinforced polyester (Valox grade 420).
The pump is designed for handling water and most water‐soluable herbicides and pesticides, as well as certain chemicals and waste solutions within specified temperatures and concentrations. Con sult the factory for information about your specific application or for a copy of our chemical compati bility guide. This pump is not recommended for handling volatile or flammable liquids.
For information or technical assistance on the mo tor, contact the motor manufacturer's local dealer or representative.
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 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.
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:
INTRODUCTION
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-2870
The following are used to alert maintenance per sonnel to procedures which require special atten tion, to those which could damage equipment, and to those which could be dangerous to personnel:
Immediate hazards which WILL 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.
Hazards or unsafe practices which
COULD result in severe personal injury or death. These instructions describe the procedure required and the injury which could result from failure to follow the procedure.
Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. These instructions describe the requirements and the possi ble damage which could result from failure to follow the procedure.
NOTE
Instructions to aid in installation, operation, and maintenance or which clarify a procedure .
PAGE I - 1
80 SERIES OM-02164
SAFETY ‐ SECTION A
This information applies to 80 Series electric motor driven pumps. Refer to the manual accompanying the motor before attempting to begin operation.
Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and pre cautions for each specific application.
Therefore, it is the owner/installer's re sponsibility to ensure that applications not addressed in this manual are per formed only after establishing that nei ther operator safety nor pump integrity are compromised by the installation.
fied temperatures and concentrations.
Do not attempt to pump volatile or flam mable materials which may damage the pump or endanger personnel as a result of pump failure.
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.
Before attempting to open or service the pump:
1. Familiarize yourself with this man ual.
2. Disconnect the incoming power to the motor and lock it out 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.
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.
This pump is designed to handle materi als which could cause illness or injury through direct exposure or emitted fumes. Wear protective clothing, such as rubber gloves, face mask and rubber apron, as necessary, before discon necting or servicing the pump or piping.
This pump is designed to handle water and most water‐soluable herbicides and pesticides, as well as certain chem icals and waste solutions within speci
SAFETY
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.
PAGE A - 1
OM-02164 80 SERIES
Do not install and operate a non‐explo sion proof motor in an explosive atmo sphere. Install, connect, and operate the motor in accordance with the Na tional Electric Code and all local codes.
If there is a conflict between the instruc tions in the manual accompanying the unit and the National Electric Code or the applicable local code, the National or local code shall take precedence.
The electrical power used to operate this pump is high enough to cause inju ry or death. Obtain the services of a qu alified electrician to troubleshoot, test and/or service the electrical compo nents of this pump.
Pumps and related equipment must be in stalled and operated according to all na tional, local and industry standards.
PAGE A - 2 SAFETY
80 SERIES OM-02164
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 in a flooded suction application where the liquid is supplied to the pump under pressure, some of the information such as mounting, line configuration, and priming must be tailored to the specific application. Since the pressure supplied to the pump is critical to performance and safety, be sure to limit the incoming pressure to 50% of the maximum permissible operating pressure as shown on the pump performance curve (see Sec tion E, Page 1).
For further assistance, contact your Gorman‐Rupp distributor or the Gorman‐Rupp Company.
Pump Dimensions
See Figure 1 for the approximate physical dimen sions of this pump.
OUTLINE DRAWING
Figure 1. Pump Model 81 1/2P47A-E2 1P
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: a. Inspect the pump and motor for cracks, dents, damaged threads, and other obvious damage.
b. Check for and tighten loose attaching hard ware. Since gaskets tend to shrink after dry
INSTALLATION PAGE B - 1
OM-02164 80 SERIES 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 motor 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.
The electrical power used to operate this pump is high enough to cause inju ry or death. Obtain the services of a qu alified electrician to troubleshoot, test and/or service the electrical compo nents of this pump.
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 existing, installed units.
PAGE B - 2
The pump assembly can be seriously damaged if the chains or cables used to lift and move the unit are improperly wrapped around the pump.
The pump casing, flanges and seal plate are made of fiberglass‐reinforced polyes ter, which can crack under impact or shock. Take every precaution against dropping the pump or striking pump com ponents.
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.
SUCTION AND DISCHARGE PIPING
Pump performance is adversely effected by in creased suction lift, discharge elevation, and fric tion losses. See the performance curve on Page
E‐1 to be sure your overall application allows pump to operate within the safe operation range.
Materials
Either pipe or hose maybe used for suction and discharge lines; however, the materials must be compatible with the liquid being pumped. If hose is used in suction lines, it must be the rigid‐wall, 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
INSTALLATION
80 SERIES OM-02164 tially increase friction loss. If elbows are necessary, use the long‐radius type to minimize friction loss.
Flexible connectors are required on suction and discharge connections in order to prevent piping loads.
The suction and discharge lines must be supported and connected to the pump with flexible connectors in order to prevent piping loads. The pump warranty will be voided if flexible connectors are not used.
Connections to Pump
Before tightening a connecting flange, align it ex actly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or cou plings.
Lines near the pump must be independently sup ported to avoid strain on the pump which could cause excessive vibration, decreased bearing life, and increased shaft and seal wear. If hose‐type lines are used, they should have adequate support to secure them when filled with liquid and under pressure.
Gauges
Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges. If these gauges are desired for pumps that are not tapped, drill and tap the suction and discharge lines not less than 18 inches (457,2 mm) from the suction and 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
INSTALLATION slopes down to the pump at any point along the suction run, air pockets will be created.
The suction line should not exceed 20 feet (6 me ters) in length.
Fittings
The use of plastic fittings to connect suction and discharge lines to the pump is recommended. Use a good grade of pipe sealant on the threads of the fittings. Draw the fittings up hand tight, then give them one full turn with a wrench.
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 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 9/16 inch
(14,3 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
PAGE B - 3
OM-02164 80 SERIES 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.
NOTE
The pipe submergence required may be reduced by installing a standard pipe increaser fitting at the end of the suction line. The larger opening size will reduce the inlet velocity. Calculate the required submergence using the following formula based on the increased opening size (area or diameter).
PAGE B - 4
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
INSTALLATION
80 SERIES OM-02164
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
A check valve in the discharge line is normally rec ommended, but it is not necessary in low dis charge head applications.
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.
With high discharge heads, it is recommended that a throttling valve and a system check valve be in stalled in the discharge line to protect the pump from excessive shock pressure and reverse rota tion when it is stopped.
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.
ELECTRICAL CONNECTIONS
Before connecting the motor to the incoming power, check that the electrical service available matches the pump motor requirements stamped on the motor nameplate.
The electrical power used to operate this pump is high enough to cause inju ry or death. Obtain the services of a qu alified electrician to make all electrical connections.
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
Do not install and operate a non‐explo sion proof motor in an explosive atmo sphere. Install, connect, and operate the motor in accordance with The Na tional Electric Code and all local codes.
If there is a conflict between the instruc tions in the manual accompanying the unit and The National Electric Code or the applicable local code, The National or local code shall take precedence.
Refer to the following motor data before making electrical connections.
MODEL
81 1/2P47A-E2 1P
VOLTAGE PHASE HP
115/230 1 2
Hz
60
RPM
3450
F.L. AMPS
20.0/10.0
INSTALLATION PAGE B - 5
80 SERIES OM-02164
OPERATION - SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and decals attached to the pump.
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.
This pump is designed to handle water and most water‐soluable herbicides and pesticides, as well as certain chem icals and waste solutions within speci fied temperatures and concentrations.
Do not attempt to pump volatile or flam mable materials which may damage the pump or endanger personnel as a result of pump failure.
Do not install and operate a non‐explo sion proof motor in an explosive atmo sphere. Install, connect, and operate the motor in accordance with the Na tional Electric Code and all local codes.
If there is a conflict between the instruc tions in the manual accompanying the unit and the National Electric Code or the applicable local code, the National or local code shall take precedence.
Never operate this pump unless there is liquid in the pump casing. The pump will 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.
Pump speed and operating condition points must be within the continuous per formance range shown on the curve (see
Section E, Page 1).
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
OPERATION
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.
This pump is not equipped with a plug for filling the pump casing. To fill the pump, remove the dis charge line and add approximately 1 gallon (3,8 li ters) of clean liquid. Reconnect the discharge line and proceed with pump operation.
STARTING
Consult the operations manual furnished with the motor.
PAGE C - 1
OM-02164 80 SERIES
OPERATION ture or explode. If overheating occurs, stop the pump and allow it to cool before servicing it. Refill the pump casing with cool liquid.
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 motor. Priming is indicated by a positive reading on the discharge pressure gauge or by a quieter op eration. The pump may not prime immediately be cause 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
PAGE C - 2
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.
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 (see Section E,
Page 1).
Pump Vacuum Check
Since this pump does not have a suction check valve, the discharge line must be fitted with a check valve if a pump vacuum reading is to be taken.
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 mm) or more of mercury. If it does not, check for air leaks in the seal, gasket, or discharge valve.
Open the suction line, and read the vacuum gauge with the pump primed and at operation speed.
Shut off the pump. The vacuum gauge reading will immediately drop proportionate to static suction lift, and should then stabilize. If the vacuum reading
OPERATION
80 SERIES OM-02164 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.
Cold Weather Preservation
In below freezing conditions, drain the pump to prevent damage from freezing. Also, clean out any solids by flushing with a hose. Operate the pump for approximately one minute; this will remove any remaining liquid that could freeze the pump rotat ing parts.
If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.
After stopping the pump, disconnect the incoming power to the motor and lock it out to ensure that the pump will remain inoperative.
If the pump will be idle for more than a few hours, or if it has been pumping liquids containing a large amount of solids, drain the pump, and flush it thor oughly with clean water. To prevent large solids from clogging the drain port and preventing the pump from completely draining, insert a rod or stiff wire in the drain port, and agitate the liquid during the draining process. Clean out any remaining sol ids by flushing with a hose.
OPERATION PAGE C - 3
80 SERIES
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.
OM-02164
Before attempting to open or service the pump:
1. Familiarize yourself with this manual.
2. Disconnect the incoming power to the motor and lock it out 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
PUMP FAILS TO
PRIME
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
POSSIBLE CAUSE
Not enough liquid in casing.
PROBABLE REMEDY
Add liquid to casing. See PRIMING .
Suction check valve contaminated or damaged.
Air leak in suction line.
Lining of suction hose collapsed.
Clean or replace check valve.
Correct leak.
Replace suction hose.
Leaking or worn seal or pump gasket.
Check pump vacuum. Replace leaking or worn seal or gasket.
Suction lift or discharge head too high.
Check piping installation and install bypass line if needed. See INSTAL
LATION .
Strainer clogged.
Check strainer and clean if neces sary.
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.
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.
TROUBLESHOOTING PAGE D - 1
OM-02164 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
Leaking or worn seal or pump gasket.
Check pump vacuum. Replace leaking or worn seal or gasket.
Impeller clogged.
Free impeller of debris.
Low or incorrect voltage.
Measure control box voltage, both when pump is running and when shut off.
No voltage at line side of circuit breaker.
Check power source for blown fuse, open circuit breaker or control box, broken lead, or loose connection.
Suction lift or discharge head too high.
Check piping installation and install bypass line if needed. See INSTAL
LATION .
Motor shaft or bearings defective.
Disassemble pump and check mo tor and bearings.
Discharge head too low.
Adjust discharge valve.
Liquid solution too thick.
Discharge flow too slow.
Suction check valve or foot valve clogged or binding.
Dilute if possible.
Open discharge valve fully to in crease flow rate, and run motor at maximum governed speed.
Clean valve.
EXCESSIVE NOISE Cavitation in pump.
Pumping entrained air.
Pump or drive not securely mounted.
Impeller clogged or damaged.
Reduce suction lift and/or friction losses in suction line. Record vac uum and pressure gauge readings and consult local representative or factory.
Locate and eliminate source of air bubble.
Secure mounting hardware.
Clean out debris; replace damaged parts.
PAGE D - 2 TROUBLESHOOTING
80 SERIES OM-02164
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 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 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.
Item
Preventive Maintenance Schedule
Daily
Service Interval*
Weekly Monthly Semi‐
Annually
Annually
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.)
Pump Performance (Gauges, Speed, Flow)
Bearing Lubrication
Seal Lubrication (And Packing Adjustment,
If So Equipped)
V‐Belts (If So Equipped)
Air Release Valve Plunger Rod (If So Equipped)
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
I
I
I
I
I
I
C
I
I
R
R
I
I
I
I
I
I
C
Legend:
I = Inspect, Clean, Adjust, Repair or Replace as Necessary
C = Clean
R = Replace
* Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually.
Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.
TROUBLESHOOTING PAGE D - 3
80 SERIES OM-02164
PUMP MAINTENANCE AND REPAIR ‐ SECTION E
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK
OPERATING PERFORMANCE.
STANDARD PERFORMANCE FOR PUMP MODEL 81 1/2P47A-E2 1P
Based on 70 F (21 C) clear water at sea level with minimum suction lift. Since pump installations are seldom identical, your performance may be dif ferent due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.
If your pump serial number is followed by an “N”, your pump is NOT a standard production model.
Contact the Gorman‐Rupp Company to verify per formance or part numbers.
Pump speed and operating condition points must be within the continuous per formance range shown on the curve. Use caution not ot overload the motor when handling liquids with a specific gravity greater than 1.0.
MAINTENANCE & REPAIR PAGE E - 1
OM-02164
PARTS PAGE
SECTION DRAWING
80 SERIES
PAGE E - 2
Figure 1. Pump Model 81 1/2P47A-E2 1P
MAINTENANCE & REPAIR
80 SERIES OM-02164
PARTS LIST
Pump Model 81 1/2P47A-E2 1P
(From S/N 801799 Up)
If your pump serial number is followed by an “N”, your pump is NOT a standard production model. Contact the Gorman‐Rupp Company to verify part numbers.
ITEM
NO.
9
10
11
7
8
3
4
5
6
1
2
12
13
14
15
16
17
18
19
20
21
22
23
24
NOT SHOWN:
PART NAME
PUMP CASING
IMPELLER
SEAL ASSEMBLY
IMPELLER KEY
O‐RING
TAP SCREW
HEX HD CAPSCREW
FLAT WASHER
MOTOR, 2 H.P., 1P
SPACER
INTERMEDIATE
IMP ADJ SHIM SET
O‐RING
HEX HD CAPSCREW
HEAVY NYLOCK NUT
RD HD MACH SCREW
VANE PLATE
VANE PLATE O‐RING
PIPE PLUG
FLOW GUIDE O‐RING
FLOW GUIDE
TAP SCREW
NAME PLATE
WARNING DECAL
STRAINER
WARNING DECAL
WARNING DECAL
G‐R DECAL
ROTATION DECAL
INSTRUCTION TAG
SUCTION STICKER
DISCHARGE STICKER
OPTIONAL:
26841-007
2613FE
2613FF
GR-02
2613M
38817-029
6588AG
6588BJ
SUCTION NIPPLE
DISCHARGE ELBOW
26523-303
26525-202
REPAIR KIT (INCLUDES ALL ITEMS ABOVE) 48221-019
PART
NUMBER
38231-401
38617-703
25271-412
N0302-1/2
25152-363
21287-596
B0503S
KB05
28156-560
31133-114
38264-213
48261-032
25152-010
B0405
21765-146
X0403S
38632-507
25152-134
26471-003
25152-155
38354-018
21287-584
38812-052
38816-091
---
---
---
---
---
---
---
---
MAT'L
CODE
---
---
17000
---
17000
23200
---
---
---
23200
---
---
---
23200
23200
---
17000
---
---
17000
17000
---
15030
23200
---
---
---
1
1
1
1
1
1
1
1
1
1
1
QTY
1
1
10
10
1
1
1
1
1
1
2
1
1
1
1
1
4
4
1
1
1
2
1
1
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 3
OM-02165 80 SERIES
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 view (see Figure 1) and the accompa nying parts list.
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 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.
Before attempting to service the pump, disconnect incoming power to the motor and lock it out to en sure that it will remain inoperative. Close all valves in the suction and discharge lines.
For motor disassembly and repair, consult the lit erature supplied with the motor, or contact your lo cal motor representative.
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.
This pump is designed to handle materi als which could cause illness or injury through direct exposure or emitted fumes. Wear protective clothing, such as rubber gloves, face mask and rubber apron, as necessary, before discon necting or servicing the pump or piping.
Pump Casing and Vane Plate Removal
Before attempting to service the pump, remove the pump casing drain plug (25) and drain the pump.
Clean the drain plug and wrap the threads with
PTFE thread tape before reinstallation.
To service the impeller (2), vane plate (17) or seal assembly (3), disconnect the suction and dis charge piping.
Remove the capscrews and nuts (14 and 15) and self‐tapping screws (6) securing the pump casing
(1) to the intermediate (11). Remove the pump cas ing by pulling straight away.
The flow guide (21) rarely requires removal or re placement, but if replacement is necessary, disen gage the self‐tapping screws. Pull the flow guide out of the pump casing and remove the O‐ring (20).
Pull the vane plate off of the alignment pins on the intermediate. Remove the vane plate and casing
O‐rings (5 and 18).
Before attempting to open or service the pump:
1. Familiarize yourself with this man ual.
2. Disconnect the incoming power to the motor and lock it out to ensure that the pump will remain inopera tive.
3. Allow the pump to completely cool if overheated.
PAGE E - 4
Impeller Removal
Insert a large screwdriver in the slot in the end of the motor shaft to prevent shaft rotation. Remove the impeller screw and O‐ring (13 and 16) and pull the impeller off the shaft; retain the impeller key (4).
MAINTENANCE & REPAIR
80 SERIES OM-02165
Inspect the impeller and replace it if cracked or badly worn. Slide the impeller adjusting shims (12) off the impeller shaft. Tie and tag the shims, or measure and record their thickness for ease of reassembly.
Seal Removal
(Figures 1 and 2)
To remove the seal assembly (3), remove the rotat ing seat and element from the impeller cavity. Use a pair of stiff wires with hooked ends if necessary.
NOTE
The stationary portion of the seal assembly is se cured in the intermediate bore with “Loctite 30516
Aviation Gasket Sealant”. The seal cage can be damaged during removal; only remove the station ary seal components if replacement is required.
Pry the remainder of the seal components from the intermediate as a unit. If the intermeidate is re moved, the seal components can be pressed our from the back of the intermediate.
To remove the intermediate, disengage the hard ware (7 and 8) securing it to the motor (9).
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 an old seal in an emer gency, carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.
Handle the seal parts with extreme care to prevent damage. Be careful not to contaminate precision finished faces; even fingerprints on the faces can shorten seal life. If necessary, clean the faces with a non‐oil based solvent and a clean, lint‐free tissue.
Wipe lightly in a concentric pattern to avoid scratching the faces.
Inspect the seal components for wear, scoring, grooves, and other damage that might cause leak age. Clean and polish the seal area of the shaft.
Small nicks and burrs can be removed using a fine file or emery cloth. If any components are worn, re place the complete seal; never mix old and new seal parts .
Seal Reassembly and Installation
(Figures 1 and 2)
Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent.
Most cleaning solvents are toxic and
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 seal area of the shaft with water or a very small amount of oil, and apply a drop of light lubricating oil on the finished faces. Assemble the seal as follows, (see
Figure 2).
MAINTENANCE & REPAIR PAGE E - 5
OM-02165
IMPELLER
IMPELLER
KEY
BELLOWS SPRING
80 SERIES
INTERMEDIATE
IMPELLER
SHAFT
ROTATING
ELEMENT
ROTATING
SEAT
STATIONARY
ELEMENT
RETAINER
Figure 3. Seal Assembly mounting flange pointed down. Secure the inter mediate to the motor (9) with the hardware 97 and
8). Torque the capscrews (7) alternately to 55 in.
lbs. (6,3 m. kg.).
This seal is not designed for operation at temperatures above 160 F (71 C). Do not use at higher operating temperatures.
When pressing the stationary seal components into the intermediate, use hand pressure only. A push tube cut from a length of plastic pipe will aid in this installation. The I.D. of the push tube should be just large enough to slide over the stationary ele ment and seat against the shoulder on the seal re tainer.
Apply a small amount of “Loctite 30516 Aviation
Gasket Sealant” or equivalent compound to the
O.D. of the seal retainer and carefully press this as sembly into the bore of the intermediate until fully seated. Clean any residual aviation cement off of the seal retainer and intermediate.
Apply a drop of water or light oil on the seal face of the stationary elment; never use grease.
Clean all of the old aviation gasket sealant from the intermediate bore before attempting to install the stationary seal components.
Subassemble the rotating element into the rotating seat. Apply a small amount of light oil to the O.D. of the rotating seat and press this assembly into the impeller until fully seated.
If removed at disassembly, slide the intermediate
(11) over the shaft and spacer (10).
The intermediate is offset and not concentric to the shaft; be sure to position the intermediate against the motor with the drain holes in the neck of the
PAGE E - 6
Impeller Installation
Inspect the impeller, and replace it if cracked or badly worn. Install the same thickness of impeller shims (14) as previously removed. Install the im
MAINTENANCE & REPAIR
80 SERIES OM-02165 peller key (4) and slide the impeller onto the shaft, taking care not to damage the sealing elements.
Install a new impeller O‐ring (13). Insert a large screwdriver in the slot in the end of the motor shaft to prevent shaft rotation. Install the impeller screw
(16) to 15 to 20 in. lbs. (1,7 to 2,3 m. kg.).
The vane plate (17) will seat properly in only one position; do not try to force the vane plate onto the intermediate alignment pins.
A clearance of .008 to .015 inch ( 0,30 to 0,38 mm) between the impeller and the vane plate (17) is necessary for maximum pump efficiency. Position the vane plate over the impeller and the alignment pins on the intermediate. The vane plate will seat properly in only one position; do not try to force the vane plate onto the intermediate alignment pins.
Use a feeler gauge to measure this clearance. Add or remove impeller shims until the proper clear ance is achieved.
Vane Plate and Pump Casing Installation flow guide to the pump casing (1) by torquing the self‐tapping screws (22) in an alternating pattern to
8 to 10 ft. lbs. (0,9 to 1,1 m. kg.).
Install the vane plate O‐ring (18) and the pump cas ing O‐ring (5). Position the vane plate over the im peller and the alignment pins on the intermediate.
Check impeller‐to‐vane plate clearance as de scribed in Impeller Installation .
Carefully slide the pump casing over the vane plate and secure it to the intermediate by torquing the self‐tapping screws (6) in an alternating pattern to
15 to 20 in. lbs. (1,7 to 2,3 m. kg.).
Install the capscrews and nuts (14 and 15) and torque them in an alternating pattern to 20 to 25 in.
lbs. (2,3 to 2,9 m. kg.).
Final Pump Assembly
Be sure the pump and motor are securely mounted to the base.
Install the suction and discharge lines and open all valves. Make certain that all piping connections are tight, properly supported and secure.
Fill the pump casing with clean liquid.
Refer to OPERATION , Section C, before putting the pump back into service.
Follow all torque recommendations when securing the pump hardware. Over‐tight ening can cause pump components to crack or threads to strip.
If the flow guide (21) was removed at disassembly, install a new flow guide O‐ring (20) and secure the
LUBRICATION
Seal Assembly
The seal assembly is lubricated by the medium be ing pumped. No additional lubrication is required.
MAINTENANCE & REPAIR PAGE E - 7
For U.S. and International Warranty Information,
Please Visit www.grpumps.com/warranty or call:
U.S.: 419-755-1280
International: +1-419-755-1352
For Canadian Warranty Information,
Please Visit www.grcanada.com/warranty or call:
519-631-2870
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA
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