advertisement
OM-07214-05
April 26, 2019
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
RS & RD SERIES PUMP
MODEL
RD3A32-BAR
GORMAN‐RUPP PUMPS
www.grpumps.com
e
2019 Gorman‐Rupp Pumps Printed in U.S.A.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE B - 1
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupled Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE B - 1
PAGE B - 1
PAGE B - 2
PAGE B - 2
PAGE B - 2
PAGE B - 2
PAGE B - 2
PAGE B - 2
PAGE B - 2
PAGE B - 3
PAGE B - 3
PAGE B - 3
PAGE B - 3
PAGE B - 3
PAGE B - 3
PAGE B - 3
PAGE B - 4
PAGE B - 4
PAGE B - 4
PAGE B - 4
PAGE B - 5
OPERATION - SECTION C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE C - 1
PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hand Primers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Temperature And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strainer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEARING TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING - SECTION D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 - 2
PAGE C - 3
PAGE D - 1
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP MAINTENANCE AND REPAIR ‐ SECTION E . . . . . . . . . . . . . . . . .
PAGE D - 3
PAGE E - 1
STANDARD PERFORMANCE CURVE
PARTS LISTS:
Pump Model
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE E - 1
PAGE E - 3 i
TABLE OF CONTENTS
(continued)
Bearing Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical RD Pump Model Assembly
Typical Bearing Housing Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Group Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY
Separating Pump From Motor
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Release Valve Removal
Pump Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Group Grind Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft And Bearing Removal And Disassembly
Shaft and Bearing Reassembly and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Reassembly and Installation
Group Grind Reassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Group Grind Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Group Grind Replacement
Group Grind Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Group Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE E - 5
PAGE E - 6
PAGE E - 7
PAGE E - 8
PAGE E - 9
PAGE E - 10
PAGE E - 10
PAGE E - 10
PAGE E - 10
PAGE E - 11
PAGE E - 11
PAGE E - 11
PAGE E - 12
PAGE E - 13
PAGE E - 15
PAGE E - 15
PAGE E - 16
PAGE E - 17
PAGE E - 17
PAGE E - 17
PAGE E - 17
PAGE E - 17
PAGE E - 17
PAGE E - 17
PAGE E - 17 ii
RD & RS SERIES OM-07214
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 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:
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.
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
For information or technical assistance on the pow er source, contact the power source manufactur er's local dealer or representative.
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.
INTRODUCTION PAGE I - 1
RD & RS SERIES OM-07214
SAFETY - SECTION A
The following information applies throughout this manual to Gorman‐
Rupp Roto‐Prime r Series basic pumps.
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, established main tenance procedures are used, and that any procedures not addressed in this manual are performed only after estab lishing that neither personal safety nor pump integrity are compromised by such practices.
This pump is designed to handle petro leum products or other similar hydro carbon liquids. Do not attempt to pump water, corrosive materials, or any liq uids which may damage the pump or en danger personnel as a result of pump failure.
After the pump has been positioned, make certain that the pump and all pip ing connections are tight, properly sup ported and secure before operation.
Before attempting to open or service the pump:
1. Familiarize yourself with this man ual.
2. Lock out or disconnect the power source or take other precautions to ensure that the pump will remain inoperative.
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.
SAFETY
Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.
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
PAGE A - 1
OM-07214 deteriorate, and the liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode.
RD & RS SERIES
5. Vent the pump slowly and cau tiously.
6. Refer to instructions in this manual before restarting the pump.
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.
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.
Overheated pumps can cause severe burns and injuries , and produce explo sive fumes. 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 any covers, plates, gauges, or plugs.
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. All electrical equipment supplied with this pump conformed to applicable federal regulations and national codes in effect on the date of manufacture.
PAGE A - 2 SAFETY
RD & RS SERIES OM-07214
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 RD3A32-BAR
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 engine for cracks, dents, damaged threads, and other obvious damage.
b. Check for and tighten loose attaching hard ware. Since gaskets tend to shrink after dry
INSTALLATION PAGE B - 1
OM-07214 RD & RS 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 has been stored for more than 12 months, some of the components or lubri cants may have exceeded their maximum shelf life. These must be inspected or re placed to ensure maximum pump service.
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.
Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be
PAGE B - 2 damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.
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
Materials
Either pipe or hose maybe used for suction and discharge lines; however, the materials must be compatible with the liquid being pumped. If hose is used in suction lines, it must be the rigid‐wall, rein forced type to prevent collapse under suction. Us ing piping couplings in suction lines is not recom mended.
Line Configuration
Keep suction and discharge lines as straight as possible to minimize friction losses. Make mini mum use of elbows and fittings, which substan tially increase friction loss. If elbows are necessary, use the long‐radius type to minimize friction loss.
Connections to Pump
Before tightening a connecting flange, align it ex actly with the pump port. Never pull a pipe line into 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.
INSTALLATION
RD & RS SERIES OM-07214
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.
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
To avoid air pockets which could affect pump prim ing, the suction line must be as short and direct as possible. When operation involves a suction lift, the line must always slope upward to the pump from the source of the liquid being pumped; if the line slopes down to the pump at any point along the suction run, air pockets will be created.
Fittings
Suction lines should be the same size as the pump inlet. If reducers are used in suction lines, they should be the eccentric type, and should be in stalled with the flat part of the reducers uppermost to avoid creating air pockets. Valves are not nor mally used in suction lines, but if a valve is used, install it with the stem horizontal to avoid air pock ets.
Strainers
If a strainer is 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 2‐inch (50,8 mm) diameter spherical solids.
Sealing
Since even a slight leak will affect priming, head, and capacity, especially when operating with a
INSTALLATION
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 di ameter 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 diame ter of the suction pipe. The baffle will allow en trained 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 - 3
OM-07214 RD & RS SERIES
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.
If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.
ALIGNMENT
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.
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.
PAGE B - 4
This pump is designed for direct coupled drive only. Use of a V‐belt drive will dam age the pump and void the pump warranty.
The alignment of the pump and its power source is critical for trouble‐free mechanical operation. The driver and pump must be mounted so that their shafts are aligned with and parallel to each other. It is imperative that alignment be checked after the pump and piping are installed, and before opera tion.
INSTALLATION
RD & RS SERIES
NOTE
Check Rotation , Section C, before final alignment of the pump.
OM-07214
When mounted at the Gorman‐Rupp factory, driver and pump are aligned before shipment. Misalign ment will occur in transit and handling. Pumps must be checked and realigned before operation.
Before checking alignment, tighten the foundation bolts. The pump casing feet and/or pedestal feet, and the driver mounting bolts should also be tightly secured.
Figure 3A. Aligning Spider‐Type Couplings
When checking alignment, disconnect the power source to ensure that the pump will remain inoperative.
Adjusting the alignment in one direction may alter the alignment in another direc tion. check each procedure after altering alignment.
Coupled Drives
When using couplings, the axis of the power source must be aligned to the axis of the pump shaft in both the horizontal and vertical planes.
Most couplings require a specific gap or clearance between the driving and the driven shafts. Refer to the coupling manufacturer's service literature.
Align spider insert type couplings by using calipers to measure the dimensions on the circumference of the outer ends of the coupling hub every 90
_
.
The coupling is in alignment when the hub ends are the same distance apart at all points (see Fig ure 3A).
Figure 3B. Aligning Non‐Spider Type Couplings
Align non‐spider type couplings by using a feeler gauge or taper gauge between the coupling halves every 90
_
. The coupling is in alignment when the hubs are the same distance apart at all points (see
Figure 3B).
Check parallel adjustment by laying a straightedge across both coupling rims at the top, bottom, and side. When the straightedge rests evenly on both halves of the coupling, the coupling is in horizontal parallel alignment. If the coupling is misaligned, use a feeler gauge between the coupling and the straightedge to measure the amount of misalign ment.
Do not operate the pump without the guard in place over the rotating parts .
exposed rotating parts can catch cloth ing, fingers, or tools, causing severe in jury to personnel.
INSTALLATION PAGE B - 5
RD & RS SERIES OM-07214
OPERATION - SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and decals attached to the pump.
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.
This pump is designed to handle most non‐volatile, non‐flammable liquids containing specified entrained solids.
Do not attempt to pump volatile, corro sive, or flammable liquids which may damage the pump or endanger person nel as a result of pump failure.
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 is not a self‐priming pump, so an external priming device must be used if the pump is in stalled on a suction lift . A foot valve may be in stalled at the end of the suction pipe to maintain the prime; however, this may adversely affect pump performance due to friction loss. Many standard centrifugal models are equipped with a hand‐oper ated vacuum pump, exhaust primer, or ejector for this purpose. If a priming device was not furnished with the pump, it may be ordered from the factory as an option.
Before attempting to operate the priming device, close the discharge throttling valve. (Installation of a spring‐loaded check valve is also recommended to facilitate priming.) Once the pump is fully primed, close the valve between the priming de vice and pump to preserve the prime. Start the pump and open the discharge valve slowly to fill the discharge line.
OPERATION
Hand Primers
Hand‐operated primers are usually mounted on the pump and, when operated, draw air out of the suction line and pump casing. To prime a pump with a hand vacuum pump, open the cock on the pump priming line. Operate the hand pump until liquid flows out of the check valve on the bottom of the primer pump. Once the pump is primed, close the valve located between the primer and the pump so that the prime will not be lost.
HANDLE
DRAIN COCK
Figure 1. Hand Primer Assembly
STARTING
Consult the operations manual furnished with the power source .
PAGE C - 1
OM-07214 RD & RS SERIES
OPERATION
Leakage
No leakage should be visible at pump mating sur faces, or at pump connections or fittings. Keep all line connections and fittings tight to maintain maxi mum pump efficiency.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
160
_
F (71
_
C). Do not apply it at a higher operating temperature.
Overheating can occur if operated with the valves in the suction or discharge lines closed. Operating against closed valves could bring the liquid to a boil, build pressure, and cause the pump to rup ture or explode. If overheating occurs, stop the pump and allow it to cool before servicing it. Refill the pump casing with cool liquid.
Allow an over‐heated pump to cool be fore servicing . Do not remove plates, covers, gauges, or fittings from an over‐ heated pump. Liquid within the pump can reach boiling temperatures, and va por pressure within the pump can cause parts being disengaged to be ejected with great force. After the pump cools, drain the liquid from the pump by re moving the casing drain plug. Use cau tion when removing the plug to prevent injury to personnel from hot liquid.
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.
PAGE C - 2
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 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 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.
If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.
After stopping the pump, disconnect the power source to ensure that the pump will remain inop erative.
Cold Weather Preservation
In below freezing conditions, drain the pump to prevent damage from freezing. Also, clean out any
OPERATION
RD & RS SERIES OM-07214 solids by flushing with a hose. Operate the pump for approximately one minute; this will remove any remaining liquid that could freeze the pump rotat ing parts. If the pump will be idle for more than a few hours, or if it has been pumping liquids con taining a large amount of solids, drain the pump, and flush it thoroughly with clean water. To prevent large solids from clogging the drain port and pre venting the pump from completely draining, insert a rod or stiff wire in the drain port, and agitate the liquid during the draining process. Clean out any remaining solids by flushing with a hose.
BEARING TEMPERATURE CHECK
Bearings normally run at higher than ambient tem peratures because of heat generated by friction.
Temperatures up to 160
_
F (71
_
C) are considered normal for bearings, and they can operate safely to at least 180
_
F (82
_
C).
Checking bearing temperatures by hand is inaccu rate. Bearing temperatures can be measured ac curately by placing a contact‐type thermometer against the housing. Record this temperature for future reference.
A sudden increase in bearing temperatures is a warning that the bearings are at the point of failing to operate properly. Make certain that the bearing lubricant is of the proper viscosity and at the cor rect level (see LUBRICATION in Section E). Bear ing overheating can also be caused by shaft misalignment and/or excessive vibration.
When pumps are first started, the bearings may seem to run at temperatures above normal. Con tinued operation should bring the temperatures down to normal levels.
OPERATION PAGE C - 3
RD & RS SERIES
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.
OM-07214
Before attempting to open or service the pump:
1. Familiarize yourself with this manual.
2. Lock out or disconnect the power source 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.
POSSIBLE CAUSE PROBABLE REMEDY TROUBLE
PUMP FAILS TO
PRIME
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
Air leak in suction line.
Lining of suction hose collapsed.
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.
Suction check valve or foot valve clogged or binding.
Check strainer and clean if neces sary.
Clean valve.
Air leak in suction line.
Lining of suction hose collapsed.
Pump speed too high.
Impeller or other wearing parts worn or damaged.
Strainer clogged.
Correct leak.
Replace suction hose.
Check driver output.
Replace worn or damaged parts.
Check that impeller is properly centered and rotates freely.
Check strainer and clean if neces sary.
TROUBLESHOOTING PAGE D - 1
OM-07214 RD & RS SERIES
TROUBLE
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE (cont.)
PUMP REQUIRES
TOO MUCH
POWER
PUMP CLOGS
FREQUENTLY
POSSIBLE CAUSE PROBABLE REMEDY
Pump speed too slow.
Impeller clogged.
Suction lift too high.
Check driver output; consult the operation manual.
Free impeller of debris.
Measure lift w/vacuum gauge. Re duce lift and/or friction losses in suction line.
Leaking or worn seal or pump gasket.
Check pump vacuum. Replace leaking or worn seal or gasket.
Discharge head too high.
Install bypass line.
Suction intake not submerged at proper level or sump too small.
Pump speed too high.
Discharge head too low.
Liquid solution too thick.
Discharge flow too slow.
Check installation and correct sub mergence as needed.
Check driver output.
Adjust discharge valve.
Dilute if possible.
Open discharge valve fully to in crease flow rate, and run driver at maximum governed speed.
Clean valve.
Suction check valve or foot valve clogged or binding.
EXCESSIVE NOISE Cavitation in pump.
BEARINGS RUN
TOO HOT
Pumping entrained air.
Pump or drive not securely mounted.
Impeller clogged or damaged.
Bearing temperature is high, but within limits.
Low or incorrect lubricant.
Suction and discharge lines not prop erly supported.
Drive misaligned.
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.
Check bearing temperature regu larly to monitor any increase.
Check for proper type and level of lubricant.
Check piping installation for proper support.
Align drive properly.
PAGE D - 2 TROUBLESHOOTING
RD & RS SERIES OM-07214
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
RD & RS SERIES OM-07214
PUMP MAINTENANCE AND REPAIR ‐ SECTION E
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK
OPERATING PERFORMANCE.
STANDARD PERFORMANCES FOR PUMP MODEL RD3A32-BAR
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 ference due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.
Contact the Gorman‐Rupp Company to verify per formance or part numbers.
If your pump serial number is followed by an “N”, your pump is NOT a standard production model.
Pump speed and operating condition points must be within the continuous per formance range shown on the curve.
MAINTENANCE & REPAIR PAGE E - 1
OM-07214
PARTS PAGE
ILLUSTRATION
RD & RS SERIES
18
19
20
21
4
22
23
24
25
6
5
11 12 17
16
15
14
12
11
13
10
3
9
4
4
8
7
3
1
2
PAGE E - 2
Figure 1. Pump Model RD3A32-BAR
MAINTENANCE & REPAIR
RD & RS SERIES
.
INCLUDED W/REPAIR PUMP CASING ASSY
INDICATES PARTS RECOMMENDED FOR STOCK
46474-351
OM-07214
PARTS LIST
Pump Model RD3A32-BAR
(From S/N 1695564 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.
PART NAME
.
1
2
3
.
4
.
5
.
6
7
10
11
12
.
13
14
8
9
19
20
21
22
23
15
16
17
18
24
25
NOT SHOWN:
PUMP CASING BODY
STRAINER
CONNECTOR
PIPE PLUG
PIPE PLUG
STUD
RETURN TUBE ASSEMBLY
SUCTION TUBE ASSEMBLY
AIR RELEASE VALVE ASSEMBLY
MALE ELBOW
LOCK WASHER
HEX HEAD CAP SCREW
HEX NUT
BEARING HOUSING ASSEMBLY
SHAFT KEY
SUPPORT BRG HOUSING
FLAT WASHER
DRIVE SCREW
NAME PLATE
IMPELLER KEY
PUMP CASING GASKET
DISCHARGE TUBE ASSY
IMPELLER
LOCK WASHER
IMPELLER NUT
LUBRICATION DECAL
DISCHARGE STICKER
SUCTION STICKER
G‐R DECAL
INSTRUCTION TAG
BEARING TAG
ROTATION DECAL
CHECK VALVE BODY GASKET
PART
NUMBER
QTY
SEE NOTE BELOW 1
26841-094 1
25812-214 3
P02 15079 4
P06 15079
C0807 15991
46335-086
1
12
1
46335-076
GRP33-08B
25812-011
J08 15991
B0805 15991
D08 15991
44143-105
1
4
1
1
4
12
1
N0611 15990
R12852-01 15990
K08 15991
BM#04-03 17000
2613DZ 13990
K79329-23 15990
R12531 20000
46335-097
38623-536 13048
23962-519
K75776 15111
1
1
1
1
1
1
1
2
2
1
1
38816-081
6588BJ
6588AG
GR-03
38817-011
6588ABB
2613M
11589GA 18000
1
1
1
1
1
1
1
1
1
MAINTENANCE & REPAIR PAGE E - 3
OM-07214 RD & RS SERIES
ILLUSTRATION
15
16
33
ÑÑ
ÑÑ
ÑÑ ÌÌÌÌ
ÑÑ ÌÌÌÌ
ÌÌÌÌ
32
31
29
28
27
ÌÌÌÌÌÌ
ÌÌÌÌÌÌ ÑÑ
ÌÌÌÌÌÌ ÑÑ
ÌÌÌÌÌÌ ËË Ë ËË ËË ÏÏÏÏ ËËË ÎÎ ËË ÑÑ
ÏÏ ËËË ÎÎ ËË ÑÑ Ñ
30
18
11
19
20
21
22
6
SEAL DETAIL AREA
23
26
25
24
1
2
3
17
7
8
13
12
11
9
10
4
13 14 10
ÇÇÇ
ÇÇÇ
ÇÇÇ
ÇÇÇ ÌÌÌÌ
ÌÌÌÌ
PAGE E - 4
6
5
Figure 2. Bearing Housing Assembly
MAINTENANCE & REPAIR
ITEM
NO.
10
11
12
8
9
6
7
3
4
5
1
2
17
18
19
20
21
13
14
15
16
22
23
24
25
26
27
28
29
30
31
32
33
RD & RS SERIES OM-07214
PART NAME
GROUP GRIND
CONNECTOR
PIPE PLUG
BODY COVER
ROLL PIN
CENTER PLATE GASKET
SPACER PLATE GASKET
DOWEL PIN
HEX HEAD CAP SCREW
LOCK WASHER
PIPE PLUG
BEARING HOUSING
OIL SEAL
HEX HEAD CAP SCREW
BEARING HOUSING CAP
BEARING CAP GASKET
MALE ELBOW
AIR VENT
AIR VENT
MECH SEAL 1-5/8
RETAINING RING
SPACER PLATE
PUMP BLADE
PRESSURE REGULATING SPRING
GASKET
SPRING CAP
RETAINING RING
BALL BEARING
WOODRUFF KEY
IMPELLER SHAFT
BALL BEARING
BRG LOCKWASHER
BRG LOCKNUT
PARTS LIST
Bearing Housing Assembly
PART
NUMBER
QTY
LK05418 1
25812-214 1
P06 15079
T07826-04 10140
21154-666
1
1
1
N14145 18010
N14144 18000
21133-073
B0612 15991
J06 15991
P02 15079
W01172-03 11010
2
8
3
1
12
3
1
25227-240
B0605 15991
R12770-02 10010
N18938-01 18000
25812-011
S1703
S2162
25271-921
24124-243
1
1
1
1
1
1
1
2
4
N14129-02 11010
K79300-22
K76301
38681-021 19060
K68064 15991
24124-245
23282-010
K61559 15990
T08467-02 15010
23282-011
23962-511
23962-011
1
1
1
1
1
6
1
1
1
1
1
1
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 5
OM-07214
DRIVE SHAFT
KEY
RS AND RD SERIES
SECTION DRAWING
NAME
PLATE
PIPE PLUG
SUCTION TUBE
ASSEMBLY
IMPELLER KEY
BEARING
HOUSING
IMPELLER
LOCKWASHER
DISCHARGE
TUBE
IMPELLER
NUT
AIR RELEASE
VALVE
MOUNTING
HARDWARE
BEARING
HOUSING
SUPPORT
PUMP CASING
IMPELLER
RETURN TUBE
ASSEMBLY
PIPE PLUG
BODY GASKET
PIPE PLUG
STRAINER
PIPE PLUG
CONNECTOR
PAGE E - 6
Figure 3. Typical RD Model Pump Assembly (“BAR” Version)
MAINTENANCE & REPAIR
RS AND RD SERIES OM-07214
SECTION DRAWING
DRIVE END VIEW
SEAL AREA DETAIL
RETAINING
RING
SEAL
ASSEMBLY
CONNECTOR
MALE
ELBOW
BEARING CAP
ATTACHING
HARDWARE SPACER PLATE GASKET
AIR VENT
LOCKWASHER
BEARING HOUSING
IMPELLER SHAFT
BEARING
BEARING CAP
GASKET
BEARING
AIR VENT
SPACER PLATE
SPRING CAP
AND GASKET
BODY COVER
BEARING CAP
BEARING
LOCKNUT
PRESSURE
REGULATOR
SPRING
WOODRUFF KEY
ROTOR BLADE
PIPE PLUG
RETAINING RING
OIL SEAL
GROUP
GRIND
LOCATING
PIN
CENTER PLATE
GASKET
PIPE PLUG
CENTER PLATE GASKET
BODY COVER
ATTACHING HARDWARE
AND DOWEL PIN
Figure 4. Typical RD Series Bearing Housing Assembly
MAINTENANCE & REPAIR PAGE E - 7
OM-07214
SECTION DRAWING
RS AND RD SERIES
SIDES TO BE FLAT AND PARALLEL
WITHIN 1.249/1.250 THICKNESS
SLIDE MUST MOVE SMOOTHLY
THROUGH FULL VERTICAL TRAVEL
WITHIN CENTER PLATE
CENTER PLATE
ROTOR
SLIDE
NOTE RELATIONSHIP BETWEEN
PIPE PLUG HOLE IN CENTER
PLATE AND RELIEF HOLE IN SLIDE
PAGE E - 8
Figure 5. Typical Group Grind
MAINTENANCE & REPAIR
RS AND RD SERIES
PUMP AND SEAL DISASSEMBLY
AND REASSEMBLY
OM-07214
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 (see Figures 1, 2, 3, 4 and 5). If your pump is equipped with an Air Release Valve
Assembly (“BAR” Models), maintenance and re pair instructions for the Air Release Valve are cov ered separately in the specific literature shipped with the unit.
As described on the following pages, this manual will alert personnel to known procedures which re quire special attention, to those which could dam age equipment, and to those which could be dan gerous to personnel. However, this manual cannot possibly anticipate and provide detailed precau tions for every situation that might occur during maintenance of the unit. Therefore, it is the respon sibility of the owner/maintenance personnel to en sure that only safe, established maintenance pro cedures are used, and that any procedures not ad dressed in this manual are performed only after es tablishing that neither personal safety nor pump in tegrity are compromised by such practices.
For part numbers, quantities, suction, discharge and return tube positioning for your specific pump, refer to pages E-2 thru E-5 .
All parts of this pump except the pump casing may be serviced without removing suction and dis charge lines. However, the following instructions assume complete disassembly is required.
Before attempting to service the pump, shut off the incoming power to the motor and lock it out, or take other action to ensure that it will remain inopera tive. Close all valves in the suction and discharge lines and drain the pump casing and group grind by removing the drain plugs. Clean and reinstall the drain plugs.
MAINTENANCE & REPAIR
Before attempting to open or service the pump:
1. Familiarize yourself with this man ual.
2. Shut off the incoming power to the motor and lock it out, or take other action to ensure that the pump will remain inoperative.
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 attempt to service the pump as sembly unless all power to the pump motor has been shut off and locked out, or other action taken to ensure that the pump will remain inoperative; other wise, injury or death could result.
Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift
PAGE E - 9
OM-07214 the pump or component only as high as necessary and keep personnel away from suspended objects.
This pump is designed to be used with volatile and/or flammable liquids. Be certain proper safety practices are fol lowed before operating or servicing the pump. Provide adequate ventilation, prohibit smoking, wear static‐resistant clothing and shoes. Clean up all fuel spills immediately after occurrence.
Use Only Genuine Gorman-Rupp re placement parts. Failure to do so may cre ate a hazard and damage the pump or di minish optimal pump performance. Any such hazard, damage or diminished per formance is not covered by the warranty.
NOTE
When appropriate recycling facilities are available, the user should recycle components and fluids when doing any routine maintenance / repairs and also at the end of the pump’s useful life. All other components and fluids shall be disposed of ac cording to all applicable codes and regulations.
Separating Pump From Motor
(Figure 1)
Remove the coupling guard and loosen the cou pling on the pump drive shaft. Separate the motor and drive components from the pump, and remove the drive shaft key.
PAGE E - 10
RS AND RD SERIES
Air Release Valve Removal
(Figure 1)
Disconnect the air release valve discharge tube as sembly from the bearing housing. Disconnect the return tube assembly from the pump casing.
If exterior venting tubing has been installed, dis connect the tubing at the air release valve. Remove the connecting hardware and remove the air re lease valve.
See the accompanying literature for individual parts, maintenance and repair of the Air Release
Valve.
Pump Disassembly
(Figure 1 or 2)
Disconnect the suction and discharge tube as semblies from the bearing housing and pump cas ing.
Use a suitable hoist and sling to support the bear ing housing. Remove the nuts securing the casing to the body cover (Figure 2 or 4). Install two jacking screws (RS Models, 3/8-16 UNC; RD Models,
1/2-13 UNC, not supplied) in the tapped holes in the body cover. Tighten the screws evenly to pre vent binding, and pull the bearing housing, body cover and assembled parts straight out of the pump casing.
Impeller Removal
(Figure 2 or 4)
Immobilize the impeller by inserting a brass rod be tween the impeller vanes. Be careful not to dam age the impeller vanes. Straighten the tabs on the impeller tabwasher, and remove the impeller nut and tabwasher.
Remove the brass rod. Install two 3/8-16 UNC capscrews (not supplied) in the tapped holes in the impeller, and use a suitable puller to remove the im peller from the shaft. Retain the impeller key.
NOTE
An alternate method of removing the impeller is to carefully pry on the back side of the impeller (direct ly against two opposing vanes) with equal pressure
MAINTENANCE & REPAIR
RS AND RD SERIES until the impeller comes off the shaft.
OM-07214
Some impellers are fitted with wear rings. If the wear rings are badly worn, the entire impeller must be replaced or returned to the factory for wear ring replacement.
Group Grind Disassembly
(Figure 2 or 4)
Remove the spring cap, gasket and spring.
Seal Removal
(Figure 2 or 4)
Remove the seal retaining ring with caution; ten sion on the seal spring will be released. Remove the spring centering washer. Slide the rotating por tion of the seal off the shaft, and use a pair of stiff wires with hooked ends to remove the stationary seat. Be careful not to damage the seal faces.
If no further disassembly is required, see Seal In stallation .
Shaft and Bearing Removal and Disassembly
(Figure 2 or 4)
When the pump is properly operated and main tained, the bearing housing should not require dis assembly. Disassemble the shaft and bearings only when there is evidence of wear or damage.
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.
Remove the body cover attaching hardware, and use a soft‐faced mallet to tap around the outside di ameter of the body cover until it separates from the bearing housing and group grind. Remove the out board center plate gasket(s), and use solvent to clean the mating surfaces. Be careful not to scratch or mar the surfaces.
NOTE
Use an ink marker to match mark the center plate, rotor and slide of the group grind assembly. These parts are ground as an assembly, and their relative locations must be maintained.
Shaft and bearing disassembly in the field is not recommended. These operations should be performed only in a properly equipped shop by qualified personnel.
There are no provisions for draining of flushing the bearing housing lubricant. Place a drip pan under the bearing housing before removing the shaft and bearings.
NOTE
If your pump is equipped with optional oil‐lubri cated bearings, remove the oil cup and drain the bearing cavity before removing the shaft and bear ings.
If group grind replacement is necessary, slide the group grind assembly, blade spacers and rotor blades off the shaft. Retain the rotor woodruff key.
Tap the group grind dowel pins out of the bearing housing.
Remove the inboard center plate gasket, spacer plate and spacer plate gasket. Clean any gasket adhesive from the mating surfaces using solvent.
Be careful not to scratch or mar the surfaces.
MAINTENANCE & REPAIR
Disengage the attaching hardware and remove the bearing cap and gasket. Use an arbor (or hydrau lic) press to remove the oil seal from the bearing cap.
Place a block of wood against the impeller end of the shaft, and tap the shaft and assembled bear ings from the bearing housing.
If your pump is equipped with an oil seal in the bearing housing between the bearing and seal
PAGE E - 11
OM-07214 cavity, use a screwdriver or other suitable tool to re move the oil seal from the bearing housing.
After removing the shaft and bearings, clean and inspect the bearings in place as follows.
To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place . It is strongly recommended that the bearings be replaced any time the shaft and bear ings are removed.
Clean the bearing housing, shaft and all compo nent parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage and replace as necessary.
RS AND RD SERIES
The bearing tolerances provide a tight press fit onto the shaft and a snug slip fit into the bearing housing. Replace the bearings, shaft, or bearing housing if the proper bearing fit is not achieved.
If bearing replacement is required, remove the snap ring from the impeller shaft, and use a bear ing puller to remove the inboard bearing from the shaft.
Straighten the tabs on the bearing washer and re move the bearing lock nut and washer. Use a bear ing puller to remove the outboard bearing from the shaft.
Shaft and Bearing Reassembly and Installation
(Figure 2 or 4)
Inspect the shaft for distortion, nicks or scratches, or for thread damage on the impeller end. Dress small nicks and burrs with a fine file or emery cloth.
Replace the shaft if defective.
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.
Clean the bearings thoroughly in fresh cleaning solvent. Dry the bearings with filtered compressed air and coat with light oil.
Bearings must be kept free of all dirt and foreign material. Failure to do so will great ly shorten bearing life. Do not spin dry bearings. This may scratch the balls or races and cause premature bearing fail ure.
Rotate the bearings by hand to check for rough ness or binding and inspect the bearing balls. If ro tation is rough or the bearing balls are discolored, replace the bearings.
PAGE E - 12
To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place . It is strongly recommended that the bearings be replaced any time the shaft and bear ings are removed.
The bearings may be heated to ease installation.
An induction heater, hot oil bath, electric oven, or hot plate may be used to heat the bearings. Bear ings should never be heated with a direct flame or directly on a hot plate.
NOTE
If a hot oil bath is used to heat the bearings, both the oil and the container must be absolutely clean. If the oil has been previously used, it must be thor oughly filtered.
Use caution when handling hot bear ings to prevent burns.
Heat the bearings to a uniform temperature no higher than 250
_
F (120
_
C), and slide the bearings
MAINTENANCE & REPAIR
RS AND RD SERIES onto the shaft, one at a time, until they are fully seated. This should be done quickly, in one con tinuous motion, to prevent the bearings from cool ing and sticking on the shaft.
NOTE
If optional oil‐lubricated bearings are used, posi tion the bearings on the shaft with the shielded sides facing away from each other. It is recom mended that two buna or viton slinger rings (not supplied) be pressed onto the shaft between the bearings. Position the rings approximately 1/2 inch from each bearing to ensure sufficient lubrication and prevent premature bearing failure.
After the bearings have been installed and allowed to cool, check to ensure that they have not moved away from the shaft shoulders in shrinking. If movement has occurred, use a suitable sized sleeve and a press to reposition the bearings against the shaft shoulders.
If heating the bearings is not practical, lubricate the bearings with light oil, and use a suitable sized sleeve, and an arbor (or hydraulic) press to install the bearings on the shaft.
OM-07214
Slide the shaft and assembled bearings into the bearing housing until the outboard bearing seats against the bearing housing shoulder. Be careful not to cut or roll the lip of the oil seal (RD Model
Pumps).
Press the oil seal into the bearing cap with the lip positioned as shown in Figures 3 or 4. Replace the bearing cap gasket, and secure the bearing cap with the attaching hardware. Be careful not to cut the oil seal lip on the shaft keyway, or roll the lip dur ing installation.
NOTE
Impeller shaft endplay should be between .002 and
.010 inch (.051 to .254 mm). Tighten the bearing cap hardware tight enough to prevent leakage and obtain the correct endplay. Do not over‐tighten.
Lubricate the bearing housing as indicated in LU
BRICATION .
Seal Reassembly And Installation
(Figures 2 or 4 and 6)
Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent.
When installing the bearings onto the shaft, never press or hit against the outer race, balls, or ball cage. Press only on the inner race.
Secure the inboard bearing on the shaft with the bearing retaining ring. Secure the outboard bear ing with the tab washer and lock nut.
If your pump is equipped with an inboard oil seal
(RD Model Pumps), lubricate the seal with light oil, and position it in the bearing housing with the lip positioned as shown in Figure 4. Press the oil seal into the bearing housing until fully seated.
When installing the shaft and bearings into the bearing bore, push against the outer race. Never hit the balls or ball cage.
MAINTENANCE & REPAIR
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 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.
PAGE E - 13
OM-07214
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 .
If a replacement seal is being used, remove it from the container and inspect the precision finished
BEARING
HOUSING
STATIONARY
ELEMENT
RS AND RD SERIES faces to ensure that they are free of any foreign matter.
To ease installation of the seal, lubricate the shaft, bellows and stationary seat O‐ring 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 6).
SPRING
SPRING
RETAINER
IMPELLER
IMPELLER
SHAFT
ROTATING
ELEMENT
O‐RING
RETAINING
RING
RETAINER
BELLOWS temperatures above 160 _ F (71 _
Figure 6. Seal Assembly
This seal is not designed for operation at
C). Do not use at higher operating temperatures.
Inspect the impeller shaft for distortion, nicks, scratches, or damage to the shaft threads. Dress small nicks and burrs with a fine file or emery cloth.
If the shaft is defective, refer to Shaft and Bearing
Removal and Disassembly and replace the shaft.
ring into the bearing housing until fully seated. A push tube cut from a length of plastic pipe would aid this installation. The I.D. of the tube should be slightly larger than the O.D. of the shaft. Be careful not to damage the seal face. After installation, wipe the seal face in a concentric pattern with a clean, lint‐free cloth.
NOTE
It is recommended that a tapered sleeve (see Fig ure 7) be installed over the shaft keyway to ease in stallation of the rotating portion of the seal. This tool can be made from steel tubing or black pipe.
Lubricate the O‐ring with a light coat of oil and in stall it in the stationary seat. Press the seat and O‐
PAGE E - 14 MAINTENANCE & REPAIR
RS AND RD SERIES OM-07214
SHAFT
THREADS
SLEEVE
32
IMPELLER
SHAFT
SHAFT KEYWAY
SEAL
AREA
Figure 7. Seal Installation Sleeve
Lubricate the tapered sleeve and position it on the shaft. Position the rotating portion of the seal (con sisting of the retainer, bellows and rotating ele ment) on the sleeve, and apply even pressure against the shoulder of the seal retainer until the ro tating subassembly slides onto the shaft and the seal faces contact. A push tube cut from a piece of plastic tubing would aid this installation. The I.D. of the tube should be approximately the same diame ter as the I.D. of the seal spring.
Remove the tapered sleeve and install the seal spring and spring centering washer. Secure the seal with the retaining ring.
Group Grind Reassembly
NOTE
If any component in the group grind assembly re quires replacement, the entire group grind assem bly must be replaced as a unit. Refer to the special instructions in Group Grind Replacement at this time.
(Figure 2 or 5)
Install a new spacer plate gasket, the spacer plate and inboard center plate gasket. Be sure the oval hole in the spacer plate matches up with the tubing hole.
Inspect the group grind rotor (Figure 5) for wear or damage. If replacement is necessary, refer to the specific instructions in Group Grind Replace ment . If the group grind is not being replaced, pro ceed as follows.
Center the inboard blade spacer on the shaft (RS
Models only) and install the rotor woodruff key.
MAINTENANCE & REPAIR
(Figure 5)
If removed, install the dowel pins in the bearing housing. Install the center plate, and install the slide in the center plate, making sure the recessed hole in the slide faces toward the impeller. Check for free movement of the slide in the center plate.
Coat both ends of the rotor with “Anti‐Wear Lubri cating And Hydraulic Oil SAE 10, Energol HLP‐HD
32” or equivalent lubricant, and install it on the shaft. Check the rotor for free movement.
(Figure 2 or 5)
Inspect the rotor blades for wear or damage and replace as required. Align the blades with the rotor slots and install the blades. Install the outboard blade spacer on the rotor (RS Models only).
Install one outboard center plate gasket.
NOTE
If the thickness of the rotor or slide is greater than the thickness of the center plate, install a second center plate gasket. To check thickness, temporari ly secure the center plate by installing two 7/16‐20
UNC by 2‐inch long bolts (not supplied) through the bearing housing and spacer plate, and into the tapped holes in the center plate. Place a straight edge across the center plate and rotate the shaft. If the rotor or blades touch the straight edge at any point, add a second center plate gasket and re check. The clearance should be no more than .001
inch (0,025 mm) from the rotor to the straight edge.
No more than two gaskets should be required. Re move the temporary bolts.
Inspect the locating pin and replace it if required.
Align the pin in the recessed hole in the slide, and use a soft‐faced mallet to tap the body cover into place on the dowel pins. Secure the body cover with the attaching hardware. Be sure the dowel pins are fully seated into the body cover.
Group Grind Check
(Figure 2 or 5)
Remove the spring cap and pressure regulating spring. Insert a screwdriver or other suitable tool into the drain plug hole, and move the slide up and down. The slide should travel 1/8 inch (3,2 mm)
PAGE E - 15
OM-07214 from the full priming position to the neutral position.
If it does not, flush the group grind with penetrating oil, and check the slide travel again. The slide should move freely.
After checking the group grind, install the pressure regulating spring, spring cap gasket and spring cap. Clean and reinstall the drain plug.
Refer to Impeller Installation .
Group Grind Replacement
(Figure 2 or 4)
RS AND RD SERIES during this procedure; otherwise, spring tension on the slide could cock the assembly and prevent ac curate measurements.
Remove the feeler gauge and install one outboard center plate gasket.
NOTE
If the thickness of the rotor or slide is greater than the thickness of the center plate, install a second center plate gasket. To check thickness, place a straight edge across the center plate and rotate the shaft. If the rotor or blades touch the straight edge at any point, add a second center plate gasket and re check. The clearance should be no more than .001
inch (0,025 mm) from the rotor to the straight edge.
No more than two gaskets should be required. Re move the temporary bolts.
If the group grind requires replacement, it is strongly recommended that the pump be returned to the factory. Fitting proce dures involve extremely close tolerances which are critical to efficient operation.
These procedures are difficult to accom plish outside the factory.
If the group grind must be replaced in the field, dowel holes in the center plate must be drilled and reamed after the group grind, body cover and im peller have been fully reassembled.
Install the spacer plate gaskets, spacer plate, blade spacers (RS Models only), and group grind parts (including the outboard blade spacer, RS
Models only) as described in Group Grind Instal lation .
Before installing the body cover, position the group grind slide in full priming position (in contact with the bottom of the center plate). To check rotor con centricity, rotate the shaft until the highest point on the rotor comes in contact with the slide. Move the center plate and slide until a .002 inch (0,05 mm) feeler gauge can be inserted between the rotor and slide at the point of contact. Secure the center plate in this position with two 7/16-20 UNF by 2 inch long capscrews (not supplied) inserted through the bearing housing and into the tapped holes in the center plate.
NOTE
The pressure regulating spring must be removed
PAGE E - 16
Inspect the locating pin and replace it if required.
Align the pin in the recessed hole in the slide, and position the body cover on the shaft. Be careful not do disturb the position of the center plate. Se cure the body cover with the hardware, but do not fully tighten the capscrews at this time.
Install the impeller as described in Impeller Instal lation . Do not bend the tabs over on the impeller washer (Figure 1 or 2) until the shaft is rotated to check for rubbing of the impeller or inboard impel ler wear ring (if so equipped) against the body cov er. If the impeller or wear ring (if so equipped) rubs, tap the body cover with a mallet until the impeller rotates freely. Now tighten the hardware securing the body cover.
NOTE
Fully tighten six of the capscrews before replacing the two capscrews used to temporarily hold the group grind.
After fully securing the body cover, bend the tabs of the impeller washer over the impeller nut.
Measure the length of the dowel pins. Use the ex isting dowel pin holes in the bearing housing as guides to drill and ream two new dowel pin holes
(.312 inch [7,9 mm] finished diameter) through the center plate. The holes should be just deep enough so the pins will be flush with the bearing housing when installed. Do not drill through the
MAINTENANCE & REPAIR
RS AND RD SERIES OM-07214 body cover. Be careful not to damage the holes in the bearing housing or body cover with the drill bit or reamer. Instal the dowel pins in the new holes.
Group Grind Check
(Figure 2 or 4)
Remove the spring cap and pressure regulating spring. Insert a screwdriver or other suitable tool into the drain plug hole, and move the slide up and down. The slide should travel 1/8 inch (3,2 mm) from the full priming position to the neutral position.
If it does not, flush the group grind with penetrating oil, and check the slide travel again. The slide should move freely. Reinstall the pressure regulat ing spring and spring cap, and clean and reinstall the drain plug.
After checking the group grind, install the pressure regulating spring, spring cap gasket and spring cap.
Refer to Impeller Installation .
Final Assembly
(Figure 1 or 2)
Connect the suction and discharge tube assem blies to the bearing housing and pump casing. For part numbers, quantities, suction, discharge and return tube positioning for your specific pump, re fer to the separate Parts List manual accompany ing your pump.
Install the drive shaft key, and connect the coupling and motor. Install the coupling guards.
Air Release Valve Installation
(Figure 2)
Secure the air release valve with the mounting hardware. Connect the return tube assembly to the pump casing.
LUBRICATION
Seal Assembly
The seal assembly is lubricated by the medium be ing pumped. No additional lubrication is required.
Impeller Installation
(Figure 1 or 2)
Inspect the impeller and replace it if cracked or badly worn. Some impellers are equipped with wear rings. If the wear rings that are badly worn, the entire impeller must be replaced or returned to the factory for wear ring replacement.
Install the impeller key, and slide the impeller onto the shaft. Immobilize the impeller, and secure it with the tab washer and impeller nut. Bend the tabs on the washer over the impeller nut.
Before operation, lubricate the group grind as indi cated in LUBRICATION .
Pump Reassembly
(Figure 1 or 2)
Install the pump casing gasket. Install the bearing housing assembly in the pump casing, and secure it with the attaching hardware.
MAINTENANCE & REPAIR
Group Grind
Before starting the pump for the first time or if the pump has not been used for a long period of time, remove the 1/8‐inch NPT pipe plug (located in the bearing housing, above the seal area when viewed from the drive end). Pour approximately 8 ounces
(0,24 liter) of SAE 10 or 20 non‐detergent oil into the housing to lubricate the shaft seal and group grind rotor blades. Reinstall the plug.
Standard Bearings
(Figure 2 or 4)
Standard bearings used in this pump are perma nently sealed and lubricated by the manufacturer, and no additional lubrication is required. However, to minimize the danger of moisture contamination due to temperature changes, the bearing housing is also partially filled with grease.
When overhauling the bearing housing, remove the air vent fitting, install a lubrication fitting, and fill
PAGE E - 17
OM-07214 the cavity with approximately 15 ounces (425 g) of grease (approximately one‐third full).
Optional Oil Lubricated Bearings
The bearing housing was fully lubricated when shipped from the factory. Check the oil level regu larly at the oil cup and maintain it at the top of the cup. When lubrication is required, remove the air vent and add SAE No. 30 non‐detergent oil through the hole. Do not over‐lubricate. Over‐lubri cation can cause the bearings to over‐heat, result ing in premature bearing failure.
Under normal conditions, drain the bearing hous ing once each year and refill with clean oil. Change
RS AND RD SERIES the oil more frequently if the pump is operated con tinuously or installed in an environment with rapid temperature change.
Monitor the condition of the gearbox lubri cant regularly for evidence of rust or mois ture condensation. This is especially im portant in areas where variable hot and cold temperatures are common.
For cold weather operation, consult the factory or a lubricant supplier for the recommended grade of oil.
PAGE E - 18 MAINTENANCE & REPAIR
For Warranty Information, Please Visit www.grpumps.com/warranty or call:
U.S.: 419-755-1280
Canada: 519-631-2870
International: +1-419-755-1352
GORMAN‐RUPP PUMPS
advertisement
Related manuals
advertisement