GORMAN-RUPP PUMPS 10 Series Anwendungshandbuch

ACE OM-00905-03

July 22, 2004

Rev. B 02‐11‐14

THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO

www.grpumps.com

GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

2004 The Gorman‐Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

10 SERIES PUMP

MODEL

112E60-B

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.....................................

PREINSTALLATION INSPECTION PAGE B - 1............................................

POSITIONING PUMP PAGE B - 2.......................................................

Lifting PAGE B - 2.................................................................

Mounting PAGE B - 2.............................................................

SUCTION AND DISCHARGE PIPING PAGE B - 2.........................................

Materials PAGE B - 2..............................................................

Line Configuration PAGE B - 2......................................................

Connections to Pump PAGE B - 2..................................................

Gauges PAGE B - 3...............................................................

SUCTION LINES PAGE B - 3...........................................................

Fittings PAGE B - 3...............................................................

Strainers PAGE B - 3..............................................................

Sealing PAGE B - 3...............................................................

Suction Lines In Sumps PAGE B - 3.................................................

Suction Line Positioning PAGE B - 3................................................

DISCHARGE LINES PAGE B - 5........................................................

Siphoning PAGE B - 5.............................................................

Valves PAGE B - 5................................................................

Bypass Lines PAGE B - 5..........................................................

AUTOMATIC AIR RELEASE VALVE PAGE B - 6...........................................

Theory of Operation PAGE B - 6....................................................

Air Release Valve Installation PAGE B - 7............................................

ALIGNMENT PAGE B - 8..............................................................

Coupled Drives PAGE B - 8........................................................

V‐Belt Drives PAGE B - 9...........................................................

V‐BELT TENSIONING PAGE B - 9......................................................

General Rules of Tensioning PAGE B - 9.............................................

Tension Measurment PAGE B - 10...................................................

ELECTRICAL CONNECTIONS PAGE B - 12...............................................

OPERATION - SECTION C PAGE C - 1.......................................

PRIMING PAGE C - 1.................................................................

STARTING PAGE C - 1................................................................

Rotation PAGE C - 1..............................................................

OPERATION PAGE C - 2..............................................................

Lines With a Bypass PAGE C - 2....................................................

Lines Without a Bypass PAGE C - 2.................................................

Leakage PAGE C - 2..............................................................

Liquid Temperature And Overheating PAGE C - 2.....................................

Strainer Check PAGE C - 3.........................................................

Pump Vacuum Check PAGE C - 3..................................................

STOPPING PAGE C - 3................................................................

Cold Weather Preservation PAGE C - 3..............................................

TABLE OF CONTENTS

(continued)

BEARING TEMPERATURE CHECK PAGE C - 3..........................................

TROUBLESHOOTING - SECTION D PAGE D - 1...............................

PREVENTIVE MAINTENANCE PAGE D - 3...............................................

PUMP MAINTENANCE AND REPAIR - SECTION E PAGE E - 1.................

PERFORMANCE CURVE PAGE E - 1...................................................

PARTS LIST

Pump Model PAGE E - 3..........................................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 4.........................

Suction Check Valve Removal PAGE E - 4...........................................

Suction Elbow And Wear Plate Removal PAGE E - 4..................................

Impeller Removal PAGE E - 5......................................................

Seal Removal PAGE E - 5..........................................................

Pump Casing Removal PAGE E - 5.................................................

Shaft and Bearing Removal and Disassembly PAGE E - 6.............................

Shaft and Bearing Reassembly and Installation PAGE E - 7............................

Seal Reassembly and Installation PAGE E - 8........................................

Impeller Installation And Adjustment PAGE E - 9......................................

Pump Casing Installation PAGE E - 10................................................

Wear Plate And Suction Elbow Installation PAGE E - 10................................

Suction Check Valve Installation PAGE E - 10.........................................

Final Pump Assembly PAGE E - 10..................................................

PRESSURE RELIEF VALVE MAINTENANCE PAGE E - 11..................................

LUBRICATION PAGE E - 11.............................................................

Seal Assembly PAGE E - 11.........................................................

Bearings PAGE E - 11..............................................................

10 SERIES OM-00905

PAGE I - 1INTRODUCTION

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 a 10 Series, semi‐open impeller, self‐

priming centrifugal model with a suction check

valve. The pump is designed for handling most

non‐volatile, non‐flammable liquids containing

specified entrained solids. The basic material of

construction for wetted parts is gray iron, with

stainless steel impeller shaft and ductile iron wear

ing parts.

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 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.

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.

10 SERIES OM-00905

PAGE A - 1SAFETY

SAFETY - SECTION A

This information applies to 10 Series

basic pumps. Gorman‐Rupp has no

control over or particular knowledge of

the power source which will be used.

Refer to the manual accompanying the

power source before attempting to be

gin 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.

Before attempting to open or service the

pump:

1. Familiarize yourself with this man

ual.

2. Disconnect or lock out 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

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 most

non‐volatile, non‐flammable liquids

containing specified entrained solids.

Do not attempt to pump volatile, corro

sive, or flammable materials which may

damage the pump or endanger person

nel 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.

Do not operate the pump without the

guards in place over the rotating parts.

Exposed rotating parts can catch cloth

ing, fingers, or tools, causing severe in

jury to personnel.

Do not remove plates, covers, gauges,

pipe plugs, or fittings from an over

heated pump. Vapor pressure within the

pump can cause parts being disen

gaged to be ejected with great force. Al

low the pump to cool before servicing.

Do not operate 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.

10 SERIES OM-00905

PAGE A - 2 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.

10 SERIES OM-00905

PAGE B - 1INSTALLATION

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 B-1 for the approximate physical di

mensions of this pump.

OUTLINE DRAWING

Figure B-1. Pump Model 112E60-B

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, engine or 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

OM-00905 10 SERIES

PAGE B - 2 INSTALLATION

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. Note that the pump shaft rotates in

the required direction.

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 or power source 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.

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

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.

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.

Mounting

Locate the pump in an accessible place as close as

practical to the liquid being pumped. Level mount

ing is essential for proper operation.

The pump may have to be supported or shimmed

to provide for level operation or to eliminate vibra

tion.

If the pump has been mounted on a moveable

base, make certain the base is stationary by setting

the brake and blocking the wheels before attempt

ing to operate the pump.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in

creased suction lift, discharge elevation, and fric

tion losses. See the performance curve to be sure

your overall application allows the pump to operate

within the safe operation range.

Materials

Either pipe or hose maybe used for suction and

discharge lines; however, the materials must be

compatible with the liquid being pumped. If hose is

used in suction lines, it must be the rigid‐wall, rein

forced type to prevent collapse under suction. Us

ing piping couplings in suction lines is not recom

mended.

Line Configuration

Keep suction and discharge lines as straight as

possible to minimize friction losses. Make mini

mum use of elbows and fittings, which substan

tially increase friction loss. If elbows are necessary,

use the long‐radius type to minimize friction loss.

Connections to Pump

Before tightening a connecting flange, align it ex

actly with the pump port. Never pull a pipe line into

10 SERIES OM-00905

PAGE B - 3INSTALLATION

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

slopes down to the pump at any point along the

suction run, air pockets will be created.

Fittings

Suction lines should be the same size as the pump

inlet. If reducers are used in suction lines, they

should be the eccentric type, and should be in

stalled with the flat part of the reducers uppermost

to avoid creating air pockets. Valves are not nor

mally used in suction lines, but if a valve is used,

install it with the stem horizontal to avoid air pock

ets.

Strainers

If a strainer is furnished with the pump, be certain

to use it; any spherical solids which pass through a

strainer furnished with the pump will also pass

through the pump itself.

If a strainer is not furnished with the pump, but is

installed by the pump user, make certain that the

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 2-3/4 inch

(69,9 mm) diameter spherical solids.

Sealing

Since even a slight leak will affect priming, head,

and capacity, especially when operating with a

high suction lift, all connections in the suction line

should be sealed with pipe dope to ensure an air

tight seal. Follow the sealant manufacturer's rec

ommendations when selecting and applying the

pipe dope. The pipe dope should be compatible

with the liquid being pumped.

Suction Lines In Sumps

If a single suction line is installed in a sump, it

should be positioned away from the wall of the

sump at a distance equal to 1‐1/2 times the diame

ter of the suction line.

If there is a liquid flow from an open pipe into the

sump, the flow should be kept away from the suc

tion inlet because the inflow will carry air down into

the sump, and air entering the suction line will re

duce pump efficiency.

If it is necessary to position inflow close to the suc

tion inlet, install a baffle between the inflow and the

suction inlet at a distance 1‐1/2 times the diameter

of the suction pipe. The baffle will allow entrained

air to escape from the liquid before it is drawn into

the suction inlet.

If two suction lines are installed in a single sump,

the flow paths may interact, reducing the efficiency

of one or both pumps. To avoid this, position the

suction inlets so that they are 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

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