GORMAN-RUPP PUMPS 10 Series Application guide

OM-06721-01

January 26, 2015

GORMAN‐RUPP PUMPS

www.grpumps.com

2015 Gorman‐Rupp Pumps Printed in U.S.A.

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

10 SERIES PUMP

MODEL

16D60-QSF2.8P FT4

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:

The engine exhaust from this

product contains chemicals

known to the State of California to

cause cancer, birth defects or

other reproductive harm.

TABLE OF CONTENTS

INTRODUCTION PAGE I - 1.................................................

SAFETY ‐ SECTION A PAGE A - 1............................................

INSTALLATION - SECTION B PAGE B - 1....................................

Pump Dimensions PAGE B - 1.....................................................

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

Battery Specifications And Installation PAGE B - 2....................................

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

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

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

Clearance PAGE B - 3.............................................................

SUCTION AND DISCHARGE PIPING PAGE B - 3.........................................

Materials PAGE B - 3..............................................................

Line Configuration PAGE B - 3......................................................

Connections to Pump PAGE B - 3..................................................

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

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

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

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

Sealing PAGE B - 4...............................................................

Suction Lines in Sumps PAGE B - 4.................................................

Suction Line Positioning PAGE B - 4................................................

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 - 7..............................................................

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

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

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

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

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

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

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

OPERATIONAL CHECKS PAGE C - 3...................................................

Leakage PAGE C - 3..............................................................

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

Liquid Temperature And Overheating PAGE C - 3.....................................

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

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

Manual Stopping PAGE C - 3.......................................................

Automatic Stopping PAGE C - 4....................................................

Safety Shutdown System PAGE C - 4...............................................

TABLE OF CONTENTS

(continued)

PERIODIC CHECKS PAGE C - 4.......................................................

Seal Cavity and Bearing Lubrication PAGE C - 4......................................

Bearing Temperature Check PAGE C - 4.............................................

Engine Fuel Filter PAGE C - 4......................................................

Engine Oil PAGE C - 4.............................................................

COLD WEATHER PRESERVATION PAGE C - 4...........................................

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

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

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

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

PARTS LISTS:

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

Power Unit Kit PAGE E - 5.........................................................

Pump End Assembly PAGE E - 7...................................................

Drive Assembly PAGE E - 8........................................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 9.........................

Back Cover And Wear Plate Removal PAGE E - 9.....................................

Suction Check Valve Removal PAGE E - 9...........................................

Separating Intermediate and Drive Assembly From Engine PAGE E - 10..................

Loosening Impeller PAGE E - 10.....................................................

Pump Casing Removal PAGE E - 11.................................................

Impeller Removal PAGE E - 11......................................................

Seal Removal and Disassembly PAGE E - 11..........................................

Shaft and Bearing Removal and Disassembly PAGE E - 11.............................

Shaft and Bearing Reassembly and Installation PAGE E - 12............................

Securing Intermediate and Drive Assembly To Engine PAGE E - 13......................

Seal Reassembly and Installation PAGE E - 14........................................

Impeller Installation And Adjustment PAGE E - 15......................................

Pump Casing Installation PAGE E - 16................................................

Suction Check Valve Installation PAGE E - 16.........................................

Back Cover Installation PAGE E - 16.................................................

Final Pump Assembly PAGE E - 17..................................................

LUBRICATION PAGE E - 17.............................................................

Seal Assembly PAGE E - 17.........................................................

Bearings PAGE E - 17..............................................................

Engine PAGE E - 17................................................................

10 SERIES OM-06721

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.

Because pump installations are seldom identical,

this manual cannot possibly provide detailed in

structions and precautions for every aspect of

each specific application. Therefore, it is the re

sponsibility of the owner/installer of the pump to

ensure that applications not addressed in this

manual are performed only after establishing that

neither operator safety nor pump integrity are com

promised by the installation. Pumps and related

equipment must be installed and operated ac

cording to all national, local and industry stan

dards.

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

power source, contact the power source manufac

turer's local dealer or representative.

HAZARD AND INSTRUCTION

DEFINITIONS

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-06721

PAGE A - 1SAFETY

SAFETY ‐ SECTION A

These warnings apply to 10 Series en

gine driven pumps. Refer to the manual

accompanying the engine before at

tempting to begin operation.

Because pump installations are seldom

identical, this manual cannot possibly

provide detailed instructions and pre

cautions for each specific application.

Therefore, it is the owner/installer's re

sponsibility to ensure that applications

not addressed in this manual are per

formed only after establishing that nei

ther operator safety nor pump integrity

are compromised by the installation.

Before attempting to open or service the

pump:

1. Familiarize yourself with this man

ual.

2. Switch off the engine ignition and

disconnect the positive battery

cable 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 large entrained solids. Do

not attempt to pump volatile, corrosive,

or flammable liquids which may dam

age the pump or endanger personnel as

a result of pump failure.

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.

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

10 SERIESOM-06721

PAGE A - 2 SAFETY

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.

Fuel used by internal combustion en

gines present an extreme explosion and

fire hazard. Make certain that all fuel

lines are securely connected and free of

leaks. Never refuel a hot or running en

gine. Avoid overfilling the fuel tank. Al

ways use the correct type of fuel.

Do not operate an internal combustion

engine in an explosive atmosphere.

When operating internal combustion

engines in an enclosed area, make cer

tain that exhaust fumes are piped to the

outside. These fumes contain carbon

monoxide, a deadly gas that is color

less, tasteless, and odorless.

Never tamper with the governor to gain

more power. The governor establishes

safe operating limits that should not be

exceeded. Refer to the performance

curve, page E-1, for the maximum con

tinuous operating speed for this pump.

Pumps and related equipment must be in

stalled and operated according to all na

tional, local and industry standards.

10 SERIES OM-06721

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.

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 and trailer.

OUTLINE DRAWING

Figure 1. Pump Model 16D60-QSF2.8P FT4

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 trailer for cracks, dents,

damaged threads, and other obvious dam

age.

b. Check for and tighten loose attaching hard

ware. Since gaskets tend to shrink after dry

OM-06721 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.

d. Check levels and lubricate as necessary. Re

fer to LUBRICATION in the MAINTENANCE

AND REPAIR section of this manual and per

form duties as instructed.

e. If the pump and engine have been stored for

more than 12 months, some of the compo

nents or lubricants may have exceeded their

maximum shelf life. These must be inspected

or replaced to ensure maximum pump serv

ice.

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.

Battery Specifications And Installation

Unless otherwise specified on the pump order, the

engine battery was not included with the unit. Re

fer to the following specifications when selecting a

battery.

Table 1. Battery Specifications

20.5L

12 Volts 960‐975 365 175 8.75W

9.75H

Voltage

Cold Reserve Approx.

Crank Capacity Amp/ Overall

Amps @80°F Hr. Dims.

@ 0°F (Minutes) Rating (Inches)

Refer to the information accompanying the battery

and/or electrolyte solution for activation and charg

ing instructions.

Before installing the battery, clean the positive and

negative cable connectors, and the battery termi

nals. Secure the battery by tightening the

holddown brackets. The terminals and clamps

may be coated with petroleum jelly to retard corro

sion. Connect and tighten the positive cable first,

then the negative cable.

POSITIONING PUMP

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.

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.

Mounting

Locate the pump in an accessible place as close as

practical to the liquid being pumped. Level mount

ing is essential for proper operation.

The pump may have to be supported or shimmed

to provide for level operation or to eliminate vibra

tion.

If the pump has been mounted on a moveable

base, make certain the base is stationary by setting

the brake and blocking the wheels before attempt

ing to operate the pump.

To ensure sufficient lubrication and fuel supply to

the engine, do not position the pump and engine

more than 15off horizontal for continuous opera

tion. The pump and engine may be positioned up

to 30off horizontal for intermittent operation

10 SERIES OM-06721

PAGE B - 3INSTALLATION

only; however, the engine manufacturer should be

consulted for continuous operation at angles

greater than 15.

Clearance

When positioning the pump, allow a minimum

clearance of 18 inches (457,2 mm) in front of the

back cover to permit removal of the cover and easy

access to the pump interior.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in

creased suction lift, discharge elevation, and fric

tion losses. See the performance curve and notes

on Page E‐1 to be sure your overall application al

lows pump to operate within the safe operation

range.

Materials

Either pipe or hose maybe used for suction and

discharge lines; however, the materials must be

compatible with the liquid being pumped. If hose is

used in 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.

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 2-5/8‐inch

(66,5 mm) diameter spherical solids.

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