GORMAN-RUPP PUMPS 60 Series Application guide

COM-05171-OE01

January 5, 2001

REV A 09/14/10

C+PP

THE GORMAN‐RUPP COMPANY DMANSFIELD, OHIO

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

ECopyright by the Gorman‐Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

60 SERIES PUMP

62 1/2D1-CH23 S/G

MODEL

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 PAGE B - 1.....................................................

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

POSITIONING PUMP 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 - 2...............................................................

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 - 4........................................................

Siphoning PAGE B - 4.............................................................

Valves PAGE B - 4................................................................

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

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

Exhaust Primer PAGE C - 1........................................................

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

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

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

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

Strainer Check PAGE C - 2.........................................................

Pump Vacuum Check PAGE C - 2..................................................

STOPPING PAGE C - 2................................................................

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

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

PREVENTIVE MAINTENANCE PAGE D - 2..................................................

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

STANDARD PERFORMANCE CURVE FOR PUMP MODEL 62 1/2D1-CH23 S/G PAGE E - 1..

PARTS LIST:

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

Pump End Assembly PAGE E - 5...................................................

Exhaust Primer Assembly PAGE E - 6...............................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 7.........................

TABLE OF CONTENTS

(continued)

Discharge Check Valve Disassembly PAGE E - 7.....................................

Exhaust Primer Disassembly PAGE E - 7............................................

Pump Disassembly PAGE E - 7.....................................................

Seal Removal and Disassembly PAGE E - 8..........................................

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

Impeller Installation PAGE E - 10.....................................................

Pump Reassembly PAGE E - 10.....................................................

Exhaust Primer Reassembly PAGE E - 10.............................................

Discharge Check Valve Reassembly PAGE E - 11......................................

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

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

Engine PAGE E - 11................................................................

60 SERIES OM-05171

PAGE I - 1INTRODUCTION

INTRODUCTION

This Installation, Operation, and Maintenance

manual is designed to help you achieve the best

performance and longest life from your Gorman‐

Rupp pump.

This pump is a 60 Series, single‐stage centrifugal

model designed for agricultural or fire fighting ser

vice. It is close‐coupled to a Kohler CH23 v‐twin cyl

inder O.H.V. air cooled gasoline engine and pro

tected by a wrap‐around roll cage with rubber

mounting feet. The pump features compact, light

weight design for portability, as well as rugged

construction for easy, low‐cost maintenance. The

basic material of construction for wetted parts is

aluminum with bronze wear ring, and a self lubri

cated mechanical seal.

If there are any questions regarding the pump or its

application which are not covered in this manual or

in other literature accompanying this unit, please

contact your Gorman‐Rupp distributor, or write:

The Gorman‐Rupp Company or Gorman‐Rupp of Canada Limited

P.O. Box 1217 70 Burwell Road

Mansfield, Ohio 44901-1217 St. Thomas, Ontario N5P 3R7

For information or technical assistance on the engine, contact the engine manufacturer's local dealer or

representative.

The following are used to alert maintenance personnel to procedures which require special attention, 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.

60 SERIES OM-05171

PAGE A - 1SAFETY

SAFETY - SECTION A

This information applies to 60 Series

Engine Driven pumps. Refer to the man

ual accompanying the engine before at

tempting to begin operation.

This manual will alert personnel to

known procedures which require spe

cial attention, to those which could

damage equipment, and to those which

could be dangerous to personnel. How

ever, this manual cannot possibly antici

pate and provide detailed instructions

and precautions for every situation that

might occur during maintenance of the

unit. Therefore, it is the responsibility of

the owner/maintenance personnel to

ensure that only safe, 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.

Before attempting to open or service the

pump:

1. Familiarize yourself with this man

ual.

2. Shutdown the engine and discon

nect the park plug wires to ensure

that the pump will remain inopera

tive.

3. Allow the pump to completely cool

if overheated.

4. Check the temperature before

opening any covers, plates, or

plugs.

5. Close the suction and discharge

valves.

6. Vent the pump slowly and cau

tiously.

7. Drain the pump.

This pump is designed to handle clear

water for high pressure distribution. 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.

Do not operate the pump against a

closed discharge valve for long periods

of time. This could bring the liquid to a

boil, build pressure, and cause the

pump casing to rupture or explode.

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 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.

Fuel used by internal combustion en

gines presents an extreme explosion

60 SERIES

OM-05171

PAGE A - 2 SAFETY

and fire hazard. Make certain that all

fuel lines are securely connected and

free of leaks. Never refuel a hot or run

ning engine. Avoid overfilling the fuel

tank. Always use the correct type of fuel. Never tamper with the governor to gain

more power. The governor establishes

safe operating limits that should not be

exceeded.

OM-0517160 SERIES

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 posi

tioned 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 and engine.

OUTLINE DRAWING

Figure 1. Pump Model 62 1/2D1-CH23 S/G

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 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

ing, check for loose hardware at mating sur

faces.

OM-05171 60 SERIES

PAGE B - 2 INSTALLATION

c. Carefully read all tags, decals and markings

on the pump assembly, and follow the instruc

tions indicated.

d. Check all lubricant levels and lubricate as

necessary. Refer to LUBRICATION in the

MAINTENANCE AND REPAIR section of this

manual and perform duties as instructed.

e. If the pump and engine have been stored for

more than 12 months, some of the compo

nents or lubricants may have exceeded their

maximum shelf life. These must be inspected

or replaced to ensure maximum pump serv

ice.

f. Check to ensure the following standard

equipment items are included with the pump

assembly:

SPortable 6.5 gallon fuel tank complete with

quick‐connect fitting.

SSuction strainer.

SRubber foot mounting kit (must be

installed). To install feet, position flat wash

ers on capscrews, slide the capscrews

through the rubber feet and holes in the

base, and secure with the flanged hex nut.

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

This pump is designed to be very light‐weight and

portable. The total pump weight is approximately

240 pounds (109 kg), not including accessories

or engine fuel. Customer installed equipment such

as suction and discharge hoses must be removed

before attempting to lift.

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.

To ensure sufficient lubrication and fuel supply to

the engine, do not position the pump and engine

more than 15_off horizontal for continuous opera

tion. The pump and engine may be positioned up

to 30_off horizontal for intermittent operation

only; however, the engine manufacturer should be

consulted for continuous operation at angles

greater than 15_.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in

creased suction lift, discharge elevation, and fric

tion losses. See the performance curve and oper

ating range shown on Page E‐1 to be sure your

overall application allows pump to operate within

the safe operation range.

Materials

Either pipe or hose maybe used for suction and

discharge lines; however, the materials must be

compatible with the liquid being pumped. If hose is

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

forced type to prevent collapse under suction. Us

ing piping couplings in suction lines is not recom

mended.

Line Configuration

Keep suction and discharge lines as straight as

possible to minimize friction losses. Make mini

mum use of elbows and fittings, which substan

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

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