GORMAN-RUPP PUMPS 83C52-B Application guide

OM-00893-03

November 18, 2005

ABCDE

THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO

www.grpumps.com

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

80 SERIES PUMP

MODELS

83C52−B

Gorman-Rupp pump online at

www.grpumps.com/register.

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 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISCHARGE LINES PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Siphoning PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bypass Lines PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTOMATIC AIR RELEASE VALVE PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Theory of Operation PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Release Valve Installation PAGE B − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALIGNMENT PAGE B − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coupled Drives PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Belts PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE BELT TENSIONING PAGE B − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Rules of Tensioning PAGE B − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GROUNDING PAGE B − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION − SECTION C PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMING PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotation PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

BEARING TEMPERATURE CHECK PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

(continued)

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 LIST:

Pump Model PAGE E − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Suction Check Valve Disassembly PAGE E − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Casing Removal PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Removal PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Removal and Disassembly 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 − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Check Valve Installation PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final Pump Assembly PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Assembly PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearings PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Source PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 SERIES OM−00893

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 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 an 80 Series, semi-open impeller, self-

priming centrifugal model with a suction check

valve. The pump is designed for straight-in suction

where the medium being pumped enters directly

into the impeller eye. It is designed for handling

most non-volatile, non-flammable liquids contain-

ing specified entrained solids. The basic material

of construction for wetted parts is gray iron, with a

steel wear plate and impeller shaft.

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

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

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.

80 SERIES OM−00893

PAGE A − 1SAFETY

SAFETY - SECTION A

This information applies to 80 Series ba-

sic pumps. Gorman-Rupp has no con-

trol over or particular knowledge of the

power source which will be used. Refer

to the manual accompanying the power

source before attempting to begin oper-

ation.

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. 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

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.

Only the Gorman-Rupp Company or an

authorized Gorman-Rupp distributor

may modify a pump or approve its use

for handling volatile, flammable liquids.

If the pump is used for handling volatile,

flammable liquids, all drivers and/or

controls must meet industry standards

and codes for use in an explosive atmo-

sphere. Do not attempt to pump liquids

for which the pump, driver and/or con-

trols have not been approved, or which

may damage the pump or endanger per-

sonnel as a result of pump failure.

If this pump has been approved for use

with volatile and/or flammable liquids,

be certain proper safety practices are

followed 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.

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

80 SERIESOM−00893

PAGE A − 2 SAFETY

the applicable local code, the National

or local code shall take precedence.

Use lifting and moving equipment in

good repair and with adequate capacity

to prevent injuries to personnel or dam-

age to equipment. The bail is intended

for use in lifting the pump assembly

only. Suction and discharge hoses and

piping must be removed from the pump

before lifting.

After the pump has been installed, make

certain that the pump and all piping or

hose connections are tight, properly

supported and secure before operation.

Do not operate the pump without the

shields and/or guards in place over the

drive shaft, belts, and/or couplings, or

other rotating parts. Exposed rotating

parts can catch clothing, fingers, or

tools, causing severe injury to person-

nel.

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.

Overheated pumps can cause severe

burns and injuries. 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.

5. Vent the pump slowly and cau-

tiously.

6. Refer to instructions in this manual

before restarting the pump.

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 completely cool before

servicing.

Never run this pump backwards. Be cer-

tain that rotation is correct before fully

engaging the pump.

Pumps and related equipment must be in-

stalled and operated according to all na-

tional, local and industry standards.

80 SERIES OM−00893

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 1 for the approximate physical dimen-

sions of this pump.

OUTLINE DRAWING

Figure 1. Pump Model 83C52−B

80 SERIES

OM−00893

PAGE B − 2 INSTALLATION

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.

c. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties

indicated.

Only operate this pump in the direction in-

dicated by the arrow on the pump body

and on the accompanying decal. Other-

wise, the impeller could become loosened

from the shaft and seriously damage the

pump. Refer to ROTATION in

OPERATION, Section C.

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

Use lifting and moving equipment in

good repair and with adequate capacity

to prevent injuries to personnel or dam-

age to equipment. Suction and dis-

charge hoses and piping must be re-

moved from the pump before lifting.

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.

The pump assembly can be seriously

damaged if the cables or chains used to lift

and move the unit are improperly wrapped

around the pump.

Mounting

Locate the pump in an accessible place as close as

practical to the liquid being pumped. Level mount-

ing is essential for proper operation.

The pump may have to be supported or shimmed

to provide for level operation or to eliminate vibra-

tion.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in-

creased suction lift, discharge elevation, and fric-

tion losses. See the performance curve on Page

E−1 to be sure your overall application allows

pump to operate within the safe operation range.

80 SERIES OM−00893

PAGE B − 3INSTALLATION

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 7/8−inch

(22,4 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.

This manual suits for next models

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