GORMAN-RUPP 10 SERIES Operating instructions

PUBLICATION NUMBER MR--04885

December 1, 1998

Rev. B 12/10/01

Use With: OM--04760

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

10 SERIES PUMPS

12B, 12C, 12D, 13A, 13C And 13E

Electric Motor Or Engine Driven Pumps

with Self Lubricated or Grease Seal

The engine exhaust from this

product contains chemicals

known tothe State of Californiato

cause cancer, birth defects or

other reproductive harm.

MR--0488510 SERIES PUMPS

PAGE I -- 1

INTRODUCTION

Thank You for purchasing a Gorman-Rupp 10

Series Pump. Read this manual carefully to learn

howtosafelymaintainandserviceyourpump.Fail-

ure to do so could result in personal injury or dam-

age to the pump.

A set of three manuals accompanies your pump.

TheInstallation/OperationManualcontainsessen-

tial information on installing and operating the

pump. The Parts List Manual provides a perform-

ance curve, a pump model cross-section drawing,

andpartslistforyourpump.

This Maintenance and Repair Manual provides

troubleshooting and maintenance instructions re-

quiredto properlydiagnose operationalproblems,

and to service the pump components.

As described on the following page, this manual

willalert personnel toknown procedures which re-

quire specialattention, to those which could dam-

age equipment, and to those which could be dan-

gerous topersonnel. However, this manualcannot

possibly anticipate and provide detailed precau-

tions for every situation that might occur during

maintenance of the pump. Therefore, it is the re-

sponsibility of the owner/maintenance personnel

to ensure that only safe, established maintenance

proceduresare used, and that any procedures not

addressed in this manualare performed only after

establishing that neither personalsafety nor pump

integrity are compromised by such practices.

Pumps and related equipment must be installed

andoperatedaccordingtoallnational,localandin-

dustry standards.

If there are any questions regarding the pump

which are not covered in this manual or in other lit-

erature accompanying the unit, please contact

your Gorman-Rupp distributor or the Gorman-

Rupp Company:

The Gorman-Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901--1217

or:

Gorman-Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

CONTENTS

SAFETY -- SECTION A

TROUBLESHOOTING -- SECTION B

PREVENTIVE MAINTENANCE PAGE B --- 3..................................................

PUMP MAINTENANCE AND REPAIR -- SECTION C

GENERAL INFORMATION PAGE C --- 1.....................................................

Lifting PAGE C --- 1....................................................................

PARTS IDENTIFICATION LIST:

Pump Assembly w/Self Lubricated Seal PAGE C --- 3......................................

Pump Assembly w/Grease Seal PAGE C --- 5.............................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE C --- 6............................

Impeller Clearances PAGE C --- 11......................................................

LUBRICATION PAGE C --- 12...............................................................

Self Lubricated Seal Assembly PAGE C --- 12.............................................

Grease Seal Assembly PAGE C --- 12....................................................

Power Source PAGE C --- 13...........................................................

MR--04885 10 SERIES PUMPS

PAGE I -- 2 INTRODUCTION

RECORDING MODEL AND

SERIAL NUMBERS

Pleaserecordthepumpmodel,serialnumber,volt-

age,andphaseinthespacesprovidedbelow.Your

Gorman-Rupp distributor needs this information

when you require parts or service.

Pump Model:

Serial Number:

Voltage:

Phase:

WARRANTY INFORMATION

The warranty provided with your pump is part of

Gorman-Rupp’s support program for customers

who operate and maintain their equipment as de-

scribed in this and the other accompanying litera-

ture. Please note that should the equipment be

abused or modified to change its performance be-

yond the original factory specifications, the war-

ranty will become void and any claim will be de-

nied.

The following are used to alert 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.

HazardsorunsafepracticeswhichCOULD

resultinminorpersonalinjuryorproductor

property damage. These instructions de-

scribe the requirements and the possible

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 PUMPS MR--04885

PAGE A -- 1SAFETY

SAFETY - SECTION A

This information applies to 10 Series

electric motor or engine driven pumps.

Refer to the manual accompanying the

power source before attempting to be-

gin 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,thismanualcannotpossiblyantici-

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

ensurethatonlysafe, 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.

Thismanual containsessentialinforma-

tion on troubleshooting and maintain-

ing the pump.In additionto this manual,

see the separate literature covering

installation and operation, pump parts,

and any optional equipment shipped

with the pump.

Beforeattemptingtoopenorservicethe

pump:

1. Familiarize yourself with this man-

ual.

2. Disconnect or shut down the pow-

er source and take the necessary

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.

Do not attempt to pump any liquids the

pump has not been designed for, and

which may damage the pump or endan-

ger personnel as a result of pump fail-

ure. Consult the factory to determine

compatibilitybetweenthepumpandliq-

uid.

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.

After the pump has been positioned,

make certain that the pump and all pip-

ing or hose connections are tight,prop-

erly supported and secure before oper-

ation.

Do not operate the pump against a

closeddischarge valveforlongperiods

oftime.Ifoperatedagainstacloseddis-

charge valve, pump components will

10 SERIES PUMPSMR--04885

PAGE A -- 2 SAFETY

deteriorate, and the liquid could come

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-

heatedpump. Vaporpressure within the

pump can cause parts being disen-

gaged to be ejected with great force.Al-

low the pump to cool before servicing.

Thesepumpsmaybeusedtohandle

productswhichifoverheatedcouldpro-

duce dangerous fumes. Use extreme

caution when venting the pump, or

whenremovingcovers,plates,plugs,or

fittings.

Neverrunthispumpbackwards.Becer-

tain that rotation is correct before fully

engaging the pump.

If the pump is used to pump materials

which could cause serious illness or in-

jury through direct exposure or emitted

fumes, wear protective clothing, such

asrubbergloves,facemask,andrubber

apron, as necessary before disassem-

bling the pump or piping.

Do not operate the pump without

shields and/or guards in place over the

drive shafts, belts, and/or couplings, or

other rotating parts. Exposed rotating

parts can catch clothing, fingers, or

tools, causing severe injury to person-

nel.

If the pump is powered by an electric

motor, do not operate a non-explosion

proof motor in an explosive atmo-

sphere. An explosion, which may cause

severe personal injury or death, could

result. Install, connect and operate the

motor in accordance with the National

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

applicable local code, the National or

Local code shall take precedence. All

electrical equipment supplied with the

pump conforms to applicable federal

regulations and national codes in effect

on the date of manufacture.

If the pump is electric motor driven, the

electrical power used to operate this

pump is high enough to cause injury or

death. Obtain the servicesof aqualified

electrician to troubleshoot, test and/or

service the electrical components of

this pump.

If the pump is powered by an internal

combustion engine, do not operate in

anexplosiveatmosphere.Whenoperat-

ing internal combustion engines in an

enclosed area, make certain that ex-

haust fumes are piped to the outside.

These fumescontain carbon monoxide,

a deadly gas that is colorless, tasteless,

and odorless.

10 SERIES PUMPS MR--04885

PAGE A -- 3SAFETY

Fuel used by internal combustion en-

gines presents an extreme explosion

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.Alwaysusethe correcttypeoffuel.

Never tamper with the engine governor

to gain more power. The governor esta-

blishessafeoperatinglimitsthatshould

not be exceeded. The maximum contin-

uous operating speed for the pump is

shownontheperformancecurve(see

the Parts List Manual).

Pumps and related equipment must be in-

stalled and operated according to all na-

tional, local and industry standards.

MR--0488510 SERIES PUMPS

TROUBLESHOOTING PAGE B -- 1

TROUBLESHOOTING --- SECTION B

Review all SAFETY information in Section A.

Beforeattempting toopenorservice the

pump:

1. Familiarize yourself with this manual.

2. Disconnect or shut down the power

source and take the necessary pre-

cautions 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.

Table B-1 Troubleshooting Chart

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO PRIME Not enough liquid in casing.

Suction check valve contaminatedor

damaged.

Air leak in suction line.

Lining of suction hose collapsed.

Leakingorwornsealorpumpgas-

ket.

Suction lift or discharge head too

high.

Strainer clogged.

Addliquidtocasing.SeePRIMING.

Clean or replace check valve.

Correct leak.

Replace suction hose.

Check pump vacuum. Replace leak-

ingorwornsealorgasket.

Check piping installation and install

bypass line if needed. See INSTAL-

LATION.

Check strainer and clean if neces-

sary.

PUMP STOPS OR FAILS

TO DELIVER RATED

FLOW OR PRESSURE

Air leak in suction line.

Lining of suction hose collapsed.

Suction intake not submerged at

proper level or sump too small.

Correct leak.

Replace suction hose.

Check installation and correct sub-

mergence as needed.

MR--04885 10 SERIES PUMPS

TROUBLESHOOTINGPAGE B -- 2

Table B-1 Troubleshooting Chart (continued)

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP STOPS OR FAILS

TO DELIVER RATED

FLOW OR PRESSURE

(cont.)

Impellerorotherwearingpartsworn

or damaged.

Leakingorwornsealorpumpgas-

ket.

Impeller clogged.

Pump speed too slow.

Pump running backwards (electric

motor driven models).

Suction lift or discharge head too

high.

Replace worn or damaged parts.

Check that impeller is properly cen-

tered and rotates freely.

Check pump vacuum. Replace leak-

ingorwornsealorgasket.

Free impeller of debris.

Check driver output; check belts or

couplings for slippage.

Check direction of rotation. Correct

3-phase wiring by interchanging any

two motor leads at control box. (See

Pump Rotation in the Installation

and Operations Manual.

Check piping installation and install

bypass line if needed. See INSTAL-

LATION in the Installation and Op-

erations manual.

PUMP REQUIRES TOO

MUCH POWER Pump speed too high.

Discharge head too low.

Liquid solution too thick.

Check driver output, check that

sheaves or couplings are correctly

sized.

Adjust discharge valve.

Dilute if possible.

PUMP CLOGS

FREQUENTLY Discharge flow too slow.

Suction check valve or foot valve

clogged or binding.

Open discharge valve filly to in-

crease flow rate, and run power

source at maximum governed

speed.

Clean valve.

EXCESSIVE NOISE Cavitation in pump.

Pumping entrained air.

Pump or drive not securely

mounted.

Impeller clogged or damaged.

Reduce suction lift and/or friction

losses in suction line. Record vacu-

um 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.

MR--0488510 SERIES PUMPS

TROUBLESHOOTING PAGE B -- 3

PREVENTIVE MAINTENANCE

Sincepumpapplicationsareseldomidentical,and

pump wear is directly affected by such things as

the abrasive qualities, pressure and temperature

oftheliquidbeingpumped, thissectionisintended

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.Theappearanceofwearingpartsshouldalso

bedocumentedat each inspectionforcomparison

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

beforefailureoccurs, reducingunscheduleddown

time.

For new applications, a first inspection of wearing

partsat250hourswillgiveinsightintothewearrate

foryourparticularapplication.Subsequentinspec-

tions should be performed at the intervals shown

on the chart below. Critical applications should be

inspected more frequently.

General Condition (Temperature, Unusual

Noises or Vibrations, Cracks, Leaks,

Loose Hardware, Etc.) I

Pump Performance (Gauges, Speed, Flow) I

Bearing Lubrication I R

Seal Lubrication (And Packing Adjustment,

If So Equipped) I R

V-Belts (If So Equipped) I

Air Release Valve Plunger Rod (If So Equipped) I C

Front Impeller Clearance (Wear Plate) I

Rear Impeller Clearance (Seal Plate) I

Check Valve I

Pressure Relief Valve (If So Equipped) C

Pump and Driver Alignment I

Shaft Deflection I

Bearings I

Bearing Housing I

Piping I

Driver Lubrication --- See Mfgr’s Literature

Legend:

I = Inspect, Clean, Adjust, Repair or Replace as Necessary

C= Clean

R= Replace

* Service interval based on an intermittant duty cycle equal to approximately 4000 hours annually.

Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.

Preventive Maintenance Schedule

Item Daily Weekly Monthly Semi-

Annually Annually

Service Interval*

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