ACE OM-00955-07 August 22, 2005 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST 80 SERIES PUMPS MODEL 86A2−F3L THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO www.gormanrupp.com GORMAN-RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA eCopyright by the Gorman-Rupp Company Printed in U.S.A.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (continued) TROUBLESHOOTING − SECTION D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP MAINTENANCE AND REPAIR - SECTION E . . . . . . . . . . . . . . . . . PARTS LISTS: Pump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump End Assembly . . . . . . . . . . . . . . . . . . . . . .
80 SERIES OM−00955 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. neither operator safety nor pump integrity are compromised by the installation. Pumps and related equipment must be installed and operated according to all national, local and industry standards.
80 SERIES OM−00955 SAFETY − SECTION A This information applies to 80 Series Engine Driven pumps. Refer to the manual accompanying the engine before attempting to begin operation. Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and precautions for each specific application.
OM−00955 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 overheated pump. Vapor pressure within the pump can cause parts being disengaged to be ejected with great force. Allow the pump to completely cool before servicing. Do not operate an internal combustion engine in an explosive atmosphere.
0 SERIES OM−00955 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 arrange 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.
OM−00955 80 SERIES Table 1. Battery Specifications PREINSTALLATION INSPECTION The pump assembly was inspected and tested before shipment from the factory. Before installation, inspect the pump for damage which may have occurred during shipment. Check as follows: a. Inspect the pump and engine for cracks, dents, damaged threads, and other obvious damage. b. Check for and tighten loose attaching hardware. Since gaskets tend to shrink after drying, check for loose hardware at mating surfaces. c.
80 SERIES OM−00955 Mounting Connections to Pump Locate the pump in an accessible place as close as practical to the liquid being pumped. Level mounting is essential for proper operation. Before tightening a connecting flange, align it exactly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or couplings. The pump may have to be supported or shimmed to provide for level operation or to eliminate vibration.
OM−00955 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 1-15/16 inch (49,21 mm) diameter spherical solids. 80 SERIES pipe dope.
80 SERIES friction losses. Never install a throttling valve in a suction line. With high discharge heads, it is recommended that a throttling valve and a system check valve be installed in the discharge line to protect the pump from excessive shock pressure and reverse rotation when it is stopped. OM−00955 Bypass Lines If a system check valve is used due to high discharge head, it may be necessary to vent trapped air from the top of the pump during the priming process.
OM−00955 80 SERIES OPERATION − SECTION C Review all SAFETY information in Section A. Follow the instructions on all tags, labels and decals attached to the pump. Do not operate an internal combustion engine in an explosive atmosphere. When operating internal combustion engines in an enclosed area, make certain that exhaust fumes are piped to the outside. These fumes contain carbon monoxide, a deadly gas that is colorless, tasteless, and odorless.
OM−00955 80 SERIES NOTE OPERATION This pump is self-priming; however, it is not suited for unattended reprime applications. In the event of suction check valve failure and loss of prime, the pump casing must be refilled through the fill cover or fill plug. STARTING Pump speed and operating condition points must be within the continuous performance range shown on the curve. (See Section E, Page 1.
OM−00955 80 SERIES No leakage should be visible at pump mating surfaces, or at pump connections or fittings. Keep all line connections and fittings tight to maintain maximum pump efficiency. Never introduce air or steam pressure into the pump casing or piping to remove a blockage. This could result in personal injury or damage to the equipment. If backflushing is absolutely necessary, liquid pressure must be limited to 50% of the maximum permissible operating pressure shown on the pump performance curve.
OM−00955 cable to ensure that the pump will remain inoperative. Safety Shutdown System The unit is equipped with a safety system to automatically shut down the engine under certain conditions. The engine will automatically shut down: 1. If the engine exceeds its safe operating temperature. 2. If the engine oil pressure drops below design limits. 3. If the engine fails to start within a pre-set period of time.
80 SERIES tinued operation should bring the temperatures down to normal levels. Cold Weather Preservation In below freezing conditions, drain the pump to prevent damage from freezing. Also, clean out any solids by flushing with a hose. Operate the pump for approximately one minute; this will remove any OPERATION OM−00955 remaining liquid that could freeze the pump rotating parts.
10 SERIES OM−00955 TROUBLESHOOTING − SECTION D Review all SAFETY information in Section A. Before attempting to open or service the pump: 1. Familiarize yourself with this manual. 2. Switch off 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 cautiously. 7.
OM−00955 TROUBLE PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE (cont.) PUMP REQUIRES TOO MUCH POWER PUMP CLOGS FREQUENTLY EXCESSIVE NOISE BEARINGS RUN TOO HOT PAGE D − 2 10 SERIES POSSIBLE CAUSE PROBABLE REMEDY Suction intake not submerged at proper level or sump too small. Check installation and correct submergence as needed. Impeller or other wearing parts worn or damaged. Replace worn or damaged parts. Check that impeller is properly centered and rotates freely. Impeller clogged.
10 SERIES OM−00955 PREVENTIVE MAINTENANCE Since pump applications are seldom identical, and pump wear is directly affected by such things as the abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however, following a routine preventive maintenance schedule will help assure trouble-free performance and long life from your Gorman-Rupp pump.
80 SERIES OM−00955 PUMP MAINTENANCE AND REPAIR - SECTION E MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE. STANDARD PERFORMANCE FOR PUMP MODEL 86A2−F3L Based on 70_ F (21_ C) clear water at sea level with minimum suction lift. Since pump installations are seldom identical, your performance may be different due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.
OM−00955 80 SERIES SECTION DRAWING Figure 1.
80 SERIES OM−00955 PARTS LIST Pump Model 86A2−F3L (From S/N 1330589 up) If your pump serial number is followed by an N", your pump is NOT a standard production model. Contact the Gorman-Rupp Company to verify part numbers. ITEM PART NAME NO.
OM−00955 80 SERIES SECTION DRAWING Figure 2.
80 SERIES OM−00955 PARTS LIST Pump End Assembly 86A2−(SAE 4/10) ITEM NO.
OM−00955 80 SERIES SECTION DRAWING Figure 3. Drive Assembly For Pump End 86A2−(SAE 4/10) ITEM NO.
80 SERIES PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Review all SAFETY information in Section A. Follow the instructions on all tags, label and decals attached to the pump. This pump requires little service due to its rugged, minimum-maintenance design. However, if it becomes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the sectional views (see Figures 1, 2 and 3) and the accompanying parts lists.
OM−00955 charge hoses and piping must be removed from the pump before lifting. Disengage the hardware (6 and 7) securing the drive assembly to the intermediate. Separate the pump end and drive assembly from the engine by pulling the pump end straight away from the engine. As the assemblies separate, the flexible portion of the coupling assembly (3) will remain on the shaft. To remove the coupling from the shaft, unscrew the two allen head setscrews from the bushing (2).
80 SERIES 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. Inspect the wear plate (38), and replace if scored or worn. To remove the wear plate, disengage the hardware (40 and 41) from the wear plate studs, and pull the wear plate from the pump casing.
OM−00955 the shaft, it is recommended that bearings be cleaned and inspected in place. It is strongly recommended that the bearings be replaced any time the shaft and bearings are removed. Clean the intermediate, shaft and all component parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage and replace as necessary. Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat, sparks, and flame.
80 SERIES OM−00955 inboard bearing cone (32) fully engages the inboard bearing cup. Press the outboard bearing cup (26) over the outboard bearing cone (27). Install the same thickness of bearing adjusting shims (30) as previously remove, and secure them with the bearing cap (28) and hardware (22 and 23). Check the shaft endplay. NOTE Shaft endplay should be between .003 and .005 inch (0,08 to 0,13mm). Add or remove bearing shims to establish the correct endplay.
OM−00955 80 SERIES PACKING RINGS GREASE CUP PIPING SEAL PLATE SEAL WASHER SEAL LINER IMPELLER STATIONARY SEAL SEATS IMPELLER SHAFT ROTATING ELEMENTS IMPELLER SHIMS SPACER SLEEVE SPRING STATIONARY WASHERS Figure 5. GS1250 Seal Assembly This seal is not designed for operation at temperatures above 110_F (43_C). Do not use at higher operating temperatures. Inspect the seal liner (14) and impeller shaft for burrs or sharp corners, and remove any that exist.
80 SERIES OM−00955 Slide the seal spacer washer (15) onto the shaft with the chamfered side facing the outboard rotating element. Reinstall the automatic grease cup and piping (16, 17 and 18) in the seal plate. After the impeller has been installed, lubricate the seal as indicated in LUBRICATION. Impeller Installation NOTE The seal plate must be tight against the intermediate while setting the back impeller clearance.
OM−00955 80 SERIES If the complete coupling assembly is being replaced, apply ‘Loctite Retaining Compound No. 242’ or equivalent to the threads of the hardware (4 and 5), and secure the outer ring of the coupling to the engine flywheel by torquing the hardware to 45 ft. lbs. (540 in. lbs. or 6,2 m. kg.). Using a suitable lifting device, position the intermediate (21, Figure 2) so the flexible portion of the coupling seats inside the outer ring attached to the engine flywheel.
80 SERIES OM−00955 capes from the relief hole. Turn the grease cup arm counterclockwise until it is at the top of the stem; this will release the spring to apply grease to the seal (see Figure 6). LUBRICATION Seal Assembly (Figure 2) Fill the grease cup (18) through the grease fitting with No.
For U.S. and International Warranty Information, Please Visit www.grpumps.com/warranty or call: U.S.: 419−755−1280 International: +1−419−755−1352 For Canadian Warranty Information, Please Visit www.grcanada.com/warranty or call: 519−631−2870 THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO GORMAN-RUPP OF CANADA LIMITED D ST.
