GORMAN-RUPP PUMPS 16A2-4045T Manual
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GORMAN-RUPP PUMPS 16A2-4045T Manual

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ACDEU
COM-06540-01
February 14, 2012
REV A. August 1, 2014
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
10 SERIES PUMP
MODEL
16A2-4045T
THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO
www.grpumps.com
D
GORMAN‐RUPP OF CANADA LIMITED
ST. THOMAS, ONTARIO, CANADA
Printed in U.S.A.
e
2012 The Gorman‐Rupp Company

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  • Page 1 REV A. August 1, 2014 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST 10 SERIES PUMP MODEL 16A2-4045T THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO www.grpumps.com GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A. 2012 The Gorman‐Rupp Company...
  • Page 2 Register your new Gorman‐Rupp pump online at www.grpumps.com Valid serial number and e‐mail address required. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. RECORD YOUR PUMP MODEL AND SERIAL NUMBER Please record your pump model and serial number in the spaces provided below.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ..........PAGE I - 1 SAFETY - SECTION A .
  • Page 4 TABLE OF CONTENTS (continued) PUMP MAINTENANCE AND REPAIR - SECTION E ....PAGE E - 1 PERFORMANCE CURVE ........... PAGE E - 1 PARTS LISTS: PUMP MODEL ASSEMBLY...

  • Page 5: Introduction

    10 SERIES OM-06540 INTRODUCTION Thank You for purchasing a Gorman‐Rupp pump. For information or technical assistance on the en­ Read this manual carefully to learn how to safely gine, contact the engine manufacturer's local install and operate your pump. Failure to do so dealer or representative.

  • Page 6: Safety - Section A

    10 SERIES OM-06540 SAFETY - SECTION A This information applies to 10 Series en­ corrosive, or flammable materials, or gine driven pumps. Refer to the manual any liquids which may damage the accompanying the engine before at­ pump or endanger personnel as a result tempting to begin operation.
  • Page 7 10 SERIES OM-06540 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 Do not operate an internal combustion ning engine. Avoid overfilling the fuel engine in an explosive atmosphere.

  • Page 8: Installation - Section B

    See Figure 1 for the approximate physical dimen­ specific application. Since the pressure supplied sions of this pump. OUTLINE DRAWING Figure 1. Pump Model 16A2-4045T INSTALLATION PAGE B - 1...

  • Page 9: Preinstallation Inspection

    OM-06540 10 SERIES PREINSTALLATION INSPECTION Table 1. Battery Specifications Cold Reserve Approx. Amp/ Crank Capacity Overall Voltage Amps Dims. @ 80 The pump assembly was inspected and tested be­ (Minutes) (Inches) Rating fore shipment from the factory. Before installation, 20.5L inspect the pump for damage which may have oc­...

  • Page 10: Mounting

    10 SERIES OM-06540 damaged if the cables or chains used to lift Line Configuration and move the unit are improperly wrapped Keep suction and discharge lines as straight as around the pump. possible to minimize friction losses. Make mini­ mum use of elbows and fittings, which substan­ Mounting tially increase friction loss.

  • Page 11: Strainers

    OM-06540 10 SERIES install it with the stem horizontal to avoid air pock­ sump at a distance equal to 1 1/2 times the diame­ ets. ter of the suction line. If there is a liquid flow from an open pipe into the sump, the flow should be kept away from the suc­...

  • Page 12: Discharge Lines

    10 SERIES OM-06540 Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity DISCHARGE LINES If the application involves a high discharge Siphoning head, gradually close the discharge throttling valve before stopping the pump. Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a si­...

  • Page 13: Automatic Air Release Valve

    OM-06540 10 SERIES ameter to minimize the chance of plugging. be a full‐opening, ball‐type valve to pre­ vent plugging by solids. In low discharge head applications (less than 30 feet (9,1 m)), it is recommended that the bypass line be run back to the wet well, and located 6 inches below the water level or cut‐off point of the A manual shut‐off valve should not be low level pump.

  • Page 14: Air Release Valve Installation

    10 SERIES OM-06540 Air Release Valve Installation tween the pump discharge port and the inlet side of the discharge check valve (see Figure 3). The inlet The Automatic Air Release Valve must be inde­ opening in the Air Release Valve is equipped with pendently mounted in a horizontal position be­...

  • Page 15: Operation - Section C

    OM-06540 10 SERIES OPERATION - SECTION C Review all SAFETY information in Section A. Add liquid to the pump casing when: 1. The pump is being put into service for the Follow the instructions on all tags, labels and first time. decals attached to the pump.

  • Page 16: Lines Without A Bypass

    OM-06540 10 SERIES the priming cycle. When the pump is fully primed move plates, covers, gauges, or fittings and liquid is flowing steadily from the bypass line, from an over‐heated pump. Liquid with­ open the discharge throttling valve. Liquid will then in the pump can reach boiling tempera­...

  • Page 17: Stopping

    OM-06540 10 SERIES large solids from clogging the drain port and pre­ STOPPING venting the pump from completely draining, insert a rod or stiff wire in the drain port, and agitate the Never halt the flow of liquid suddenly. If the liquid liquid during the draining process.

  • Page 18: Troubleshooting - Section D

    OM-06540 10 SERIES 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 the engine ignition and dis­ connect the positive battery cable to ensure that the pump will remain in­...
  • Page 19 OM-06540 10 SERIES TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP STOPS OR Suction intake not submerged at Check installation and correct sub­ FAILS TO DELIVER proper level or sump too small. mergence as needed. RATED FLOW OR Impeller or other wearing parts worn Replace worn or damaged parts.
  • Page 20 OM-06540 10 SERIES PREVENTIVE MAINTENANCE equipped) between regularly scheduled inspec­ tions can indicate problems that can be corrected Since pump applications are seldom identical, and before system damage or catastrophic failure oc­ pump wear is directly affected by such things as curs.
  • Page 21 10 SERIES 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 16A2-4045T Based on 70 F (21 C) clear water at sea level Contact the Gorman‐Rupp Company to verify per­...
  • Page 22 OM-06540 10 SERIES PARTS PAGE ILLUSTRATION Figure 1. Pump Model 16A2-4045T PAGE E - 2 MAINTENANCE & REPAIR...
  • Page 23 OM-06540 10 SERIES PARTS LIST Pump Model 16A2-4045T (From S/N 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 MAT'L...
  • Page 24 OM-06540 10 SERIES ILLUSTRATION Figure 2. 46143-153 Power Unit Kit PAGE E - 4 MAINTENANCE & REPAIR...
  • Page 25 OM-06540 10 SERIES PARTS LIST 46143-153 Power Unit Kit ITEM PART MAT'L PART NAME NUMBER CODE JOHN DEERE ENGINE 29224-302 BASE/FUEL TANK 41553-029 24150 LIFTING BAIL KIT 48274-804 MUFFLER GUARD ASSEMBLY 42331-061 MALE ELBOW 26351-131 CONNECTOR S1447 HOSE ASSEMBLY 46341-789 CONTROL PANEL 48122-552 BATTERY BOX KIT...
  • Page 26 OM-06540 10 SERIES ILLUSTRATION Figure 3. 16A2-(SAE4/10) Pump End Assy PAGE E - 6 MAINTENANCE & REPAIR...
  • Page 27 OM-06540 10 SERIES PARTS LIST 16A2-(SAE4/10) Pump End Assy ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE PUMP CASING 7748 10010 OIL SEAL 25258-622 IMPELLER 7759B 11000 WAVY WASHER 23963-327 SEAL ASSY GS1500 BALL BEARING S1077 PRIMING STICKER 6588AH...
  • Page 28 OM-06540 10 SERIES ILLUSTRATION Figure 4. 44162-119 Drive Assembly PARTS LIST ITEM PART MAT'L PART NAME NUMBER CODE COUPLING KIT 48112-001 -BUSHING 24131-345 -COUPLING ASSEMBLY 44165-011 -LOCKWASHER 15991 -LOCKWASHER 21171-536 -SOCKET HD CAPSCREW BD0606-1/2 15991 -SOCKET HD CAPSCREW 22644-220 HEX HD CAPSCREW B0605 15991 HEX HD CAPSCREW...
  • Page 29 OM-06540 10 SERIES PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Before attempting to open or service the pump: Review all SAFETY information in Section A. 1. Familiarize yourself with this man­ ual. Follow the instructions on all tags, label and de­ 2.
  • Page 30 OM-06540 10 SERIES Inspect the wear plate and replace it if badly scored Remove any leveling shims used under the casing or worn. To remove the wear plate, disengage the mounting feet. Tie and tag the shims for ease of hardware (55 and 56).
  • Page 31 OM-06540 10 SERIES If no further disassembly is required, refer to Seal Disengage the hardware (34 and 35) and remove Reassembly And Installation. the bearing cap (36), gasket (33), outboard oil seal (45), and wavy washer (46). Press the oil seal from the bearing cap.
  • Page 32 OM-06540 10 SERIES tation is rough or the bearing balls are discolored, the shaft, it is recommended that bearings replace the bearings. be cleaned and inspected in place. It is strongly recommended that the bearings The bearing tolerances provide a tight press fit be replaced any time the shaft and bear­...
  • Page 33 OM-06540 10 SERIES If heating the bearings is not practical, use a suit­ crews in the center of the coupling must be posi­ able sized sleeve, and an arbor (or hydraulic) press tioned toward the pump end of the shaft. to install the bearings on the shaft.
  • Page 34 OM-06540 10 SERIES Do not use petroleum‐based lubricants, or any oth­ The seal is not normally reused because wear pat­ er substance which may soften or otherwise dam­ terns on the finished faces cannot be realigned age the rubber. during reassembly. This could result in premature failure.
  • Page 35 OM-06540 10 SERIES PIPE NIPPLE PACKING RINGS SEAL PLATE SEAL LINER IMPELLER ADJ SHIMS ROTATING ELEMENT IMPELLER SHAFT STATIONARY SEAL SEAT IMPELLER SHAFT SLEEVE STATIONARY WASHER STATIONARY WASHER SPRING Figure 6. GS1500 Seal Assembly Slide the seal plate onto the shaft until fully seated against the intermediate.
  • Page 36 OM-06540 10 SERIES Impeller Installation And Adjustment NOTE An alternate method of adjusting this clearance is to (Figure 3) reach through the discharge port with a feeler gauge and measure the gap. Add or subtract pump Inspect the impeller, and replace it if cracked or casing gaskets accordingly.
  • Page 37 OM-06540 10 SERIES Clean any scale or debris from the contacting sur­ Install the suction and discharge lines and open all faces in the pump casing that might interfere or valves. Make certain that all piping connections are prevent a good seal with the back cover. Replace tight, properly supported and secure.
  • Page 38 OM-06540 10 SERIES Bearings stalled in an environment with rapid temperature change. (Figure 3) The intermediate was fully lubricated when shipped from the factory. Check the oil level regu­ larly through the sight gauge (41) and maintain it at Monitor the condition of the bearing lubri­ the middle of the gauge.
  • Page 39 For Warranty Information, Please Visit www.grpumps.com/warranty or call: U.S.: 419-755-1280 Canada: 519-631-2870 International: +1-419-755-1352 GORMAN‐RUPP PUMPS...

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10 series

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