GORMAN-RUPP PUMPS 80 Series User manual

OM-00900-07
August 22, 2005
Rev A. - 08/14/19
GORMAN‐RUPP PUMPS
www.grpumps.com
2005 Gorman‐Rupp Pumps Printed in U.S.A.
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
80 SERIES PUMP
MODEL
84A2-F3L

Register your new
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:
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
i
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............................................
Battery Specifications And Installation PAGE B - 2....................................
POSITIONING PUMP PAGE B - 2.......................................................
Lifting PAGE B - 2.................................................................
Mounting PAGE B - 2.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 3.........................................
Materials PAGE B - 3..............................................................
Line Configuration PAGE B - 3......................................................
Connections to Pump PAGE B - 3..................................................
Gauges PAGE B - 3...............................................................
SUCTION LINES PAGE B - 3...........................................................
Fittings PAGE B - 3...............................................................
Sealing PAGE B - 3...............................................................
Suction Line Positioning PAGE B - 4................................................
FLOAT SWITCHES PAGE B - 4.........................................................
Installation PAGE B - 4............................................................
DISCHARGE LINES PAGE B - 5........................................................
Siphoning PAGE B - 5.............................................................
Valves PAGE B - 5................................................................
Bypass Lines PAGE B - 5..........................................................
ALIGNMENT PAGE B - 5..............................................................
OPERATION - SECTION C PAGE C - 1.......................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 2................................................................
Manual Starting PAGE C - 2........................................................
Automatic Starting PAGE C - 2.....................................................
OPERATION PAGE C - 3..............................................................
Lines With a Bypass PAGE C - 3....................................................
Lines Without a Bypass PAGE C - 3.................................................
Leakage PAGE C - 3..............................................................
Liquid Temperature And Overheating PAGE C - 3.....................................
Strainer Check PAGE C - 3.........................................................
Pump Vacuum Check PAGE C - 4..................................................
STOPPING PAGE C - 4................................................................
Manual Stopping PAGE C - 4.......................................................
Automatic Stopping PAGE C - 4....................................................
Safety Shutdown System PAGE C - 4...............................................
OPERATION IN EXTREME HEAT PAGE C - 5............................................
BEARING TEMPERATURE CHECK PAGE C - 5..........................................
Cold Weather Preservation PAGE C - 5..............................................

TABLE OF CONTENTS
(continued)
ii
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 LISTS:
Pump Model PAGE E - 3.............................................................
Pump End Assembly PAGE E - 5......................................................
Drive Assembly PAGE E - 6...........................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 7............................
Suction Check Valve Removal PAGE E - 8...........................................
Separating Pump and Intermediate from Engine PAGE E - 8...........................
Loosening the Impeller PAGE E - 8.................................................
Pump Casing and Wear Plate Removal PAGE E - 9...................................
Impeller Removal PAGE E - 9......................................................
Seal Removal and Disassembly PAGE E - 9..........................................
Shaft And Bearing Removal And Disassembly PAGE E - 10.............................
Shaft and Bearing Reassembly And Installation PAGE E - 11............................
Securing Intermediate And Drive Assembly To Engine PAGE E - 12......................
Seal Reassembly and Installation PAGE E - 12........................................
Impeller Installation PAGE E - 14.....................................................
Pump Casing and Wear Plate Installation PAGE E - 14.................................
Suction Check Valve Installation PAGE E - 15.........................................
Final Pump Reassembly PAGE E - 15................................................
LUBRICATION PAGE E - 15.............................................................
Seal Assembly PAGE E - 15.........................................................
Bearings PAGE E - 16..............................................................
Engine PAGE E - 16................................................................

8O SERIES OM-00900
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 handling most
non‐volatile, non‐flammable liquids containing
specified entrained solids. It is powered by a three
cylinder air‐cooled Deutz diesel engine, model
F3L-912D. The basic material of construction for
all wetted parts is gray iron and steel.
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
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: [phone]
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: [phone]
For information or technical assistance on the en
gine, contact the engine manufacturer's local
dealer or representative.
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.
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-00900
PAGE A - 1SAFETY
SAFETY - SECTION A
This information applies to 80 Series
Engine Driven pumps. Refer to the man
ual accompanying the engine before at
tempting to begin operation.
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and pre
cautions for each specific application.
Therefore, it is the owner/installer's re
sponsibility to ensure that applications
not addressed in this manual are per
formed only after establishing that nei
ther operator safety nor pump integrity
are compromised by the installation.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Switch off the 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 cau
tiously.
7. Drain the pump.
If the pump is equipped with the option
al automatic starting system, it is sub
ject to automatic restart. Keep hands
and clothing away from the unit to pre
vent injury during automatic operation.
Disconnect the positive battery cable
before performing any maintenance.
Failure to do so may result in serious
personal injury.
Before attempting to install, operate, or
service this pump, familiarize yourself
with this manual, and with all other liter
ature shipped with the pump. Unfamil
iarity with all aspects of pump operation
covered in this manual could lead to de
struction of equipment, injury, or death
to personnel.
This pump is designed to handle most
non‐volatile, non‐flammable liquids
containing specified entrained solids.
Do not attempt to pump volatile, corro
sive, or flammable materials, or any liq
uids which may damage the pump or en
danger personnel as a result of pump
failure.
Death or serious personal injury and
damage to the pump or components
can occur if proper lifting procedures
are not observed. Make certain that
hoists, chains, slings or cables are in
good working condition and of suffi
cient capacity and that they are posi
tioned so that loads will be balanced
and the pump or components will not be
damaged when lifting. Suction and dis
charge hoses and piping must be re
moved from the pump before lifting. Lift
the pump or component only as high as

80 SERIESOM-00900
PAGE A - 2 SAFETY
necessary and keep personnel away
from suspended objects.
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
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.
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.
Pumps and related equipment must be in
stalled and operated according to all na
tional, local and industry standards.
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating an internal combustion
engine in an enclosed area, make sure
exhaust fumes are piped to the outside.
These fumes contain carbon monoxide,
a deadly gas that is colorless, tasteless
and odorless.
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. 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. The maximum continuous
operating speed for this pump is 2300
RPM.

80 SERIES OM-00900
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.) If the pump is fitted with a Gorman‐
Rupp double grease lubricated seal, the maximum
incoming pressure must be reduced to 10 p.s.i.
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 84A2-F3L
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 and engine 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

OM-00900 80 SERIES
PAGE B - 2 INSTALLATION
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.
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 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.
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.
Battery Specifications And Installation
Unless otherwise specified on the pump order, the
engine battery was not included with the unit. Re
fer to the following specifications when selecting a
battery.
Table 1. Battery Specifications
Crank
@ 0F
Reserve
Capacity
(Minutes)
@ 80F
Overall
Dims.
(Inches)
960-975 365
20.5L
Cold
Amps
Approx.
Amp/
Hr.
Rating
175 8.75W
9.75H
x
x
Voltage
12 Volts
Refer to the information accompanying the battery
and/or electrolyte solution for activation and charg
ing instructions.
Before installing the battery, clean the positive and
negative cable connectors, and the battery termi
nals. Secure the battery by tightening the
holddown brackets. The terminals and clamps
may be coated with petroleum jelly to retard corro
sion. Connect and tighten the positive cable first,
then the negative cable.
POSITIONING PUMP
Death or serious personal injury and
damage to the pump or components
can occur if proper lifting procedures
are not observed. Make certain that
hoists, chains, slings or cables are in
good working condition and of suffi
cient capacity and that they are posi
tioned so that loads will be balanced
and the pump or components will not be
damaged when lifting. Suction and dis
charge hoses and piping must be re
moved from the pump before lifting. Lift
the pump or component only as high as
necessary and keep personnel away
from suspended objects.
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.
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.
If the pump has been mounted on a moveable
base, make certain the base is stationary by setting
the brake and blocking the wheels before attempt
ing to operate the pump.
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

80 SERIES OM-00900
PAGE B - 3INSTALLATION
only; however, the engine manufacturer should be
consulted for continuous operation at angles
greater than 15.
SUCTION AND DISCHARGE PIPING
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 (457,20 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 1‐1/8 inch
(28,6 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 Line Positioning
The depth of submergence of the suction line is
critical to efficient pump operation. Figure 2 shows

OM-00900 80 SERIES
PAGE B - 4 INSTALLATION
recommended minimum submergence vs. veloc
ity.
NOTE
The pipe submergence required may be reduced
by installing a standard pipe increaser fitting at the
end of the suction line. The larger opening size will
reduce the inlet velocity. Calculate the required
submergence using the following formula based
on the increased opening size (area or diameter).
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
FLOAT SWITCHES
Installation
The standard pump is not furnished with a means
to automatically regulate liquid level. However, if
the unit is equipped with the optional auto‐start
control system, the pump can be conformed to
start and stop as the liquid level in the wet well or
sump rises and falls. The autostart option employs
either a single or double float switch system, where
a bulb raises or lowers (floats) with the liquid level,
thus activating an enclosed miniature switch. The
floats are equipped with a socket type connector
that plugs into a matching receptacle on the auto‐
start control box.
Standard floats are equipped with 50 feet (15,2 m)
of cable.
When installing the floats, note the following:
a. Be sure to provide sufficient room in the wet
well or sump so that floats do not get ob
structed or drawn into the suction line. If a flex
ible suction hose is used, it may be extended
to lay along the bottom of the wet well or sump
and the float can be attached to the hose
above the point where it bends along the bot
tom. Direct the suction line toward the flow,
and the float(s) away from the flow. If a stand
pipe is available, attach the float switch cable
to the standpipe in the sump at the approxi
mate desired liquid level.
b. In a single float system, the cable can be teth
ered to the suction line or standpipe approxi

80 SERIES OM-00900
PAGE B - 5INSTALLATION
mately 6 inches (152 mm) above the float.
This setting allows approximately 9 inches
(229 mm) of liquid rise between pump start/
stop. The start/stop interval may be increased
by extending the float end of the cable. The
liquid level in the sump will increase approxi
mately 8 inches (203 mm) between start/stop
intervals for every 6 inches (152 mm) of cable
increase.
c. If a double float switch system is used, posi
tion the “Start” float at the desired high water
level in the sump, and the “Stop” float at the
desired low water level in the pump.
d. Refer to Figure 3 for additional float switch
data.
OPERATING
RANGE
(See Table Below)
CABLE
TETHER
POINT
OFF
(Emptying)
ON
(Filling)
ON
(Emptying)
OFF
(Filling)
1.25” Pipe
(Not Furnished)
ENGINE
CONTROL
BOX
1.0
(0.3)
APPROXIMATE FREE CORD LENGTH IN FT. (M)
0.5
(.15)
1.0
(0.3)
1.5
(.46)
2.0
(0.6)
2.5
(.76)
3.0
(0.9)
2.0
(0.6)
3.0
(0.9)
4.0
(1.2)
Figure 3. Float Switch Data
DISCHARGE LINES
Siphoning
Do not terminate the discharge line at a level lower
than that of the liquid being pumped unless a si
phon breaker is used in the line. Otherwise, a si
phoning action causing damage to the pump
could result.
Valves
If a throttling valve is desired in the discharge line,
use a valve as large as the largest pipe to minimize
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 in
stalled in the discharge line to protect the pump
from excessive shock pressure and reverse rota
tion when it is stopped.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
Bypass Lines
If a system check valve is used due to high dis
charge head, it may be necessary to vent trapped
air from the top of the pump during the priming
process. This may be accomplished by installing a
bypass line from the top of the pump, back to the
source of liquid. The end of the bypass line must be
submerged. The line must be large enough to pre
vent clogging, but not so large as to affect pump
discharge capacity.
ALIGNMENT
The alignment of the pump and engine is critical for
trouble‐free mechanical operation. The driver and
pump must be mounted so that their shafts are
aligned with and parallel to each other. Refer to Se
curing Intermediate And Drive Assembly To En
gine in MAINTENANCE AND REPAIR, Section E
for details.

OM-00900
80 SERIES
OPERATION PAGE C - 1
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 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.
This pump is designed to handle most
non‐volatile, non‐flammable liquids
containing specified entrained solids.
Do not attempt to pump volatile, corro
sive, or flammable materials, or any liq
uids which may damage the pump or en
danger personnel as a result of pump
failure.
Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. The maximum continuous
operating speed for this pump is 2300
RPM.
PRIMING
Install the pump and piping as described in IN
STALLATION. Make sure that the piping connec
tions are tight, and that the pump is securely
mounted. Check that the pump is properly lubri
cated (see LUBRICATION in MAINTENANCE
AND REPAIR).
This pump is self priming, but the pump should
never be operated unless there is liquid in the
pump casing.
Never operate this pump unless there is
liquid in the pump casing. The pump will
not prime when dry. Extended operation of
a dry pump will destroy the seal assembly.
Add liquid to the pump casing when:
1. The pump is being put into service for the
first time.
2. The pump has not been used for a consider
able length of time.
3. The liquid in the pump casing has evapo
rated.
When installed in a flooded suction application,
simply open the system valves and permit the in
coming liquid to evacuate the air. After the pump
and piping system have completely filled, evacu
ate any remaining air pockets in the pump or suc
tion line by loosening pipe plug or opening bleeder
valves.
Once the pump casing has been filled, the pump
will prime and reprime as necessary.
After filling the pump casing, reinstall
and tighten the fill plug. Do not attempt
to operate the pump unless all connect
ing piping is securely installed. Other
wise, liquid in the pump forced out un
der pressure could cause injury to per
sonnel.
To fill the pump, remove the pump casing fill cover
or fill plug in the top of the casing, and add clean
liquid until the casing is filled. Replace the fill cover
or fill plug before operating the pump.

OM-00900 80 SERIES
OPERATIONPAGE C - 2
STARTING
If the pump is equipped with the option
al automatic starting system, it is sub
ject to automatic restart. Keep hands
and clothing away from the unit to pre
vent injury during automatic operation.
Disconnect the positive battery cable
before performing any maintenance.
Failure to do so may result in serious
personal injury.
Consult the engine operations manual before at
tempting to start the unit.
Manual Starting
On initial start‐up, set the engine speed at the half‐
throttle position. Turn the keyswitch on the control
box to the “START” position until the engine starts.
Release the key and the switch will return to the
“RUN” position.
After the engine starts and the unit is fully primed,
adjust the engine RPM until the desired flow rate is
achieved.
Pump speed and operating condition
points must be within the continuous per
formance range shown on the curve on
page E‐1.
Automatic Starting
If the unit is equipped with the optional autostart
control system, install the float(s) as described in
INSTALLATION, Section B.
Follow the procedures outlined for manual starting
and throttle adjustment, then turn the key to the
“AUTO START” position.
NOTE
For security purposes, the key can be removed with
the switch in the “AUTO START” position.
Press and hold the white “AUTO” button on the
control panel until the red “AUTO” light illuminates.
The auto‐start system is now armed.
NOTE
The unit can continue to be started manually with
the keyswitch in the “AUTO START” position by
pressing the white “MAN” button on the control. The
“Single Lightning Bolt” light on the control will illu
minate in conjunction with an audible alarm before
the unit starts. The unit can then be stopped manu
ally by pressing the “OFF/SET” button.
In the auto‐start mode, the “Single Lightning Bolt”
light will illuminate in conjunction with an audible
alarm when the liquid level in the sump or wet well
rises and activates the float(s). The light will blink
and the alarm will sound for approximately 8 sec
onds before the unit starts.
When the liquid level in the sump or wet well is suffi
ciently pumped down, the unit will automatically
shut down.
NOTE
If the keyswitch is moved to the “OFF” position
while in the auto‐start mode, the engine will stop.
However, the auto‐start process will continue as
soon as the keyswitch is moved back to the “AUTO
START” position. To cancel the auto‐start process,
press the “OFF/SET” button.
The control panel is equipped with high oil temper
ature, low oil pressure, V‐belt and start failure (3 at
tempts) safety shutdowns. If any of these problems
occur, the red “Double Lightning Bolt” light will illu
minate to indicate a system fault. When the prob
lem is corrected, press the “OFF/SET” button to re
set the control.
NOTE
The “OFF/SET” button has dual functionality when
in program mode. If necessary, consult the factory
for details on programming functions.

OM-00900
80 SERIES
OPERATION PAGE C - 3
The unit can be started manually with the key
switch in the “AUTO START” position by pressing
the white “MAN” button. The “Single Lightning
Bolt” light will illuminate in conjunction with an au
dible alarm before the unit starts.
Stop the unit manually by pressing the “OFF/SET”
button.
OPERATION
Pump speed and operating condition
points must be within the continuous per
formance range shown on the curve (see
Section E, Page 1).
Lines With a Bypass
Either a Gorman‐Rupp automatic air release valve
or a hand operated shutoff valve may be installed in
a bypass line.
If a Gorman‐Rupp Automatic Air Release Valve has
been installed, the valve will automatically open to
allow the pump to prime, and automatically close
after priming is complete (see INSTALLATION for
Air Release Valve operation).
If the bypass line is open, air from the suction line
will be discharged through the bypass line back to
the wet well during the priming cycle. Liquid will
then continue to circulate through the bypass line
while the pump is in operation.
Lines Without a Bypass
Open all valves in the discharge line and start the
power source. Priming is indicated by a positive
reading on the discharge pressure gauge or by a
quieter operation. The pump may not prime imme
diately because the suction line must first fill with
liquid. If the pump fails to prime within five minutes,
stop it and check the suction line for leaks.
After the pump has been primed, partially close the
discharge line throttling valve in order to fill the line
slowly and guard against excessive shock pres
sure which could damage pipe ends, gaskets,
sprinkler heads, and any other fixtures connected
to the line. When the discharge line is completely
filled, adjust the throttling valve to the required flow
rate.
Leakage
No leakage should be visible at pump mating sur
faces, or at pump connections or fittings. Keep all
line connections and fittings tight to maintain maxi
mum pump efficiency.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
110F (43C). Do not apply it at a higher operating
temperature.
Overheating can occur if operated with the valves
in the suction or discharge lines closed. Operating
against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to rup
ture or explode. If overheating occurs, stop the
pump and allow it to cool before servicing it. Refill
the pump casing with cool liquid.
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.
Strainer Check
If a suction strainer has been shipped with the
pump or installed by the user, check the strainer
regularly, and clean it as necessary. The strainer
should also be checked if pump flow rate begins to
drop. If a vacuum suction gauge has been in
stalled, monitor and record the readings regularly
to detect strainer blockage.
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 neces
sary, liquid pressure must be limited to 50% of the

OM-00900 80 SERIES
OPERATIONPAGE C - 4
maximum permissible operating pressure shown
on the pump performance curve. (See Section E,
Page 1.) If the pump is fitted with a Gorman‐Rupp
double grease lubricated seal, the maximum in
coming pressure must be reduced to 10 p.s.i.
Pump Vacuum Check
With the pump inoperative, install a vacuum gauge
in the system, using pipe dope on the threads.
Block the suction line and start the pump. At oper
ating speed the pump should pull a vacuum of 20
inches (508 mm) or more of mercury. If it does not,
check for air leaks in the seal, gasket, or discharge
valve.
Open the suction line, and read the vacuum gauge
with the pump primed and at operation speed.
Shut off the pump. The vacuum gauge reading will
immediately drop proportionate to static suction
lift, and should then stabilize. If the vacuum reading
falls off rapidly after stabilization, an air leak exists.
Before checking for the source of the leak, check
the point of installation of the vacuum gauge.
STOPPING
Never halt the flow of liquid suddenly. If the liquid
being pumped is stopped abruptly, damaging
shock waves can be transmitted to the pump and
piping system. Close all connecting valves slowly.
On engine driven pumps, reduce the throttle
speed slowly and allow the engine to idle briefly be
fore stopping.
Manual Stopping
In the manual mode, reduce the throttle speed
slowly, and allow the engine to idle briefly before
switching the HAND‐OFF‐AUTO switch to `OFF'.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
After stopping the pump, close and lock the control
panel cover, or disconnect the positive battery
cable to ensure that the pump will remain inopera
tive.
Automatic Stopping
In the automatic mode, the pump will stop when
the liquid in the wet well or sump lowers and acti
vates the “Off” float switch(s). The pump will restart
automatically when the liquid rises and activates
the “On” float switch(s).
Safety Shutdown System
The unit is equipped with a safety system to auto
matically shut down the engine under certain con
ditions. The engine will automatically shut down:
1. If the engine exceeds its safe operating tem
perature.
2. If the engine oil pressure drops below design
limits.
3. If the engine fails to start within a pre‐set peri
od of time.
4. If the engine speed exceeds the safe operat
ing range.
5. If the engine fan belt breaks.
Lights on the control panel will indicate which of the
safety features has caused the engine to shut
down.
Should any of the safety features cause the engine
to shut down, the cause must be determined and
corrected before putting the unit back into service.
The engine will not restart until the HAND‐OFF‐
AUTO switch has been returned to the `OFF' posi
tion for at least 10 seconds.
All safety shutdown features are pre‐set at the fac
tory for optimum performance and safety; do not
attempt to adjust these settings.
Never disconnect any of the safety shut
down features; this will void the warran
ty and could result in serious damage to
the unit and/or injury to personnel. Safe
ty shutdown features are pre‐set at the

OM-00900
80 SERIES
OPERATION PAGE C - 5
factory; do not attempt to adjust any of
the settings. Determine the cause of
shutdown before putting the unit back
into service. Consult the factory for ad
ditional information.
OPERATION IN EXTREME HEAT
The safety shutdown system will automatically
stop the unit if engine operating temperature ex
ceeds design limits. If engine over‐temperature
shutdown occurs, allow the unit to cool before re
starting.
If engine overheating continues, check the engine
lubricant level and viscosity. Consult the engine
operation manual for the recommended lubricant
for operation in extreme heat.
If the unit is equipped with the optional auto‐start
control, the float(s) may need to be adjusted to al
low shorter run and longer cooling periods, if pos
sible.
If the pump is equipped with the option
al automatic starting system, it is sub
ject to automatic restart. Keep hands
and clothing away from the unit to pre
vent injury during automatic operation.
Disconnect the battery before perform
ing any maintenance. Failure to do so
may result in serious personal injury.
BEARING TEMPERATURE CHECK
Bearings normally run at higher than ambient tem
peratures because of heat generated by friction.
Temperatures up to 160F (71C) are considered
normal for bearings, and they can operate safely to
at least 180F (82C).
Checking bearing temperatures by hand is inaccu
rate. Bearing temperatures can be measured ac
curately by placing a contact‐type thermometer
against the housing. Record this temperature for
future reference.
A sudden increase in bearing temperatures is a
warning that the bearings are at the point of failing
to operate properly. Make certain that the bearing
lubricant is of the proper viscosity and at the cor
rect level (see LUBRICATION in Section E). Bear
ing overheating can also be caused by shaft
misalignment and/or excessive vibration.
When pumps are first started, the bearings may
seem to run at temperatures above normal. Con
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
remaining liquid that could freeze the pump rotat
ing parts. If the pump will be idle for more than a
few hours, or if it has been pumping liquids con
taining a large amount of solids, drain the pump,
and flush it thoroughly with clean water. To prevent
large solids from clogging the drain port and pre
venting the pump from completely draining, insert
a rod or stiff wire in the drain port, and agitate the
liquid during the draining process. Clean out any
remaining solids by flushing with a hose.

OM-0090080 SERIES
TROUBLESHOOTING PAGE D - 1
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Switch off engine ignition and dis
connect 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 cau
tiously.
7. Drain the pump.
If the pump is equipped with the option
al automatic starting system, it is sub
ject to automatic restart. Keep hands
and clothing away from the unit to pre
vent injury during automatic operation.
Disconnect the positive battery cable
before performing any maintenance.
Failure to do so may result in serious
personal injury.
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO PRIME Not enough liquid in csing.
Suction check valve contaminated or
damaged.
Air leak in suction line.
Lining of suction hose collapsed.
Leaking or worn seal or pump gas
ket.
Suction lift or discharge head too
high.
Strainer clogged.
Suction check valve or foot valve
clogged or binding.
Add liquid to casing. See PRIMING.
Clean or replace check valve.
Correct leak.
Replace suction hose.
Check pump vacuum. Replace leak
ing or worn seal or gasket.
Check piping installation and install
bypass line if needed. See INSTAL
LATION.
Check strainer and clean if neces
sary.
Repair priming device or check
installation.
PUMP STOPS OR FAILS
TO DELIVER RATED
FLOW OR PRESSURE
Air leak in suction line.
Lining of suction hose collapsed.
Leaking or worn seal or pump gas
ket.
Suction intake not submerged at
proper level or sump too small.
Correct leak.
Replace suction hose.
Check pump vacuum. Replace leak
ing or worn seal or gasket.
Check installation and correct sub
mergence as needed.

OM-00900 80 SERIES
TROUBLESHOOTINGPAGE D - 2
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP STOPS OR FAILS
TO DELIVER RATED
FLOW OR PRESSURE
(cont.)
Strainer clogged.
Impeller or other wearing parts worn
or damaged.
Impeller clogged.
Suction lift or discharge head too
high.
Pump speed too slow.
Check strainer and clean if neces
sary.
Replace worn or damaged parts.
Check that impeller is properly cen
tered and rotates freely.
Free impeller of debris.
Check piping installation and install
bypass line if needed. See INSTAL
LATION.
Check engine output; consult engine
operation manual.
PUMP REQUIRES TOO
MUCH POWER
Pump speed too high.
Discharge head too low.
Liquid solution too thick.
Bearing(s) frozen.
Check engine output.
Adjust discharge valve.
Dilute if possible.
Disassemble pump and check bear
ing(s).
PUMP CLOGS
FREQUENTLY
Discharge flow too slow.
Suction check valve or foot valve
clogged or binding.
Discharge line clogged or restricted;
hose kinked.
Open discharge valve fully to in
crease flow rate, and run engine at
maximum governed speed.
Clean valve.
Check discharge lines; straighten
hose.
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.
BEARINGS RUN TOO
HOT
Bearing temperature is high, but
within limits.
Low or incorrect lubricant.
Suction and discharge lines not
properly supported.
Drive misaligned.
Check bearing temperature regularly
to monitor any increase.
Check for proper type and level of lu
bricant.
Check piping installation for proper
support.
Align drive properly.

OM-0090080 SERIES
TROUBLESHOOTING PAGE D - 3
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 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. The appearance of wearing parts should also
be documented at each inspection for comparison
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
before failure occurs, reducing unscheduled down
time.
For new applications, a first inspection of wearing
parts at 250 hours will give insight into the wear rate
for your particular application. Subsequent inspec
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 intermittent 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*