GORMAN-RUPP PUMPS RP Series User manual

OM-06203-01
September 9, 2008
Rev. A 11‐08‐17
GORMAN‐RUPP PUMPS
www.grpumps.com
2008 Gorman‐Rupp Pumps Printed in U.S.A.
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
RP SERIES PUMP
MODEL
RP6C60
Including FRAME And SAE Models

Register your new
Gorman‐Rupp pump online at
www.grpumps.com
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....................................
PREINSTALLATION INSPECTION PAGE B - 1............................................
Battery Installation PAGE B - 1.....................................................
ELECTRICAL CONNECECTIONS (ELECTRIC MOTOR DRIVEN UNITS) PAGE B - 1...........
Field Wiring Connections (Incoming Power) PAGE B - 2...............................
POSITIONING PUMP PAGE B - 2.......................................................
Lifting PAGE B - 3.................................................................
Mounting PAGE B - 3.............................................................
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 - 4...............................................................
Strainers PAGE B - 4..............................................................
Sealing PAGE B - 4...............................................................
Suction Lines In Sumps PAGE B - 4.................................................
Suction Line Positioning PAGE B - 4................................................
DISCHARGE LINES PAGE B - 5........................................................
Siphoning PAGE B - 5.............................................................
Valves PAGE B - 5................................................................
ALIGNMENT PAGE B - 5..............................................................
Factory Installed Engine Driven Units PAGE B - 5.....................................
Electric Motor Driven Units PAGE B - 5..............................................
Coupled Drives PAGE B - 6........................................................
V‐belt Drives PAGE B - 6...........................................................
V‐BELT TENSIONING PAGE B - 7......................................................
General Rules of Tensioning PAGE B - 7.............................................
Tension Measurement PAGE B - 7..................................................
AUTO‐START PAGE B - 9.............................................................
Float Switch Installation PAGE B - 9.................................................
Submersible Transducer Installation PAGE B - 9......................................
Submersible Connections PAGE B - 11...............................................
OPERATION - SECTION C PAGE C - 1......................................
OPERATION OF FACTORY‐EQUIPPED ELECTRIC MOTOR DRIVEN UNITS PAGE C - 1.......
Component Function PAGE C - 1...................................................
Rotation PAGE C - 2..............................................................
Priming PAGE C - 2...............................................................
OPERATION OF FACTORY‐EQUIPPED ENGINE MOTOR DRIVEN UNITS PAGE C - 2.........
Before Starting PAGE C - 2........................................................
Manual Starting (Deutz Powered Units) PAGE C - 2...................................
Manual Starting (John Deere and Caterpillar Powered Units) PAGE C - 3................

TABLE OF CONTENTS
(continued)
ii
Automatic Starting (Deutz Powered Units) PAGE C - 3.................................
Automatic Starting (John Deere and Caterpillar Powered Units) PAGE C - 4..............
PRIMING PAGE C - 4.................................................................
ROUTINE OPERATION (Engine Driven Units) PAGE C - 4.................................
OPERATION IN EXTREME HEAT (Engine Driven Units) PAGE C - 5.........................
OPERATIONAL CHECKS (All Models) PAGE C - 5........................................
Leakage PAGE C - 5..............................................................
Pump Vacuum Check PAGE C - 5..................................................
Vacuum Pump Discharge Line PAGE C - 5...........................................
Liquid Temperature And Overheating PAGE C - 5.....................................
Strainer Check PAGE C - 5.........................................................
STOPPING (Electric Motor Driven Units) PAGE C - 6......................................
STOPPING (Engine Driven Units) PAGE C - 6............................................
Manual Stopping (Deutz Powered Units) PAGE C - 6..................................
Manual Stopping (John Deere Powered Units) PAGE C - 6.............................
Automatic Stopping PAGE C - 6....................................................
Safety Shutdown System PAGE C - 6...............................................
PERIODIC CHECKS (All Models) PAGE C - 7............................................
Seal Cavity And Bearing Lubrication PAGE C - 7......................................
Bearing Temperature Check PAGE C - 7.............................................
PERIODIC CHECKS (Engine Driven Units) PAGE C - 7....................................
Engine Fuel Filter PAGE C - 7......................................................
Engine Oil PAGE C - 7.............................................................
Belts PAGE C - 7.................................................................
COLD WEATHER PRESERVATION (All Models) PAGE C - 7...............................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...............................................
PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................
PERFORMANCE CURVES PAGE E - 1..................................................
PARTS LISTS:
Pump Models PAGE E - 3.........................................................
Pump Model (SAE 4/10) PAGE E - 5................................................
Pump Model (FRAME) PAGE E - 7..................................................
Vacuum Pump Assembly PAGE E - 9...............................................
Priming Chamber Kit PAGE E - 10...................................................
Check Valve Kit PAGE E - 11........................................................
Drive Assembly (Factory‐Equipped Engine Driven Units) PAGE E - 12....................
PUMP MAINTENANCE AND REPAIR PAGE E - 13.........................................
DISCHARGE CHECK VALVE DISASSEMBLY AND REASEMBLY PAGE E - 14.................
Discharge Check Valve Removal and Disassembly PAGE E - 14.........................
Discharge Check Valve Assembly and Installation PAGE E - 14..........................
PRIMING CHAMBER DISASSEMBLY AND REASEMBLY PAGE E - 14........................
Suction Spool and Priming Chamber Removal and Disassembly PAGE E - 14.............
Suction Spool and Priming Chamber Assembly and Installation PAGE E - 15..............
VACUUM PUMP MAINTENANCE AND REPAIR PAGE E - 15................................
Vacuum Pump Removal PAGE E - 15................................................
Vacuum Pump Disassembly PAGE E - 15.............................................

TABLE OF CONTENTS
(continued)
iii
Vacuum Pump Reassembly PAGE E - 16.............................................
Vacuum Pump Installation PAGE E - 18...............................................
Vacuum Pump Lubrication PAGE E - 18..............................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 18.........................
Pump Casing Removal PAGE E - 18.................................................
Impeller Removal PAGE E - 19......................................................
Seal Removal PAGE E - 19..........................................................
Back Plate Removal PAGE E - 19....................................................
Separating Pump Frame And Drive Assembly From Engine PAGE E - 20.................
Pump Shaft and Bearing Removal and Disassembly PAGE E - 20........................
Bearing Cleaning And Inspection PAGE E - 20........................................
Pump Shaft and Bearing Reassembly and Installation PAGE E - 21......................
Drive Assembly Installation PAGE E - 22..............................................
Seal Reassembly and Installation PAGE E - 22........................................
Impeller Installation PAGE E - 24.....................................................
Pump Casing and Wear Ring Installation PAGE E - 25..................................
PUMP LUBRICATION PAGE E - 25......................................................
Seal Assembly PAGE E - 25.........................................................
Bearings PAGE E - 25..............................................................
Engine PAGE E - 25................................................................

OM-06203
RP SERIES
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 Mainte
nance manual is designed to help you achieve the
best performance and longest life from your Gor
man‐Rupp pump.
This pump is an RP Series, priming‐assisted cen
trifugal model. It is designed for handling non‐vola
tile, non‐flammable liquids containing specified en
trained solids. The basic material of construction is
gray iron.
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
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
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.
The following are used to alert personnel to proce
dures 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.
Hazards or unsafe practices which COULD
result in minor personal injury or product or
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.

RP SERIES OM-06203
PAGE A - 1SAFETY
SAFETY ‐ SECTION A
This information applies to RP Series
pumps. Refer to the manual accompa
nying the engine or power source be
fore attempting 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. Shut down the engine and discon
nect the positive battery cable, or
lock out incoming power to the mo
tor and take precautions to ensure
that the pump will remain inopera
tive.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature and make
sure the pump is cool before open
ing 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.
Do not attempt to pump volatile, corro
sive, or flammable liquids which may
damage the pump or endanger person
nel as a result of pump failure.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment. Attach lifting equip
ment to the lifting device fitted to the
pump. If chains or cable are wrapped
around the pump to lift it, make certain
that they are positioned so as not to
damage the pump, and so that the load
will be balanced. The bail is intended for
use in lifting the pump assembly only.
Suction and discharge hoses and pip
ing must be removed from the pump be
fore 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 against a
closed discharge valve. If operated
against a closed discharge valve, pump
components will deteriorate, and the
liquid could come to a boil, build pres
sure, and cause the pump casing to rup
ture or explode. Momentary closure of a
discharge valve is acceptable only
when required for startup or shutdown
procedures.
Do not remove plates, covers, gauges,

RP SERIESOM-06203
PAGE A - 2 SAFETY
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 completely before
servicing.
Do not operate the pump without a
guard in place over the rotating parts.
Exposed rotating parts can catch cloth
ing, fingers, or tools, causing severe in
jury to personnel.
This pump may be used to handle mate
rials which could cause illness through
direct exposure or emitted fumes. Wear
adequate protective clothing when
working on the pump or piping.
This pump may be equipped with auto
matic liquid level controls, and there
fore subject to automatic restart. Keep
hands and clothing away from the unit to
prevent injury during automatic opera
tion. Shut down the engine and discon
nect the positive battery cable, or lock
out incoming power to the motor before
performing any maintenance. Failure to
do so may result in serious personal in
jury.
Make sure the pump is level. Lower jack
stands and chock the wheels, if so
equipped. Use caution when positioning
the skid‐mounted unit to prevent damage
to the fuel tank.
If the pump is powered by an electric
motor, the motor must be operated
through a control box that provides
overload protection and power control.
Do not connect the pump motor directly
to the incoming power lines.
If the pump is powered by an electric
motor, the electrical power high enough
to cause injury or death. Obtain the ser
vices of a qualified electrician to make
all electrical connections. Make certain
that the pump is properly grounded;
never use gas pipe as an electrical
ground. Be sure that the incoming pow
er matches the voltage and phase of the
motor and control before connecting to
the incoming power. Do not run the
pump if the voltage is not within the lim
its.
If the pump is powered by an electric
motor, the electrical power high enough
to cause injury or death. Make certain
that the handle on the control box is in
the OFF position and locked out, or that
the power supply to the control box has
been otherwise cut off and locked out,
before attempting to open or service the
pump assembly. Tag electrical circuits
to prevent accidental start‐up.
If the pump is powered by an electric
motor, all electrical connections must
be in accordance with The National
Electric Code and all local codes. If
there is a conflict between the instruc