Gormann-Rupp Pumps 10 Series Application guide

OM-01604-09
August 22, 2005
Rev. A 10‐18‐12
ACDEU
THE GORMAN‐RUPP COMPANY DMANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
e2005 The Gorman‐Rupp Company
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
10 SERIES PUMP
MODEL
16C20‐F4L

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.....................................
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.............................................................
Clearance 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 - 3...............................................................
Strainers PAGE B - 3..............................................................
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................................................................
Bypass Lines PAGE B - 5..........................................................
AUTOMATIC AIR RELEASE VALVE PAGE B - 6...........................................
Theory of Operation PAGE B - 6....................................................
Air Release Valve Installation PAGE B - 7............................................
ALIGNMENT PAGE B - 7..............................................................
OPERATION - SECTION C PAGE C - 1.......................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 2................................................................
Starting PAGE C - 2...............................................................
OPERATION PAGE C - 2..............................................................
Lines With a Bypass PAGE C - 2....................................................
Lines Without a Bypass PAGE C - 2.................................................
Leakage PAGE C - 2..............................................................
Liquid Temperature And Overheating PAGE C - 2.....................................
Strainer Check PAGE C - 3.........................................................
Pump Vacuum Check PAGE C - 3..................................................
STOPPING PAGE C - 3................................................................
Stopping PAGE C - 3..............................................................
Safety Shutdown System PAGE C - 3...............................................
OPERATIOM IN EXTREME HEAT PAGE C - 4............................................
BEARING TEMPERATURE CHECK PAGE C - 4..........................................
Cold Weather Preservation PAGE C - 4..............................................

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.................
PARTS LISTS:
Pump Assembly PAGE E - 3..........................................................
Pump End Assembly PAGE E - 5......................................................
Drive Assembly PAGE E - 6...........................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 7.........................
Back Cover Removal PAGE E - 7...................................................
Suction Check Valve Removal PAGE E - 7...........................................
Separating Intermediate And Pump From Engine PAGE E - 8..........................
Loosening Impeller PAGE E - 8.....................................................
Pump Casing Removal PAGE E - 9.................................................
Impeller Removal PAGE E - 9......................................................
Seal Removal and Disassembly PAGE E - 9..........................................
Shaft and Bearing Removal and Disassembly PAGE E - 9.............................
Shaft and Bearing Reassembly and Installation PAGE E - 10............................
Securing Intermediate And Drive Assembly To Engine PAGE E - 11......................
Seal Reassembly and Installation PAGE E - 12........................................
Impeller Installation And Adjustment PAGE E - 13......................................
Suction Check Valve Installation PAGE E - 14.........................................
Back Cover Installation PAGE E - 15.................................................
Final Pump Assembly PAGE E - 15..................................................
LUBRICATION PAGE E - 15.............................................................
Seal Assembly PAGE E - 15.........................................................
Bearings PAGE E - 15..............................................................
Engine PAGE E - 15................................................................

10 SERIES OM-01604
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 pump is a 10 Series, semi‐open impeller, self‐
priming centrifugal model with a suction check
valve. The pump is designed to be close‐coupled
to a Deutz diesel engine.
The pump is designed for handling dirty water con
taining specified entrained solids. The basic mate
rial of construction for wetted parts is gray iron, with
ductile iron impeller and steel wearing parts.
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.
For information or technical assistance on the en
gine, contact the engine manufacturer's local
dealer or representative.
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 The Gor
man‐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]
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.

10 SERIES OM-01604
PAGE A - 1SAFETY
SAFETY - SECTION A
This information applies to 10 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 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.
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.
This pump is designed to handle dirty
water containing specified entrained
solids. Do not attempt to pump volatile,
corrosive, or flammable materials, or
any liquids which may damage the
pump or endanger personnel 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. 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
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.

10 SERIES
OM-01604
PAGE A - 2 SAFETY
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.
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 2200
RPM.
Allow an over‐heated pump to com
pletely cool before servicing. Do not re
move plates, covers, gauges, or fittings
from an over‐heated pump. Liquid with
in the pump can reach boiling tempera
tures, and vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Af
ter the pump completely cools, drain
the liquid from the pump by removing
the casing drain plug. Use caution when
removing the plug to prevent injury to
personnel from hot liquid.
Pumps and related equipment must be in
stalled and operated according to all na
tional, local and industry standards.

OM-0160410 SERIES
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 posi
tioned 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.)
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 16C20‐F4L

OM-01604 10 SERIES
PAGE B - 2 INSTALLATION
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 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
ing, check for loose hardware at mating sur
faces.
c. Carefully read all warnings and cautions con
tained in this manual or affixed to the pump,
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 has been stored for more than 12
months, some of the components or lubri
cants may have exceeded their maximum
shelf life. These must be inspected or re
placed to ensure maximum pump service.
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
20.5L
x
12 Volts 960‐975 365 175 8.75W
x
9.75H
Voltage
Cold Reserve Approx.
Crank Capacity Amp/ Overall
Amps @80°F Hr. Dims.
@ 0°F (Minutes) Rating (Inches)
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
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.
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.
The pump assembly can be seriously
damaged if the cables or chains used to lift
and move the unit are improperly wrapped
around the pump.
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 movable base,
make certain the base is stationary by setting the

OM-0160410 SERIES
PAGE B - 3INSTALLATION
brake and blocking the wheels before attempting
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
only; however, the engine manufacturer should be
consulted for continuous operation at angles
greater than 15_.
Clearance
When positioning the pump, allow a minimum
clearance of 18 inches (457 mm) in front of the
back cover to permit removal of the cover and easy
access to the pump interior.
SUCTION AND DISCHARGE PIPING
Pump performance is adversely effected by in
creased suction lift, discharge elevation, and fric
tion losses. Contact the factory to be sure your
overall application allows the pump to operate
within the safe operation range.
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 (457,2 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

OM-01604 10 SERIES
PAGE B - 4 INSTALLATION
of solids larger than the solids handling capability
of the pump.
This pump is designed to handle up to 3 inch (76,2
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 Lines In Sumps
If a single suction line is installed in a sump, it
should be positioned away from the wall of the
sump at a distance equal to 1 1/2 times the diame
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
tion inlet because the inflow will carry air down into
the sump, and air entering the suction line will re
duce pump efficiency.
If it is necessary to position inflow close to the suc
tion inlet, install a baffle between the inflow and the
suction inlet at a distance 1 1/2 times the diameter
of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into
the suction inlet.
If two suction lines are installed in a single sump,
the flow paths may interact, reducing the efficiency
of one or both pumps. To avoid this, position the
suction inlets so that they are separated by a dis
tance equal to at least 3 times the diameter of the
suction pipe.
Suction Line Positioning
The depth of submergence of the suction line is
critical to efficient pump operation. Figure 2 shows
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).

OM-0160410 SERIES
PAGE B - 5INSTALLATION
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
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
Self‐priming pumps are not air compressors. Dur
ing the priming cycle, air from the suction line must
be vented to atmosphere on the discharge side. If
the discharge line is open, this air will be vented
through the discharge. However, if a check valve
has been installed in the discharge line, the dis
charge side of the pump must be opened to atmos
pheric pressure through a bypass line installed be
tween the pump discharge and the check valve. A
self‐priming centrifugal pump will not prime if
there is sufficient static liquid head to hold the dis
charge check valve closed.
NOTE
The bypass line should be sized so that it does not
affect pump discharge capacity; however, the by
pass line should be at least 1 inch (25,4 mm) in di

OM-01604 10 SERIES
PAGE B - 6 INSTALLATION
ameter to minimize the chance of plugging.
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
low level pump. In some installations, this bypass
outline may be terminated with a six‐to‐eight foot
(1,8 to 2,4 m) length of 1‐1/4 inch (31,8 mm) I.D.
smooth‐bore hose; air and liquid vented during
the priming process will then agitate the hose and
break up any solids, grease, or other substances
likely to cause clogging.
A bypass line that is returned to a wet well
must be secured against being drawn into
the pump suction inlet.
It is also recommended that pipe unions be in
stalled at each 90_elbow in a bypass line to ease
disassembly and maintenance.
In high discharge head applications (more than
30 feet (9,1 m), an excessive amount of liquid may
be bypassed and forced back to the wet well under
the full working pressure of the pump; this will re
duce overall pumping efficiency. Therefore, it is
recommended that a Gorman‐Rupp Automatic
Air Release Valve be installed in the bypass line.
Gorman‐Rupp Automatic Air Release Valves are
reliable, and require minimum maintenance. See
Automatic Air Release Valves in this section for
installation and theory of operation of the Auto
matic Air Release Valve. Consult your Gorman‐
Rupp distributor, or contact the Gorman‐Rupp
Company for selection of an Automatic Air Release
Valve to fit your application.
Except in certain specific applications (to
prevent flooding during service of an auto
matic air release valve in a below‐ground
lift station), if a manual shut‐off valve is in
stalled anywhere in a bypass line, it must
be a full‐opening, ball‐type valve to pre
vent plugging by solids.
A manual shut‐off valve should not be
installed in any bypass line. A manual
shut‐off valve may inadvertently be left
closed during operation. A pump which
has lost prime may continue to operate
without reaching prime, causing dan
gerous overheating and possible explo
sive rupture of the pump casing. Per
sonnel could be severely injured.
Allow an over‐heated pump to com
pletely cool before servicing. Do not re
move plates, covers, gauges, or fittings
from an over‐heated pump. Liquid with
in the pump can reach boiling tempera
tures, and vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Af
ter the pump completely cools, drain the
liquid from the pump by removing the
casing drain plug. Use caution when re
moving the plug to prevent injury to per
sonnel from hot liquid.
AUTOMATIC AIR RELEASE VALVE
When properly installed and correctly adjusted to
the specific hydraulic operating conditions of the
application, the Gorman‐Rupp Automatic Air Re
lease Valve will permit air to escape through the by
pass line, and then close automatically when the
pump is fully primed and pumping at full capacity.
Theory of Operation
É
É
É
Figure 4. Valve in Open Position

OM-0160410 SERIES
PAGE B - 7INSTALLATION
Figures 4 and 5 show a cross‐sectional view of the
Automatic Air Release Valve, and a corresponding
description of operation.
During the priming cycle, air from the pump casing
flows through the bypass line, and passes through
the Air Release Valve to the wet well (Figure 4).
É
É
É
Figure 5. Valve in Closed Position
When the pump is fully primed, pressure resulting
from flow against the valve diaphragm com
presses the spring and closes the valve (Figure 5).
The valve will remain closed, reducing the bypass
of liquid to 1 to 5 gallons (3,8 to 18,9 L) per minute,
until the pump loses its prime or stops.
Some leakage (1 to 5 gallons (3,8 to 18,9
Liters) per minute) will occur when the
valve is fully closed. Be sure the bypass
line is directed back to the wet well or
tank to prevent hazardous spills.
When the pump shuts down, the spring returns the
diaphragm to its original position. Any solids that
may have accumulated in the diaphragm chamber
settle to the bottom and are flushed out during the
next priming cycle.
NOTE
The valve will remain open if the pump does not
reach its designed capacity or head. Valve closing
pressure is dependent upon the discharge head of
the pump at full capacity. The range of the valve
closing pressure is established by the tension rate
of the spring as ordered from the factory. Valve clos
ing pressure can be further adjusted to the exact
system requirements by moving the spring retain
ing pin up or down the plunger rod to increase or
decrease tension on the spring. Contact your Gor
man‐Rupp distributor or the Gorman‐Rupp Compa
ny for information about an Automatic Air Release
Valve for your specific application.
Air Release Valve Installation
The Automatic Air Release Valve must be inde
pendently mounted in a horizontal position and
connected to the discharge line of the self‐priming
centrifugal pump (see Figure 6).
NOTE
If the Air Release Valve is to be installed on a staged
pump application, contact the factory for specific
installation instructions.

OM-01604 10 SERIES
PAGE B - 8 INSTALLATION
DISCHARGE PIPE
DISCHARGE
CHECK VALVE
PUMP DISCHARGE
SELF‐PRIMING
CENTRIFUGAL
PUMP
SUCTION
LINE
SUPPORT
BRACKET
CLEAN‐OUT
COVER
INSTALL AIR RELEASE VALVE
IN HORIZONTAL POSITION
90_LONG
RADIUS
ELBOW
WET WELL
OR SUMP
BLEED LINE 1”
(25,4 MM) DIA. MIN.
(CUSTOMER FUR
NISHED) DO NOT EX
TEND BELOW PUMP
OFF LIQUID LEVEL
Figure 6. Typical Automatic Air Release Valve Installation
The valve inlet line must be installed between the
pump discharge port and the non‐pressurized side
of the discharge check valve. The valve inlet is at
the large end of the valve body, and is provided
with standard 1 inch NPT pipe threads.
The valve outlet is located at the opposite end of
the valve, and is also equipped with standard 1
inch NPT pipe threads. The outlet should be con
nected to a bleed line which slopes back to the wet
well or sump. The bleed line must be the same size
as the inlet piping, or larger. If piping is used for the
bleed line, avoid the use of elbows whenever pos
sible.
NOTE
It is recommended that each Air Release Valve be
fitted with an independent bleeder line directed
back to the wet well. However, if multiple Air Re
lease Valves are installed in a system, the bleeder
lines may be directed to a common manifold pipe.
Contact your Gorman‐Rupp distributor or the Gor
man‐Rupp Company for information about installa
tion of an Automatic Air Release Valve for your spe
cific application.
ALIGNMENT
The alignment of the pump and the engine is criti
cal for trouble‐free mechanical operation. See Sec
tion E, Securing Intermediate And Drive Assem
bly To Engine for detailed information.

OM-01604
10 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 dirty
water containing specified entrained
solids. Do not attempt to pump volatile,
corrosive, or flammable materials, or
any liquids which may damage the
pump or endanger 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 2200
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.
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.
NOTE
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.
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

OM-01604 10 SERIES
OPERATIONPAGE C - 2
and piping system have completely filled, evacu
ate any remaining air pockets in the pump or suc
tion line by loosening a pipe plug or opening
bleeder valves.
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 operations manual furnished with the
engine.
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.
OPERATION
Lines With a Bypass
Close the discharge throttling valve (if so
equipped) so that the pump will not have to prime
against the weight of the liquid in the discharge
line. Air from the suction line will be discharged
through the bypass line back to the wet well during
the priming cycle. When the pump is fully primed
and liquid is flowing steadily from the bypass line,
open the discharge throttling valve. 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
engine. Priming is indicated by a positive reading
on the discharge pressure gauge or by a quieter
operation. The pump may not prime immediately
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
160_F (71_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,

OM-01604
10 SERIES
OPERATION PAGE C - 3
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.
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
maximum permissible operating pressure shown
on the pump performance curve. (See Section E,
Page 1.)
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 (508,0 mm) or more of mercury. If it does
not, check for air leaks in the seal, gasket, or dis
charge 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.
Stopping
Reduce the throttle speed slowly, and allow the en
gine 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.
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

OM-01604 10 SERIES
OPERATIONPAGE C - 4
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
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-0160410 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 re
main 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.
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO PRIME Not enough liquid in casing.
Suction check valve contaminated or
damaged.
Air leak in suction line.
Lining of suction hose collapsed.
Leaking or worn seal or pump gasket.
Suction lift or discharge head too high.
Strainer clogged.
Add liquid to casing. See PRIMING.
Clean or replace check valve.
Correct leak.
Replace suction hose.
Check pump vacuum. Replace leaking
or worn seal or gasket.
Check piping installation and install by
pass line if needed. See INSTALLA
TION.
Check strainer and clean if necessary.
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 gasket.
Strainer clogged.
Correct leak.
Replace suction hose.
Check pump vacuum. Replace leak
ing or worn seal or gasket.
Check strainer and clean if neces
sary.