Gormann-Rupp Pumps 80 Series User manual

OM-00080-OM03
October 21, 2002
ACE
THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO
www.gormanrupp.com
GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
eCopyright by the Gorman-Rupp Company
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
80 SERIES PUMP
MODEL
80E

TABLE OF CONTENTS
i
INTRODUCTION PAGE I --- 1.................................................
SAFETY - SECTION A PAGE A --- 1............................................
INSTALLATION --- SECTION B PAGE B --- 1....................................
PUMP SPECIFICATIONS PAGE B --- 1...................................................
PREINSTALLATION INSPECTION PAGE B --- 1............................................
POSITIONING PUMP PAGE B --- 1.......................................................
Lifting PAGE B --- 1.................................................................
Mounting PAGE B --- 1.............................................................
SUCTION AND DISCHARGE LINES PAGE B --- 1..........................................
Siphoning PAGE B --- 2.............................................................
Valves PAGE B --- 2................................................................
OPE RATION --- SECT ION C PAGE C --- 1......................................
PRIMING PAGE C --- 1.................................................................
ELECTRICAL CONNECTIONS PAGE C --- 1...............................................
Testing Outlet for Ground PAGE C --- 2...............................................
Use of Extension Cords PAGE C --- 2.................................................
OPERATION PAGE C --- 2..............................................................
Leakage PAGE C --- 2..............................................................
Liquid Temperature And Overheating PAGE C --- 2.....................................
Strainer Check PAGE C --- 2.........................................................
OPERATION AS A BOOSTER PUMP PAGE C --- 3.........................................
STOPPING PAGE C --- 3................................................................
TROUBLESHOOTING --- SECTION D PAGE D --- 1..............................
PUMP MAINTENANCE AND REPAIR - SECTION E PAGE E --- 1.................
STANDARD PERFORMANCE CURVE PAGE E --- 1........................................
PARTS LIST:
Pump Model PAGE E --- 3..........................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E --- 4.........................
Brush Replacement PAGE E --- 4....................................................
Pump Casing and Rotor Removal and Inspection PAGE E --- 5..........................
Impeller and Seal Removal PAGE E --- 5..............................................
Impeller and Seal Installation PAGE E --- 5............................................
Final Pump Assembly PAGE E --- 7..................................................
LUBRICATION PAGE E --- 7.............................................................
Seal Assembly PAGE E --- 7.........................................................
Motor Bearings PAGE E --- 7........................................................

80 SERIES OM--00080
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 isdesigned tohelp you achieve the
best performance and longest life from your Gor-
man-Rupp pump.
This 80 Series, centrifugal model is very light
weight and portable and is ideal for use in many
residential, commerical, marine or agricultural ap-
plications. It is constructed with a rugged one-
piece aluminum housing with a built-in carry han-
dle and priming port. The integral 1/2 H.P. electric
motor features permanently lubricated ball bear-
ings and a moisture-proof, 3-conductor power
cord with grounded plug to guard against shock.
The suction and discharge ports are fitted with
threaded adaptors for standard garden hosehook
up. The pump is designed to handle primarily
clean water; however, it may also be used for
pumping water mixed with garden-type chemicals
for short-term applications. Since these chemicals
may be slightly corrosive, caution should be used
to prevent exposure to personnel, and the pump
should be thoroughly flushed after such use. Con-
sult the chemical packaging for further details.
Donotattempttopumpvolatile,flammableliquids,
or operate the pump in an explosive atmosphere.
If there are any questions regarding the pump or its application which are not coveredin thismanual or in
other literature accompanying this unit, please contact your Gorman-Rupp distributor, or:
The Gorman-Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901--1217
Phone: [phone]
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: [phone]
The following are used to alert maintenance personnel to procedures 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.
HazardsorunsafepracticeswhichCOULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possi-
ble damage which couldresult from failure
to follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.

80 SERIES OM--00080
PAGE A -- 1SAFETY
SAFETY - SECTION A
This information applies to 80 Series
electric motor driven pumps.
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.
Beforeattemptingtoopenorservicethe
pump:
1. Familiarize yourself with this man-
ual.
2. Unplug the power cord to the
pump and take precautions to en-
sure that the pump will remain in-
operative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Vent the pump slowly and cau-
tiously.
6. Drain the pump.
This pump is designed to handle pri-
marily clean water; however, it may also
be used for pumping water mixed with
garden-type chemicals for short-term
applications. Since these chemicals
maybeslightlycorrosive,caution
should be used to prevent exposure to
personnel, and the pump should be
thoroughly flushed after such use. Con-
sult the chemical packaging for further
details. Do not attempt to pump volatile,
flammable liquids, or operate the pump
in an explosive atmosphere.
Afterthepumphasbeeninstalled,make
certain that the pump and all piping or
hose connections are tight, properly
supportedandsecurebeforeoperation.
Do not operate the pump against a
closeddischarge valveforlongperiods
oftime.Ifoperatedagainstacloseddis-
charge valve, pump components will
deteriorate, the liquid could come to a
boil,buildpressureandcausethepump
casing to rupture or explode.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over-
heatedpump. Vaporpressure withinthe
pump can cause parts being disen-
gaged to be ejected with great force. Al-
low the pump to cool before servicing.
The electrical power used to operate
this pump is high enough to cause inju-
ry or death. Obtain the services of a qu-
alified electrician to troubleshoot, test
and/or service the electrical compo-
nents of this pump.

80 SERIESOM--00080
PAGE A -- 2 SAFETY
Connect the plug on the pump to a
3-prong grounded outlet equipped with
a ground fault interruptor device. If a
grounded outlet is not available, a plug
adaptormaybeused onatemporaryba-
sis, only when the adaptor is properly
grounded (see Electrical Connections
in the Installation Section). Otherwise,
electrical shock resulting in injury or
death to personnel could occur.
Improper use of an extension cord may
result in serious personnel injury or
death. Never attempt to change the
electrical plug or alter the length of the
power cord with a splice. Equipment
failure or injury to personnel could re-
sult if all connectionsare notwaterproof
and compatible withthe electric current
used. Never allow any portion of the
cord orreceptacle ends tosit in water or
in damp locations.
Pumps and related equipment must be in-
stalled and operated according to all na-
tional, local and industry standards.

80 SERIES OM--00080
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
staticliftapplicationwhere thepump ispositioned
above the free level of liquid to be pumped.
If installed ina 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,
besuretolimittheincomingpressureto50%ofthe
maximum permissible operating pressure as
shown on the pump performance curve (see Sec-
tion E, Page 1).
Forfurtherassistance, contact yourGorman-Rupp
distributor or the Gorman-Rupp Company.
PUMP SPECIFICATIONS
Voltage Phase H.P. RPM HZ Size
115 AC 1 1/2 8000 60 3/4”
HOSE
Table B -1. Extension Cord Table
PREINSTALLATION INSPECTION
The pump assemblywas inspectedand tested be-
fore shipment from the factory. Before installation,
inspect the pump for damage which may haveoc-
curred during shipment. Check as follows:
a. Inspectthepumpforcracks, 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 tags, decals, and markings
onthepumpassembly,andperformallduties
indicated.
d. Install all shipped-loose items, including the
rubber mounting feet, priming port plug and
hose adaptors.
POSITIONING PUMP
Lifting
Lift the pump only by the integral handle, not the
power cord. Disconnect suction and discharge
hoses before lifting.
Mounting
Locatethepumpinanaccessibleplaceascloseas
practical tothe 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.
Donotsetthepumpinwater.Ifpossible,donotop-
erate the pump industy conditionsto prolongmo-
tor brush life.
SUCTION AND DISCHARGE LINES
Threadedadaptorsarefurnishedforattachinggar-
den hose to the pump when conditions permit its
use. The suction line (marked IN) may be either
galvanized pipe, plastic pipe or reinforced hose.
Ordinarygardenhosemaycollapsifusedasasuc-
tion line, restricting the flow of liquid to the pump.
Check the suction line regularly if non-reinforced
hose is used.
Allsuction connections must be air-tight to assure
priming and efficiency. Never position the pump
more thand 15 feet above the source ofliquid. If lo-
cated above the water source, make the suction
line as shour and straight as possible with the
slope running constantly upward toward the
pump. Iftheslopesdrops down tothepump atany

OM--00080 80 SERIES
PAGE B -- 2 INSTALLATION
point, an air pocket will be created, which could re-
sult in loss of prime, inefficient pumping and/or
damage to the pump.
When pumping from a creek or pond, install the
provided plastic strainer in the end of the suction
line to prevent entry of trash. Keep the strainer off
the bottom to prevent pumping mud or sand.
Standard garden-type hose may be used for the
dischargeline(markedOUT).
Siphoning
Do not terminate the discharge line at a levellower
than that of the liquid being pumped; otherwise, a
siphoning action causing damage to the pump
could result.
Valves
If desired, a throttling valve may be installed in the
discharge line. Never install a throttling valve in a
suction line.

OM--00080
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.
This pump is designed to handle pri-
marily clean water; however, it may also
be used for pumping water mixed with
garden-type chemicals for short-term
applications. Since these chemicals
maybeslightlycorrosive,caution
should be used to prevent exposure to
personnel, and the pump should be
thoroughly flushed after such use. Con-
sult the chemical packaging for further
details. Do not attempt to pump volatile,
flammable liquids, or operate the pump
in an explosive atmosphere.
Do not install and operate a non-explo-
sion proof motor in an explosive atmo-
sphere. Install, connect and operate the
pump motor in accordance with the Na-
tional Electric Code and all local codes.
If there is a conflict between the instruc-
tions in the manual accompanying the
unit and the National Electric Code or
the applicable local code, the National
or local code shall take precedence.All
electrical equipment supplied with this
pump conformed to applicable federal
regulations and national codes in effect
on the date of manufacture.
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.
This 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 operationof
a dry pump will destroy theseal assembly.
Add liquid to the pump casing when:
1. The pump is being put into service for the
first time.
2. Thepumphasnotbeenusedforaconsider-
able length of time.
3. The liquid in the pump casing has evapo-
rated.
After filling the pump casing, reinstall
and tighten the fill plug. Do not attempt
to operate the pump unless allconnect-
ing piping is securely installed. Other-
wise, liquid in the pump forced out un-
der pressure could cause injury to per-
sonnel.
Tofillthepump,removethefillpluginthetopofthe
casing, and add clean liquid until the casing is
filled. Replace the fill plug before operating the
pump.
ELECTRICAL CONNECTIONS
Before connecting the motor to incoming power,
besuretheelectricalservicematchesthemotorre-
quirements listed in this manuals or stamped on
thepumpnameplate.Thepumpisdesignedtoop-
erate on standard 115 Volt, 60 Hertz, AC current
with a 3-prong, polarized type outlet with internal
ground. The third prong is used to ground the

OM--00080 80 SERIES
OPERATIONPAGE C -- 2
pump and reduce the possibility of fatal shocks.
Never remove the grounding prong. Formaximum
safety, the outlet should be equipped with a
ground fault interruptor device.
Iftheoutlettobeusedisanolder,2-prongtype,a
3-prong adaptor may be used temporarily. The
ground wire on the adaptor must be attached toa
grounded outlet box screw.
Connect the plug on the pump to a
3-prong grounded outlet equipped with
a ground fault interruptor device. If a
grounded outlet is not available, a plug
adaptormaybeused onatemporaryba-
sis, only when the adaptor is properly
grounded. Otherwise, electrical shock
resulting in injury or death to personnel
could occur.
Testing Outlet for Ground
Check the outlet for proper ground byusing a UL-
Listed circuit analyzer. The circuit analyzer willindi-
cate by a pattern of lights if the power, neutral and
ground wires arecorrectly connectedto theoutlet.
Use of Extension Cords
Improper use of an extension cord may
result in serious personnel injury or
death. Never attempt to change the
electrical plug or alter the length of the
power cord with a splice. Equipment
failure or injury to personnel could re-
sult if all connectionsare notwaterproof
and compatible withthe electric current
used. Never allow any portion of the
cord orreceptacle ends tosit in water or
in damp locations.
Use an extension cord only when necessary. Be
sure the extension cord is in accordance with the
properwiregaugesize listedin TableC-1. Useonly
UL-Listed,3-wiregroundedtypecordapprovedfor
outside use.
AWG Wire Fuse
Size #18 #16 #14 #12 Size
Max Length 10 Ft. 50 Ft. 100 Ft. 160 Ft. 15 Amp
TableC-1.ExtensionCordTable
The correct direction of pump rotation is indicated
by an arrow on the pump body or accompanying
decals. Ifthe pump isoperated inthe wrongdirec-
tion, the impeller could become loosened from the
shaft and seriously damage the pump.
OPERATION
Leakage
No leakage should be visible at pump mating sur-
faces, or at pump connections or fittings. Keep all
lineconnectionsandfittingstightto maintainmaxi-
mum pump efficiency.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
160_F(71_C). Donotapplyitatahigheroperating
temperature.
Overheating can occur if operated with valves in
the suction or discharge lines closed or with re-
stricted hoses. Operating against a closed valve
could bring the liquid to a boil, build pressure, and
cause the pump to rupture or explode. If overheat-
ingoccurs,stopthepumpandallowittocomplete-
ly cool before servicing it. Refill the pump casing
with cool liquid.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over-
heatedpump. Vaporpressure withinthe
pump can cause parts being disen-
gaged to be ejected with great force. Al-
low the pump to completely cool before
servicing.
Strainer Check
Asuctionstrainerhas beenshippedwiththepump
and should be installed by the user. Check the

OM--00080
80 SERIES
OPERATION PAGE C -- 3
strainer regularly, and clean it as necessary. The
strainer should also be checked if pump flow rate
begins to drop.
If the strainer continues to clog with dirt or debris,
do one of the following:
SPrepare a bed of stones on which to rest
the strainer.
STie the strainer so that it stays off the
bottom of the pit.
STie the stainer inside a basket or pail.
Do not pump water containing a large amount of
sand, silt or abrasives. THis could damage the
shaft seal.
OPERATION AS A BOOSTER PUMP
Whenusedproperly,thispumpwillboostpressure
for applications such as car washing or spraying
tall trees or structures.
Pressure boosting will normally be accomplished
by attaching a short suction hose (about 10 Ft.
long) to an outside garden hose fixture, and by at-
taching a length of hose between the pump dis-
charge and the hose end device (spray nozzle).
Bothhosesshouldbekink-freeandasshourapos-
sible to maximize performance.
Attempting to pump more water than a
standard household hose fixture can sup-
ply(about8gallonsperminute),willcause
the pump to cavitate, resulting in pressure
lose and damage to the pump. For best
pressure boost, the hose nozzle should
limit theflowfrom the pump to about 3 gal-
lons per minute.
STOPPING
If the pump has been used to pump garden-type
chemicals or corrosive liquids, be sure to flushthe
pump with clear water after operation.
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.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP WON’T
RUN
Motor hums but won’t run. Unplug pump and rotate shaft with
a screwdriver in the fan through air
openings. If shaft does not turn
freely, remove pump housing and
clean (see Section E).
Worn Brushes. Check and replace (see Section E).
Blown fuse or tripped circuit breaker. Check and replace/reset as re-
quired. If problem continues, motor
may be shorted; consult a qualified
electrician.
MOTOR RUNS,
BUT WON’T PUMP
LIQUID
Water levelbelow intake. Check and ensure suction hose is
sufficiently submerged. Lower hose
as required.
Power to outlet off. Plug another device (such as a light)
intotheoutletorcheckwithavoltme-
ter. Check fuses or circuit breaker.
Notify power company if required.
Pump air-locked. Repeat priming procedure. Be
sure lift does not exceed 15 Ft. All
suction line connections must be
air-tight.
OM--0008080 SERIES
TROUBLESHOOTING PAGE D -- 1
TROUBLESHOOTING --- SECTION D
Review all SAFETY information in Section A.
Beforeattemptingtoopenorservicethe
pump:
1. Familiarize yourself with this manual.
2. Unplug the power cord to the pump
and take precautions to ensure that
the pump will remain inoperative.
3. Allow the pump to completely cool if
overheated.
4. Check the temperature before open-
ing any covers, plates, or plugs.
5. Vent the pump slowly and cautiously.
6. Drain the pump.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
MOTOR RUNS
BUT WON’T PUMP
WATER (cont.) Repeat priming procedure. Fill
pump housing with 1/2 gallon of
clean liquid.
Pump not properly primed.
Suction line clogged. Inspect suctin hose and strainer.
Clean as necessary.
Worn shaft seal (water leaking from
seal area). Check and replace as required (see Section E).
OM--00080 80 SERIES
TROUBLESHOOTINGPAGE D -- 2

80 SERIES OM--00080
MAINTENANCE & REPAIR PAGE E -- 1
PUMP MAINTENANCE AND REPAIR - SECTION E
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK
OPERATING PERFORMANCE.
STANDARD PERFORMANCE FOR PUMP MODEL 80E
Based on 70_F(21_C) clear water at sea level
with minimumsuction lift. Since pumpinstallations
areseldomidentical,yourperformancemaybedif-
ferent due to such factors as viscosity, specific
gravity, elevation, temperature, and impeller trim. Pump speed and operating condition
points must be within the continuous per-
formance range shown on the curve.

80 SERIESOM--00080
MAINTENANCE & REPAIRPAGE E -- 2
SECTION DRAWING
Figure E-1. Pump Model 80E

ITEM
NO. PART NAME PART NUMBER MAT’L CODE QTY ITEM NO. PART NAME PART NUMBER MAT’L CODE QTY
80 SERIES OM--00080
MAINTENANCE & REPAIR PAGE E -- 3
PARTS LIST
Pump Model 80E
(From S/N 1203279 up)
1BRUSH KIT 26814---031 --- --- --- 1
2 ---BRUSH HOLDER CAP NOT AVAILABLE 2
3 ---BRUSH NOT AVAILABLE 2
4 BRUSH HOLDER KIT 26814---032 --- ------ 1
2 ---BRUSH HOLDER CAP NOT AVAILABLE 2
3 ---BRUSH NOT AVAILABLE 2
5 ---SETSCREW NOTAVAILABLE 2
6 ---BRUSH HOLDER NOT AVAILABLE 2
7 FITTING KIT 26814---033 --- --- --- 1
8 ---3/4 NPT HEX ADAPTOR NOT AVAILABLE 2
9 ---SQ HD PIPE PLUG NOT AVAILABLE 1
10 ---SUCTION STRAINER NOT AVAILABLE 1
11 IMPELLER/SEAL KIT 26814---034 --- ------ 1
12 ---SEAL ASSEMBLY NOT AVAILABLE 1
13 ---CASING GASKET NOT AVAILABLE 1
14 ---IMPELLER NOT AVAILABLE 1
15 BEARING KIT 26814---035 --- --- --- 1
16 ---SPRING WASHER NOT AVAILABLE 1
17 ---10MM BALL BEARING NOT AVAILABLE 1
18 ---SLINGER RING NOT AVAILABLE 1
19 CORD KIT 26814---036 --- --- --- 1
20 ---8’ POWER CORD NOT AVAILABLE 1
21 ---STRAIN RLF BUSHING NOT AVAILABLE 1
22 CASING KIT 26814---037 --- ------ 1
13 ---CASING GASKET NOT AVAILABLE 1
23 ---CASING NOT AVAILABLE 1
24 --- SCREW NOT AVAILABLE 1
25 ROTOR KIT 26814---038 --- --- --- 1
16 ---SPRING WASHER NOT AVAILABLE 1
17 ---SLINGER RING NOT AVAILABLE 1
26 ---1/2 H.P. ROTOR NOT AVAILABLE 1
27 BACKHEAD KIT 26814---039 --- --- --- 1
12 ---SEAL ASSEMBLY NOT AVAILABLE 1
13 ---CASING GASKET NOT AVAILABLE 1
14 ---IMPELLER NOT AVAILABLE 1
28 ---BACKHEAD NOT AVAILABLE 1
NOT SHOWN:
STRAINER 26841---006 --- --- --- 1
INSTRUCTION DECAL 38815---012 --- --- --- 1
NAME PLATE 2613EK --- ------ 1
G-R DECAL 2” GR --- 02 --- --- --- 1
INDICATES PARTS RECOMMENDED FOR STOCK

80 SERIESOM--00080
MAINTENANCE & REPAIRPAGE E -- 4
PUMP AND SEAL DISASSEMBLY
AND REASSEMBLY
Review all SAFETY information in Section A.
Followtheinstructionsonalltags,labelandde-
cals attached to the pump.
This pump requires little service due to its rugged,
minimum-maintenance design. However, if it be-
comesnecessarytoinspectorreplacethewearing
parts, follow these instructions which are keyed to
the sectionalview (see Figure E-1) and the accom-
panying parts list.
As described on the following pages, this manual
willalert personnelto known procedures which re-
quire specialattention, to those which could dam-
age equipment, and to those which could be dan-
gerous topersonnel. However, this manualcannot
possibly anticipate and provide detailed precau-
tions for every situation that might occur during
maintenanceoftheunit.Therefore,itistherespon-
sibility of the owner/maintenance personnel to en-
sure that only safe, established maintenance pro-
ceduresareused, andthatanyproceduresnotad-
dressedinthismanualareperformedonlyafteres-
tablishingthatneitherpersonalsafetynorpumpin-
tegrity are compromised by such practices.
Before attempting toservice the pump, unplugthe
pump and take precautions to ensure that the
pump will remain inoperative. Remove the suction
and discharge lines and drain all liquid from the
pump.
Beforeattemptingtoopenorservicethe
pump:
1. Familiarize yourself with this man-
ual.
2. Unplug the power cord to the
pump and take precautions to en-
sure that the pump will remain in-
operative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Vent the pump slowly and cau-
tiously.
6. Drain the pump.
Brush Replacement
Motor brushes wear out and must be periodically
replaced. The brushes (3), when replaced as rec-
ommended, will help keep the pump operating at
peak efficiency and prolong the motor life. Failure
to replace the brushes will result in damage to the
motor and significantly reduce motor life. Replace-
ment of worn brushes is considered normal main-
tenance and is not covered by the pump warranty.
Check the brushes for wear after every 100 hours
of use, or more often if the pump application re-
quires frequent starting and stopping of the motor.
Replace both brushes as follows when either
brushiswornto1/4inchorlessinlength.
To remove the brushes, unscrew the caps (2) and
pullthebrushes (3)fromthe brush holders (6). Tag
each brush so that if reused, they will be returned
to their original locations.
Inspect the brush holders and, if cracked, replace
them with new holders. To replace the holders,
loosen the setscrews (5) securing them to the mo-
tor casing. Carefully slide the brush holders from
the casing until the flat blades on the motor leads
can be grasped with a pair of needle-nose pliers.
Hold the motor blades secure while pulling the
brush holders off the blades.
It is recommended that the motor commutator be
inspected for excessive wear, grooving or pitting
each time the brushes are replaced (see Pump
Rotor Removal and Inspection). Also, do not re-
assemble the brush holders and brushes if further
disassembly is required.
Holdthemotorblades securewithneedle-nosepli-
ers and insert the blades into the replacement
brushholders.Pushthenewbrushholdersintothe
casing untilthey stop, then pull them out 1/16 inch
(1,6mm)toensuretheyarenottouchingthemotor
commutator.
Check the brush holders for proper alignment.
Theymustbeparalleltothemotorshaft(seeFigure

80 SERIES OM--00080
MAINTENANCE & REPAIR PAGE E -- 5
E-2). When properly aligned, secure the brush
holders with the setscrews (5).
Insert new brushes into the brush holders, and
screw the brush holder caps into the casing until
fully seated.
NOTE
Brush holders for the current Bill of Material issue
modelsaredarkred incolor. Brushholders forpre-
vious Bill of Material issue models were black in
color. Brush holders and other motor parts are not
interchangeable between issues. If the brush hold-
ers in your pump are not dark red in color, check
the pump Serial Number to be sure of the correct
Bill of Material issue.
CORRECT INCORRECT
BRUSH HOLDER COCKED
Figure E-2. Brush Holder Alignment
Pump Casing and Rotor Removal and
Inspection
It is recommended that the motor commutator be
inspected for excessive wear, grooving or pitting
each time the brushes are replaced.
To inspect the commutator, disengage the hard-
ware (24) and separate the pump casing (23) from
themotor. Removethecasinggasket(13).Careful-
ly pull the impeller (14), seal assembly (12), back-
head (28) and rotor (26) from the motor.
Remove the spring washer (16) from the motor.
See Figure E-3 and carefully examine the motor
commutatorforexcessivewear.Replacetherotorif
the commutator is grooved deeper than 1/32 inch
(0,8 mm).
1/32 IN. (0,8 mm)
DEEP GROOVE
COMMUTATOR
ROTOR ASSEMBLY
Figure E-3. Commutator Inspection
When installing the bearing (17), use a suitably
sized sleeve and an arbor (or hydraulic) press to
install the bearing on the shaft. The I.D. of the
sleeveshouldbejustlargeenoughtoslideoverthe
shaft. When installing the bearing, press only on
the inner bearing race.
Impeller and Seal Removal
With the brushes and pump rotor removed from
the motor, hold the rotor secure while unscrewing
the impeller (14) in a counterclockwise direction.
When the impeller is unscrewed, carefully remove
thesealstationary element, spring and slinger ring
(18).
Use a suitable puller to pull the backhead (28) and
stationaryportionofthesealoffthebearing(17).To
remove the stationary portion of the seal, lay the
seal plate on a flat surface with the impeller side
down and press the seal from the backhead bore.
The rotating portion of the seal is pressed into the
impeller hub. Use a suitable toolto pry the rotating
portion of the seal from the impeller.
Inspect the bearing (17) for contamination and to
ensure free rotation. If the bearing appears con-
taminated or does not rotate freely, use a suitable
puller to remove it from the shaft.
When installing the bearing (17), use a suitably
sized sleeve and an arbor (or hydraulic) press to
install the bearing on the shaft. The I.D. of the
sleeveshouldbejustlargeenoughtoslideoverthe
shaft. When installing the bearing, press only on
the inner bearing race.
Impeller and Seal Installation
Installthespringwasher(16)inthemotorhousing.
Carefully position the rotor in the motor housing

80 SERIESOM--00080
MAINTENANCE & REPAIRPAGE E -- 6
until the inner bearing is fully seated against the
washer.
Position the backhead (28) over the bearing (17)
and carefully press it onto the bearing until fully
seated.
Clean the sealcavity andshaft with a cloth soaked
in fresh cleaning solvent.
Most cleaning solvents are toxic and
flammable. Use them only in a well ven-
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain-
ers.
The seal is not normally reused because wear pat-
terns on the finished faces cannot be realigned
during reassembly. This could result in premature
failure.Ifnecessarytoreuseanoldsealinanemer-
gency, carefully wash all metallic parts in fresh
cleaning solvent and allow to dry thoroughly.
Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate precision
finished faces; even fingerprints on the faces can
shortenseallife.Ifnecessary,cleanthefaceswitha
non-oil based solvent and a clean, lint-free tissue.
Wipe lightly in a concentric pattern to avoid
scratching the faces.
Inspect the seal components for wear, scoring,
grooves, andotherdamage that might causeleak-
age.Ifanycomponentsareworn,replacethecom-
plete seal; never mix old and new seal parts.
To easeinstallation ofthe seal, lubricate the rubber
cupsurroundingthe rotatingelement with water or
averysmall amount ofoil, and applya drop oflight
lubricating oil on the finished faces. Assemble the
seal as follows, (see Figure E-4).
If a replacement seal is being used, remove it from
the container and inspect the precision finished
faces to ensure that they are free of any foreign
matter.
SLINGER
RING
SPRING SEAT
ROTATING
ELEMENT
BACKHEAD
IMPELLER
SHAFT
SPRING
STATIONARY ELEMENT
IMPELLER
Figure E-4. Seal Assembly Detail

80 SERIES OM--00080
MAINTENANCE & REPAIR PAGE E -- 7
This seal is not designed for operation at
temperatures above 160_F(71_C). Do not
use at higher operating temperatures.
Position the impeller (14) on a flat surface with the
back side of the impeller facing up. Lubricate the
rubber cup surrounding the rotating element with
wateroraverysmall amountof oil,and use thumb
pressure to install it into the impeller bore until fully
seated. After installation, wipe the sealing face
lightly in a concentric pattern with a clean, lint-free
tissue.
Slidetheslingerring(18)ontotheshaftuntilseated
against the backhead. Press the spring seat into
the backhead until fully seated. Slide the seal
spring over the shaft and position it in the spring
seat.
Position the seal stationary element in the seal
spring and lubricate the seal face with a drop of
light oil. Screw the assembled impeller and rotat-
ing element onto the shaft until fully seated.
Installthe casing gasket (13) over the shoulder on
the backhead. Position the casing (23) over the
backheadshoulder. Align themounting holes, and
secure the casing and backhead to the motor with
thehardware(24).
Final Pump Assembly
Install the suction and discharge hoses and open
all valves.
Remove the fill plug (9) and fill the pump casing
withcleanliquid.Reinstallthefillplugandtightenit.
Refer to OPERATION, Section C, before putting
the pump back into service.
LUBRICATION
Seal Assembly
Thesealassemblyislubricatedbythemediumbe-
ing pumped. No additional lubrication is required.
Motor Bearings
The motor bearings are permanently lubricated.
No additional lubrication is required.

For U.S. and International Warranty Information,
Please Visit www.grpumps.com/warranty
or call:
U.S.: 419−755−1280
International: +1−419−755−1352
For Canadian Warranty Information,
Please Visit www.grcanada.com/warranty
or call:
519−631−2870
THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA