GORMAN-RUPP PUMPS Super T Series, Super T6A60S-ZPP857-ESP Installation, Operation, And Maintenance Manual With Parts List

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Page 1

OM-07174-01

June 15, 2018

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

SUPER T SERIESr

ENVIRONMENTAL SILENT PUMP

MODEL

T6A60S-ZPP857-ESP

GORMAN‐RUPP PUMPS

www.grpumps.com

e2018 Gorman‐Rupp Pumps Printed in U.S.A.

Page 2

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:

Page 3

TABLE OF CONTENTS

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 - 1............................................

Battery Specifications And Installation PAGE B - 2....................................

SAFETY AND CONFORMANCE PAGE B - 2.............................................

POSITIONING PUMP PAGE B - 3.......................................................

Lifting PAGE B - 3.................................................................

Mounting PAGE B - 3.............................................................

Clearance PAGE B - 3.............................................................

NATURAL GAS FUEL PAGE B - 3......................................................

LPG FUEL PAGE B - 3................................................................

FUEL TANK (LPG ONLY) PAGE B - 4....................................................

REGULATORS (NATURAL GAS) PAGE B - 4.............................................

REGULATORS (LP GAS) PAGE B - 4...................................................

CONNECTING FUEL SUPPLY LINE TO THE UNIT PAGE B - 5.............................

CHANGING FUEL TYPE PAGE B - 5....................................................

SUCTION AND DISCHARGE PIPING PAGE B - 5.........................................

Materials PAGE B - 5..............................................................

Line Configuration PAGE B - 5......................................................

Connections to Pump PAGE B - 5..................................................

Gauges PAGE B - 5...............................................................

SUCTION LINES PAGE B - 6...........................................................

Fittings PAGE B - 6...............................................................

Strainers PAGE B - 6..............................................................

Sealing PAGE B - 6...............................................................

Suction Lines In Sumps PAGE B - 6.................................................

Suction Line Positioning PAGE B - 6................................................

SUBMERSIBLE TRANSDUCER PAGE B - 7..............................................

DISCHARGE LINES PAGE B - 8........................................................

Siphoning PAGE B - 8.............................................................

Valves PAGE B - 8................................................................

OPERATION - SECTION C PAGE C - 1......................................

OPERATION PAGE C - 1..............................................................

STARTING PAGE C - 1................................................................

PRIMING PAGE C - 1.................................................................

OPTIONAL EPS CONTROL PAGE C - 2.................................................

Features PAGE C - 2..............................................................

Functional Description PAGE C - 2..................................................

EPS Functions PAGE C - 3.........................................................

EPS Calibration PAGE C - 4........................................................

Zero Adjustment PAGE C - 4.......................................................

Span Adjustment PAGE C - 4......................................................

Level Adjustment PAGE C - 4......................................................

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TABLE OF CONTENTS

(continued)

Horn Delay PAGE C - 4............................................................

ROUTINE OPERATION PAGE C - 4.....................................................

Lines With a Bypass PAGE C - 5....................................................

Lines Without a Bypass PAGE C - 5.................................................

OPERATION IN EXTREME HEAT PAGE C - 5............................................

OPERATIONAL CHECKS PAGE C - 5...................................................

Leakage PAGE C - 5..............................................................

Pump Vacuum Check PAGE C - 5..................................................

Liquid Temperature And Overheating PAGE C - 5.....................................

Strainer Check PAGE C - 6.........................................................

STOPPING PAGE C - 6................................................................

Manual Stopping PAGE C - 6.......................................................

Automatic Stopping PAGE C - 6....................................................

Safety Shutdown System PAGE C - 6...............................................

PERIODIC CHECKS PAGE C - 6.......................................................

Seal Cavity and Bearing Lubrication PAGE C - 6......................................

Bearing Temperature Check PAGE C - 6.............................................

Engine Fuel Filter PAGE C - 7......................................................

Engine Oil PAGE C - 7.............................................................

COLD WEATHER PRESERVATION PAGE C - 7...........................................

TROUBLESHOOTING - SECTION D PAGE D - 1..............................

PREVENTIVE MAINTENANCE PAGE D - 3...............................................

PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................

STANDARD PERFORMANCE CURVE PAGE E - 1........................................

PARTS LISTS:

Pump Model PAGE E - 3..........................................................

Pump Model (Cont'd) PAGE E - 5...................................................

Pump End Assembly PAGE E - 7...................................................

Repair Rotating Assembly PAGE E - 9...............................................

Coupling Kit PAGE E - 10...........................................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 11.........................

Back Cover And Wear Plate Removal PAGE E - 12.....................................

Suction Check Valve Removal PAGE E - 12...........................................

Separating Intermediate and Coupling Kit From Engine PAGE E - 12.....................

Loosening Impeller PAGE E - 13.....................................................

Rotating Assembly Removal PAGE E - 13.............................................

Impeller Removal PAGE E - 14......................................................

Seal Removal PAGE E - 14..........................................................

Shaft and Bearing Removal and Disassembly PAGE E - 14.............................

Shaft and Bearing Reassembly and Installation PAGE E - 15............................

Seal Installation PAGE E - 16........................................................

Impeller Installation and Adjustment PAGE E - 19......................................

Rotating Assembly Installation PAGE E - 19...........................................

Suction Check Valve Installation PAGE E - 19.........................................

Back Cover Installation And Adjustment PAGE E - 20..................................

Securing Pump and Coupling Kit to Engine PAGE E - 21...............................

PRESSURE RELIEF VALVE MAINTENANCE PAGE E - 21..................................

Final Pump Assembly PAGE E - 22..................................................

Page 5

TABLE OF CONTENTS

(continued)

LUBRICATION PAGE E - 22.............................................................

Seal Assembly PAGE E - 22.........................................................

Bearings PAGE E - 22..............................................................

Engine PAGE E - 22................................................................

iii

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SUPER T SERIES

OM-07174

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.

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 or its application which are not covered in this man ual or in other literature accompanying this unit, please contact your Gorman‐Rupp distributor, or The Gorman‐Rupp Company:

HAZARD AND INSTRUCTION DEFINITIONS

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.

The Gorman‐Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901-1217

Phone: (419) 755-1011

or:

Gorman‐Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631-2870

For information or technical assistance on the power source, contact the power source manufac turer's local dealer or representative.

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.

PAGE I - 1INTRODUCTION

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SUPER T SERIES

OM-07174

SAFETY ‐ SECTION A

This information applies to Super T Se riesr engine driven pumps. Refer to the manual accompanying the engine 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, remove the key 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.

the positive battery cable before per forming any maintenance. Failure to do so may result in serious personal injury.

This pump is designed to handle dirty water containing specified entrained solids. Do not attempt to pump volatile, corrosive, or flammable liquids which may damage the pump or endanger per sonnel as a result of pump failure.

Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.

After the unit 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 for long periods

PAGE A - 1SAFETY

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SUPER T SERIESOM-07174

of time. If operated against a closed dis charge valve, pump components will deteriorate, and the liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode.

Do not remove plates, covers, gauges, pipe plugs, or fittings from an over heated pump. Vapor pressure within the pump can cause parts being disen gaged to be ejected with great force. Al low the pump to cool before servicing.

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.

precautions outlined by the National Fire Protection Association when de signing and installing the system. Make certain that the regulators and fuel lines are of the proper size and capacity for the system, and that all fuel lines are se curely connected and free of leaks.

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 tamper with the governor to gain more power. The governor establishes safe operating limits that should not be exceeded. Refer to the performance curve in Section E for the maximum con tinuous operating speed for this pump.

Pumps and related equipment must be in

Natural gas presents an extreme explo sion and fire hazard. Follow all safety

PAGE A - 2 SAFETY

stalled and operated according to all na tional, local and industry standards.

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SUPER T SERIES OM-07174

INSTALLATION - SECTION B

Review all SAFETY information in Section A.

Since pump installations are seldom identical, this section offers only general recommendations and practices required to inspect, position, and ar range the pump and piping.

Most of the information pertains to a standard static lift application where the pump is positioned above the free level of liquid to be pumped.

If installed in a flooded suction application where the liquid is supplied to the pump under pressure, some of the information such as mounting, line configuration, and priming must be tailored to the

OUTLINE DRAWING

112.58 APPROX

[ 2859,7]

[ 578,7 ]

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.

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.

22.78

DISCHARGE:

6.00−8 NPT

SUCTION:

6.00−8 NPT

82.77

[ 2102,5]

APPROX

4.00/[101,6] X 10.00/[254,0] FORK LIFT POCKET 2 PLACES

24.00

[ 609,6]

48.00

[ 1219,2]

[ 1900,9]

[ 2438,4]

74.84

96.00

37.42

[ 950,5 ]

Figure 1. Pump Model T6A60S-ZPP857-ESP

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:

65.69

[ 1668,5]

50.26

36.35

[ 923,4]

16.05

[ 407,7 ]

10.59

[ 268,9 ]

DIMENSIONS:

INCHES

[MILLIMETERS]

[ 1276,5]

1.00

[ 25,4 ]

46.00

[ 1168,4]

30.02 [ 762,4 ] APPROX

55.12

[ 1400,2]

48.00

[ 1219,2]

APPROX

24.00

[ 609,6]

.75/[19,0] DIA 6 HOLES

a. Inspect the pump assembly for cracks, dents,

damaged threads, and other obvious dam age.

b. Check for and tighten loose attaching hard

ware. Since gaskets tend to shrink after dry

PAGE B - 1INSTALLATION

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OM-07174 SUPER T SERIES

ing, check for loose hardware at mating sur faces.

c. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties indicated.

d. Check levels and lubricate as necessary. Re

fer to LUBRICATION in the MAINTENANCE AND REPAIR section of this manual and per form duties as instructed.

e. If the pump and

engine have been stored for

more than 12 months, some of the compo nents or lubricants may have exceeded their maximum shelf life. These must be inspected or replaced to ensure maximum pump serv ice.

If the maximum shelf life has been exceeded, or if anything appears to be abnormal, contact your Gorman‐Rupp distributor or the factory to deter mine the repair or updating policy. Do not put the pump into service until appropriate action has been taken.

sion. Connect and tighten the positive cable first, then the negative cable.

SAFETY AND CONFORMANCE

All aspects of the design and installation of the fuel supply system must be evaluated in terms of safety to personnel and equipment, and conformance to all applicable codes.

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

Reserve

Capacity

@ 80_ F

(Minutes)

175

Amp/

Hr.

Rating

Approx.

Overall

Dims.

(Inches)

13L

9.5H

Voltage

12 Volts

Cold Crank Amps

@ 0_ F

950

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

Natural Gas and Liquefied Petroleum Gas (LPG) presents an extreme explo sion and fire hazard. Follow all safety precautions outlined by the National Fire Protection Association when de signing and installing the system. Make certain that the regulators and fuel lines are of the proper size and capacity for the system, and that all fuel lines are se curely connected and free of leaks.

Before installing the system:

1. Check all state and local codes pertaining to installations of stationary combustion engines and fuel systems.

2. Consult the following National Fire Protection Association pamphlet:

NFPA No. 37 - Stationary Combustion Engines/Gas Turbines

NFPA No. 54 - National Fuel Gas Code Hand book.

PAGE B - 2 INSTALLATION

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SUPER T SERIES OM-07174

NFPA No. 37 - Liquefied Petroleum Gas Stor age and Handling.

Copies may be ordered from:

National Fire Protection Association 1 Batterymarch Park Quincy, Massachusets 02269

POSITIONING PUMP

Lifting

Pump unit weights will vary depending on the mounting and drive provided. Check the shipping tag on the unit packaging for the actual weight, and use lifting equipment with appropriate capacity. Drain the pump and remove all customer‐installed equipment such as suction and discharge hoses or piping before attempting to lift existing, installed units.

Mounting

To ensure sufficient lubrication to the engine, do not position the pump and engine more than 15

off horizontal for continuous operation. The pump and engine may be positioned up to 30_ off hori zontal 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 (457,2 mm) in front of the enclosure suction cover to permit removal of the cover and easy access to the pump.

NATURAL GAS FUEL

The amount of natural gas fuel required for the en gine is measured in cubic feet per hour. This is cal culated from the BTU (British Thermal Unit) con tent of the natural gas supplied, and the horsepow er required to drive the pump. This unit requires

1,141 CF/hr of natural gas with 1000 BTU con tent at 10 inches of water column. The BTU con

tent of gas varies in the United States, therefore, it will be necessary to contact your local gas supplier to determine the BTU content of the natural gas in your area.

When burning natural gas having a BTU content of 1000 or over, the engine will deliver the rated horse power as shown on the pump Specification Data Sheet. On lower grade natural gas, there will be a power loss of approximately 3% for each 100 BTU under 1000.

Natural gas pressures provided by suppliers vary, so in order to provide the optimal gas supply to the engine, Gorman‐Rupp has provided a regulator with the unit that can be adjusted to provide 10 inches of water column of gas pressure to the en gine. Install the pressure regulator supplied with the unit in the line supplying the engine, then check and adjust the fuel pressure as described in CON NECTING FUEL SUPPLY LINE TO THE UNIT.

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.

LPG FUEL

The term Liquefied Petroleum Gas (LPG) refers to any one of many butane/propane compounds, some of which have additives for specific applica tions. Commercial grade propane is recommend ed.

PAGE B - 3INSTALLATION

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OM-07174 SUPER T SERIES

FUEL TANK (LPG ONLY)

The amount of LPG fuel required for the engine is measured in BTU (British Thermal Unit) per hour.

This unit requires 1,142,038 BTU/hr of LPG fuel at 10 inches of water column.

The amount of fuel which must be stored at the in stallation will be determined by the length of time the engine must operate before refueling is neces sary. Engine operating time is predicted on system characteristics such as flow rates, pump capacity, anticipated number and duration of power failures in a given time period, programmed engine exer cise periods, etc.

On LPG fuel systems, fuel consumption is mea sured in British Thermal Units per Hour (BTU/HR). This rate of consumption will vary according to en gine speed and load. For purposes of determining BTU consumption, assume that all engine operat ing time will be at full load and at the speed re quired for rated pumping capacity. (Engine speed is shown on the performance curve on the Gor man‐Rupp Specification Data Sheet for the pump). Short periods of idle speed time need not be con sidered, as fuel consumption at idle is negligible. If extended periods of idle speed time are anticipat ed, calculated fuel consumption should be in creased accordingly.

Consult the local LPG supplier to determine the size of fuel tank required. This determination will be based on the BTU/HR consumption rate, total BTU storage required, local climate conditions, BTU content of the fuel to be supplied, and installation parameters such as local code restrictions and proposed tank location.

On all units, be sure to specify that the tank will be used for vapor withdrawal. In this type of system, fuel is taken from the top of the storage tank in the vapor state, eliminating the need for a LP gas con verter, which converts liquid fuel to the vapor re quired by the engine fuel mixer. The vapor with drawal system provides an adequate amount of fu el for an engine the size of which is on the pump unit. However, if fuel is used at a rate excessive for the tank size and ambient temperature conditions, freezing may occur in the tank. This problem can usually be anticipated by the LPG supplier and may require selection of a larger tank.

REGULATORS (NATURAL GAS)

The engine is equipped with a natural gas regula tor designed to supply the engine with natural gas gas at 6 inches of water column.

Gorman‐Rupp has provided a secondary natural gas regulator. This regulator has a maximum inlet pressure of 15 psi (1,0 bar) and an outlet pressure range of 6 to 14 inches (152 to 356 mm) water col umn. This regulator can be used to supply the 10 inches (254 mm) the engine requires when the gas supplier can only supply a pressure greater than

0.5 psi (0,03 bar). The regulator is shipped loose for field installation and should be located before any fuel lock‐off valves in the gas supply line.

REGULATORS (LP GAS)

The engine is equipped with an LP gas regulator designed to supply the engine with LP gas at 6 inches of water column. Gorman‐Rupp provides a primary regulator and a secondary regulator with the pump unit.

The pressure in an LPG storage tank with vapor withdrawal will vary depending on temperature. For example, the pressure of propane at 70°F (21°C) is approximately 100 psi (6,9 bar), but this pressure increases to 180 psi (12,4 bar) at 100°F (38°C) and decreases to 18 psi (1,2 bar) at 10°F (-23°C). The primary (first stage) regulator is ca pable of accepting this wide range of inlet pres sures while maintaining approximately 10 psi out let pressure (see the note below) and should be lo cated on or near the storage tank. The secondary (second stage) regulator then reduces this 10 psi (0,6 bar) pressure at its inlet to an outlet pressure of 10 inches of water column (see the note below). This regulator should be located before any fuel lock‐off valve in the supply line. If this regulator is located after a fuel lock‐off valve the operation of the regulator will be affected by sudden pressure increase when the lock‐off valve opens. The regu lators are sized to deliver the fuel flow required by the engine during full load operation while main taining pressures within specified limits.

NOTE

The primary regulator output pressure of 10 psi (0,7 bar) is used to illustrate a typical system. Actual pressure may be higher or lower depending on code requirements. The primary regulator supplied

PAGE B - 4 INSTALLATION

Page 13

SUPER T SERIES OM-07174

with the pumping unit has a range of 8 psi to 12 psi (0,5 to 0,8 bar).

The secondary regulator output pressure of 10 inches of water column is used to illustrate a typical system. Actual pressure may be higher or lower depending on code requirements. The secondary regulator supplied with the pumping unit has a range of 4 inches to 12 inches (102mm to 305mm) of water column.

CONNECTING FUEL SUPPLY LINE TO THE UNIT

There is a 1‐inch pipe connection on the outside of the enclosure for connecting the incoming gas supply line. Inside the enclosure, there is a 1‐inch pipe tee in the engine fuel line. The tee is equipped with a reducer and a 1/4‐inch pipe plug. Remove the pipe plug and install a pressure gauge rated in inches of water column.

Open the fuel supply to the regulator and observe the pressure gauge. If the reading is less or greater than 10 inches of water column, remove the cap on the regulator to expose the adjusting screw plug beneath it. Turn the adjusting plug clockwise to in crease the fuel supply or counter‐clockwise to de crease the fuel supply.

When the supply is properly adjusted to 10 inches of water column, reinstall the protective cap over the adjusting screw on the regulator. Remove the pressure gauge from the fuel line and reinstall the 1/4‐inch pipe plug to avoid vibration damage to the gauge.

CHANGING FUEL TYPE

If it is necessary to change the type of fuel from nat ural gas to LP gas or vice‐versa, the fuel line inside the enclosure to the engine must first be switched to the correct regulator on the engine for the de sired fuel. After switching the fuel line, set the tog gle switch on the engine control to the desired fuel. This tells the engine control module the fuel has been changed so the engine can compensate for the change in fuel supply. After these changes are complete, check the fuel pressure as described in

CONNECTING FUEL SUPPLY LINE TO THE UNIT.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in creased suction lift, discharge elevation, and fric tion losses. See the performance curve and notes on Page E‐1 to be sure your overall application al lows 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 substantial ly 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.

PAGE B - 5INSTALLATION

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OM-07174 SUPER T SERIES

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

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 a strainer is furnished with the pump, be certain to use it; any spherical solids which pass through a strainer furnished with the pump will also pass through the pump itself.

If a strainer is not furnished with the pump, but is installed by the pump user, make certain that the total area of the openings in the strainer is at least three or four times the cross section of the suction line, and that the openings will not permit passage of solids larger than the solids handling capability of the pump.

This pump is designed to handle up to 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

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. veloci

ty.

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).

PAGE B - 6 INSTALLATION

Page 15

SUPER T SERIES OM-07174

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

SUBMERSIBLE TRANSDUCER

This unit is equipped with an optional Electronic Pressure Switch (EPS) that works in conjunction with a submersible transducer. The submersible transducer converts pressure to an electrical sig nal proportional to liquid level. This electrical signal is distributed to the digital display on the EPS through a scaling circuit which converts the electri cal signal to “feet of water”.

When installing the submersible transducer, note the following:

a. Handle the signal cable and transducer with

care during installation. Carefully lower the transducer into the wet well or sump; do not drop it to the bottom. To avoid clogging, sus pend the transducer off the bottom.

b. Be sure to provide sufficient room in the wet

well or sump so that the transducer does not get drawn into the suction line. To prevent this, a flexible suction hose may be extended to lay along the bottom of the wet well or sump. The transducer can then be attached to the hose

above the point where it bends along the bot tom. See Figure 3 for a typical installation.

c. The wet well or sump must be vented to at

mosphere.

d. The EPS is scaled in feet of water column. If

the measured medium is other than 1.0 spe cific gravity, the reading on the EPS should be divided by the specific gravity of the mea sured medium to obtain the actual level.

e. Thoroughly clean the transducer after each

use to prevent clogging.

Do not disassemble the transducer or loosen the compression nut at the signal cable entry. This will void warranty. There are no user‐serviceable parts inside. Do not nick or cut the jacket of the signal ca ble; this will cause leakage and void war

ranty.

PAGE B - 7INSTALLATION

Page 16

OM-07174 SUPER T SERIES

SUCTION

DISCHARGE

LINE

SIGNAL CABLE

(ATTACH TO

SUCTION LINE)

SUBMERSIBLE

TRANSDUCER

(DOWNSTREAM

FROM SUCTION)

SUCTION

STRAINER

Figure 3. Typical Submersible Transducer Installation

DISCHARGE LINES

Siphoning

Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a siphon 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

FLOW

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 throt tling valve before stopping the pump.

PAGE B - 8 INSTALLATION

Page 17

SUPER T SERIES

OPERATION - SECTION C

OPERATION

Review all SAFETY information in Section A.

OM-07174

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 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.

This pump is designed to handle most non‐volatile, non‐flammable liquids containing specified entrained solids and corrosives. Do not attempt to pump volatile, corrosive, or flammable liquids which may damage the pump or endan ger personnel as a result of pump fail ure.

Pump speed and operating condition points must be within the continuous per formance range shown on the perfor mance curve on page E-1.

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.

This pump is equipped with an automat ic starting system, and is subject to au tomatic restart. Keep hands and cloth ing away from the unit to prevent injury during automatic operation. Disconnect the positive battery cable before per forming any maintenance. Failure to do so may result in serious personal injury.

Consult the engine operations manual before at tempting to start the unit.

Consult the manual accompanying the engine control box and start the pump.

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.

STARTING

Check the fuel level and oil levels in the engine, air compressor, pump bearings and seal housing.

Never operate this pump unless there is liquid in the pump casing. The pump will

Make sure the pump is level. Lower the jack stands and chock the wheels, if so equipped.

OPERATION PAGE C - 1

not prime when dry. Extended operation of a dry pump will destroy the seal assembly.

Page 18

OM-07174 SUPER T SERIES

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.

S Three switches on front panel for all adjust

ments

S Battery level indicator on LCD screen to alert

operator of low battery condition

S Microprocessor Control

S Error display to alert user of errors in calibra

tion

Functional Description

Front Panel Controls/Displays

1. The LCD screen displays level information, A and B setpoint off/on levels, Horn delay, and calibration information.

Typical Messages on the display:

a) EEP bAd... Eeprom memory is not cor

rect, user must recalibrate unit.

b) USr CAL... User calibrate mode, i.e.,

user wants to calibrate unit.

c) SEt a.oF... A OFF setpoint, units of lev

el.

d) SEt a.on... A ON setpoint, units of level.

NOTE

If the suction or discharge piping is open, a hose can be used to fill the casing through the piping.

OPTIONAL EPS CONTROL

Features

The optional EPS Control is equipped with a 12VDC Electronic Pressure Switch which includes the following features:

S 3 Output Relays: 1. A output, delayed

2. B output, no delay

3. Horn output, no delay

S 3 Inputs: 1. Horn silence

2, Pressure transducer

3. Low Temp Thermostat

S LCD screen with backlight for function moni

toring

S Bright LEDs to indicate output status and dis

play modes

e) SEt b.oF... B OFF setpoint, units of lev

el.

f) SEt b.on... B ON setpoint, units of level.

g) Hrn dLy... Horn on, A output delay

time, 5-30 seconds, in 5‐second increments.

h) LO BAT... Indicator, shows battery

voltage level is below 12VDC.

i) Lo tpt... Shows status of Low Tem

perature Thermostat con tacts.

2. LEDs:

a) When the green LED is lighted, the unit is

showing level on the LCD display.

b) When the A output LED is lighted, the A

output relay is closed.

c) When the B output LED is lighted, the B

output relay is closed

NOTE

LED's and all segments of the display are lighted

OPERATIONPAGE C - 2

Page 19

SUPER T SERIES

OM-07174

upon connection of power as a lamp test feature. However, no relay outputs are closed during test.

3. Switches:

a) The switch functions as a “round rob

in” type switch. Pressing this switch will cause the unit to show the next selection in the order listed above.

b) The switch functions to decrease the

selection showing. This switch can be used to decrease the smallest digit by “bumping” the switch, or to continuously decrease the digit by pressing and hold ing for at least one second and releasing when desired setting is reached.

c. The switch functions to increase the

selection showing. This switch can be used to increase the smallest digit by “bumping” the switch, or to continuously increase the digit by pressing and hold ing for at least one second and releasing when desired setting is reached.

Liquid level adjustment of the Electronic Pressure Switch is accomplished using the three buttons on the control. For EPS functions and level adjust ment, refer to the following instructions.

EPS Functions

When the pressure decreases to a level equal to or less than the “A.of” setpoint, A output con tacts will open in approximately one second.

If an optional Low Temperature Thermostat is connected to the unit and the thermostat con tacts close, the unit displays “lo tpt” on the dis play. In approximately 1 second, the Horn out put contacts close, then after the “Hrn dLy” time, A output contacts close. A output con tacts will remain closed as long as Low Tem perature Thermostat contacts are closed.

When the Low Temperature Contacts open, A output contact will open only if the level is equal to or less than the “A.off” setpoint.

As long a the Low Temperature Thermostat contacts are closed, the display will show “lo

tpt” unless switch is pressed to display some other information. Level is not viewable until the Low Temperature Thermostat con tacts open.

The user may wish to check Setpoints Off/On and Horn output/A output delay times. “Bump

ing” the switch will display all of the informa tion desired.

NOTE

One second delays in contact opening/closing is a result of time sampling of the pressure signal to fil ter false signals that could cause “nuisance” trip ping of the contacts.

Actual functions of the control occur as follows:

Power is applied to the unit.

Unit performs display test for approximately 4 seconds.

When the pressure level showing is equal to or greater than the “A.on” setpoint, the Horn out put contacts will close in approximately 1 sec ond and a delay, equal to the “Hrn dLy” time, will occur before the A output contacts close.

When the level showing is equal to or greater than the “B.on” setpoint, the B output contacts will close in approximately 1 second.

When the pressure decreases to a level equal to or less than the “B.of” setpoint, B output contacts will open in approximately one sec ond.

OPERATION PAGE C - 3

If the “Hrn dLy” is changed during the actual A out put delay cycle, the current cycle is not changed; the change becomes effective on the next A output delay cycle.

Use caution to ensure that the “‐‐.on” set point (i.e. “A.on”) is not adjusted to a level less than the corresponding “‐‐.of” set point (i.e. “A.of”). Improper adjustment of the off/on setpoints will render the unit non‐ functional, resulting in flooding.

NOTE

Page 20

OM-07174 SUPER T SERIES

EPS Calibration

NOTE

Zero offset and span adjustments are only neces sary to calibrate a new unit, or when replacing the transducer. Once calibrated, “ON” and “OFF” set points will be stored in the unit's memory. Liquid level adjustments will be used whenever “ON” and “OFF” liquid levels must be reset.

There are two reasons for the user to calibrate the unit. When power is applied, the unit confirms set points and other calibration information for validity. If the setpoints are not valid, the LCD screen shows “EEP bAd” and the unit must be recalibrated. Also, if the unit is moved, or some other external change takes place, the unit must be recalibrated.

Zero Adjustment

Zero adjustment tells the unit when the transducer is exposed to zero water (atmospheric) pressure. When recalibration is desired, hold the transducer in hand and apply power to the unit. The LCD

screen will display “Level ABC”. Press and hold for 5 seconds. The LCD screen displays “Input? External XDUCR”. Perform the following calibration procedures.

Press 3 times and the LCD screen will display

“Calibrate Zro”. Press or until a character or number on the display changes.

Level Adjustment

Level adjustment tells the unit when to turn the pump on and off. To set:

From “Level ABC” display, press once and

“Pump Setpt A On” will display. Press to in

crease or to decrease to the desired level at

which the pump turns on. Press to advance to

“Pump Setpt A Off”. Press to increase or to decrease to the desired level at which the pump turns off.

Press again to advance to “Pump Setpt B On”. If “B” is to be used, repeat the procedure described above for adjusting level “A”.

Horn Delay

The horn delay is pre‐set from the factory through the engine control panel, therefore this function is not utilized through the EPS.

ROUTINE OPERATION

Adjust the engine speed to achieve the desired output. Do not exceed the factory set engine speed and system operating pressure. Do not operate below the recommended operating speed (if appli cable).

Press to accept the entry and advance to “Cali brate Span”.

Span Adjustment

Span adjustment calibrates the unit to a known wa ter pressure (depth). To set:

Submerge the transducer to an exact known depth. At “Calibrate Span”, the span setting in the

unit's memory will display. Press to increase or

to decrease the value unitl the LCD screen dis play equals the actual known depth of the trans ducer.

Never tamper with the governor to gain more power. The governor establishes safe operating limits that should not be exceeded. Refer to the Performance Curve in Section E for the maximum continuous operating speed for this pump.

A Gorman‐Rupp automatic air release valve may be installed in a bypass line, or the bypass line may be left open.

OPERATIONPAGE C - 4

Page 21

SUPER T SERIES

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.

Lines With a Bypass

OM-07174

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 being operated in the automatic mode, adjust the liquid level device(s) to allow shorter run and longer cooling periods, if possible.

OPERATIONAL CHECKS

If a Gorman‐Rupp Automatic Air Release Valve has been installed, the valve will automatically open to allow the pump to prime, and automatically close after priming is complete (see INSTALLATION for Air Release Valve operation).

If the bypass line is open, air from the suction line will be discharged through the bypass line back to the wet well during the priming cycle. Liquid will then continue to circulate through the bypass line while the pump is in operation.

Lines Without a Bypass

Open all valves in the discharge line and start the 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.

Leakage

Once the pump is fully primed, no leakage should be visible at pump mating surfaces, or at pump connections or fittings. Keep all line connections and fittings tight to maintain maximum pump effi ciency.

Pump Vacuum Check

Read the vacuum gauge with the pump primed and at operation speed. Shut off the pump. The vacuum gauge reading will immediately drop pro portionate to static suction lift, and should then sta bilize. 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 installa tion of the vacuum gauge.

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.

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.

OPERATION PAGE C - 5

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 immediately and allow it to completely cool before servicing it. Approach any over‐heated

pump cautiously.

Page 22

OM-07174 SUPER T SERIES

Automatic Stopping

In the automatic mode, the pump will stop when the liquid in the wet well or sump lowers and acti

Allow an over‐heated pump to com pletely cool before servicing. Do not re move plates, covers, gauges, or fittings

vates the “Off” liquid level device(s). The pump will restart automatically when the liquid rises and acti vates the “On” liquid level device(s).

from an overheated pump. Liquid within the pump can reach boiling tempera

Safety Shutdown System

tures, and vapor pressure within the pump can cause parts being disen gaged to be ejected with great force. Af ter the pump cools, drain the liquid from

The unit is equipped with a safety system to auto matically shut down the engine under certain con ditions.

the pump by removing the casing drain plug. Use caution when removing the plug to prevent injury to personnel from hot liquid.

Displays on the control panel will indicate which of the safety features has caused the engine to shut down.

Strainer Check

Check the strainer regularly, and clean it as neces sary. The strainer should also be checked if pump flow rate begins to drop. Monitor and record the vacuum suction gauge 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.

STOPPING

Manual Stopping

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.

All safety shutdown features are pre‐set at the fac tory for optimum performance and safety; do not attempt to adjust these settings.

Never disconnect any of the safety shut down features; this will void the warran ty and could result in serious damage to the unit and/or injury to personnel. Safe ty shutdown features are pre‐set at the 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.

In the manual mode, reduce the throttle speed slowly, and allow the engine to idle briefly before turning the keyswitch to `OFF'.

If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.

PERIODIC CHECKS

Seal Cavity and Bearing Lubrication

Both the seal and bearing cavities were fully lubri cated at the factory. Check the lubrication levels before startup, and regularly thereafter as indi cated in Section E, Maintenance and Repair. When lubrication is required, use only SAE No. 30 non‐detergent oil.

OPERATIONPAGE C - 6

Page 23

SUPER T SERIES

OM-07174

Bearing Temperature Check

Bearings normally run at higher than ambient tem peratures because of heat generated by friction. Temperatures up to 160 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, Main tenance and Repair). Bearing overheating can also be caused by shaft misalignment and/or ex cessive 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.

Engine Fuel Filter

Consult the manual accompanying the engine, and change the fuel filter periodically as indicated. If operated under extremely dusty and/or humid

F (71_C) are considered

conditions, change the filter more frequently. Irreg ular performance and loss of power usually indi cate a dirty fuel filter.

Engine Oil

The engine was lubricated for test at the factory. However, always check the lubrication level before startup.

Consult the manual accompanying the engine, and change the oil filter periodically as indicated. If operated under extremely dusty conditions, change the filter more frequently.

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.

OPERATION PAGE C - 7

Page 24

TROUBLESHOOTING - SECTION D

OM-07174SUPER T SERIES

Review all SAFETY information in Section A.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Shut down the engine, remove the key 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.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO PRIME Not enough liquid in casing.

5. Close the suction and discharge valves.

6. Vent the pump slowly and cau tiously.

7. Drain the pump.

Add liquid to casing. See PRIMING.

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE

Suction check valve contaminated or damaged.

Air leak in suction line.

Lining of suction hose collapsed.

Leaking or worn seal or pump gas ket.

Suction lift or discharge head too high.

Strainer clogged.

Air leak in suction line.

Lining of suction hose collapsed.

Leaking or worn seal or pump gas ket.

Strainer clogged.

Clean or replace check valve.

Correct leak.

Replace suction hose.

Check pump vacuum. Replace leak ing or worn seal or gasket.

Check piping installation and install bypass line if needed. See INSTAL LATION.

Check strainer and clean if neces sary.

Correct leak.

Replace suction hose.

Check pump vacuum. Replace leaking or worn seal or gasket.

Check strainer and clean if neces sary.

Suction intake not submerged at proper level or sump too small.

TROUBLESHOOTING PAGE D - 1

Check installation and correct sub mergence as needed.

Page 25

OM-07174 SUPER T SERIES

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE (cont.)

PUMP REQUIRES TOO MUCH POWER

Impeller or other wearing parts worn or damaged.

Impeller clogged.

Discharge head too high.

Suction lift too high.

Pump speed too slow.

EPS limit switches set improperly or submersible transducer clogged.

Pump speed too high.

Discharge head too low.

Liquid solution too thick.

Bearing(s) frozen.

Replace worn or damaged parts. Check that impeller is properly cen tered and rotates freely.

Free impeller of debris.

Install bypass line.

Measure lift w/vacuum gauge. Re duce lift and/or friction losses in suction line.

Check engine output; consult en gine operation manual.

Check EPS limit settings; check and clean submersible transducer.

Check engine output.

Adjust discharge valve.

Dilute if possible.

Disassemble pump and check bearing(s).

PUMP CLOGS FREQUENTLY

EXCESSIVE NOISE Cavitation in pump.

BEARINGS RUN TOO HOT

Discharge flow too slow.

Suction check valve or foot valve clogged or binding.

Liquid solution too thick.

Pumping entrained air.

Pump or drive not securely mounted.

Impeller clogged or damaged.

Bearing temperature is high, but within limits.

Open discharge valve fully to in crease flow rate, and run engine at maximum governed speed.

Clean valve.

Dilute if possible.

Reduce suction lift and/or friction losses in suction line. Record vacu um and pressure gauge readings and consult local representative or factory.

Locate and eliminate source of air bubble.

Secure mounting hardware.

Clean out debris; replace damaged parts.

Check bearing temperature regular ly to monitor any increase.

Low or incorrect lubricant.

Suction and discharge lines not properly supported.

Drive misaligned.

Check for proper type and level of lubricant.

Check piping installation for proper support.

Align drive properly.

TROUBLESHOOTINGPAGE D - 2

Page 26

OM-07174SUPER T SERIES

PREVENTIVE MAINTENANCE

Since pump applications are seldom identical, and pump wear is directly affected by such things as the abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however, following a routine pre ventive maintenance schedule will help assure trouble‐free performance and long life from your Gorman‐Rupp pump. For specific questions con cerning your application, contact your Gorman‐ Rupp distributor or the Gorman‐Rupp Company.

Record keeping is an essential component of a good preventive maintenance program. Changes in suction and discharge gauge readings (if so

equipped) between regularly scheduled inspec tions can indicate problems that can be corrected before system damage or catastrophic failure oc curs. The appearance of wearing parts should also be documented at each inspection for comparison as well. Also, if records indicate that a certain part (such as the seal) fails at approximately the same duty cycle, the part can be checked and replaced before failure occurs, reducing unscheduled down time.

For new applications, a first inspection of wearing parts at 250 hours will give insight into the wear rate for your particular application. Subsequent inspec tions should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently.

Preventive Maintenance Schedule

Service Interval*

Item

General Condition (Temperature, Unusual

Noises or Vibrations, Cracks, Leaks,

Loose Hardware, Etc.) I Pump Performance (Gauges, Speed, Flow) I Bearing Lubrication I R Seal Lubrication (And Packing Adjustment,

If So Equipped) I R V‐Belts (If So Equipped) I Air Release Valve Plunger Rod (If So Equipped) I C Front Impeller Clearance (Wear Plate) I Rear Impeller Clearance (Seal Plate) I Check Valve I Pressure Relief Valve (If So Equipped) C Pump and Driver Alignment I Shaft Deflection I Bearings I Bearing Housing I Piping I Driver Lubrication - See Mfgr's Literature

Daily Weekly Monthly Semi‐

Annually

Legend: I = Inspect, Clean, Adjust, Repair or Replace as Necessary C = Clean R = Replace

* Service interval based on an intermittant duty cycle equal to approximately 4000 hours annually.

Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.

TROUBLESHOOTING PAGE D - 3

Page 27

SUPER T SERIES OM-07174

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 T6A60S-ZPP857-ESP

Based on 70_F (21_C) clear water at sea level with

minimum suction lift. Since pump installations are seldom identical, your performance may be differ ent due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.

Contact the Gorman‐Rupp Company to verify per formance or part numbers.

Pump speed and operating condition

If your pump serial number is followed by an “N”, your pump is NOT a standard production model.

MAINTENANCE & REPAIR PAGE E - 1

points must be within the continuous per formance range shown on the curve.

Page 28

PARTS PAGE

SUPER T SERIESOM-07174

ILLUSTRATION

5251

DETAIL A

30 29 62

68 69

715659

5655

5659

272625 4

5 4

7 8

Figure 1. Pump Model T6A60S-ZPP857-ESP

MAINTENANCE & REPAIRPAGE E - 2

28 29 30

Page 29

SUPER T SERIES OM-07174

PARTS LIST

Pump Model T6A60S-ZPP857-ESP

(From S/N 1703506 Up)

If your pump serial number is followed by an “N”, your pump is NOT a standard production model. Contact the Gorman‐Rupp Company to verify part numbers.

ITEM

PART NAME PART

NO.

NUMBER

QTY ITEM

NO.

PART NAME PART

NUMBER

QTY

1 BASE WELDMENT 41565-603 24150 1 2 SUB BASE ASSY 41531-576 24150 1 3 COMPRESSION MOUNT 24631-104 6 4 LOCK WASHER J08 15991 24 5 HEX HEAD CAP SCREW B0805 15991 18 6 HEX HEAD CAP SCREW B1006 15991 4 7 LOCK WASHER J10 15991 14 8 HEX NUT D10 15991 14

9 PUMP MNTG BRCKT ASSY 41581-094 24150 1 10 ZENITH ZPP857 ENGINE 29267-008 1 11 THERMO HOSE X 36" LG 18533-173 1 12 TBOLT CLAMP 3.5 IN 26518-164 4 13 EXHAUST TUBING 31417-076 15210 1 14 AIR INTAKE REDCG INSRT 29284-043 1 15 T‐BOLT CLAMP 4 IN 26518-165 3 16 SLEEVE 26413-002 1 17 HOSE CLAMP 26518-678 1 18 ELBOW, REDUCING, 90° 29284-040 2 19 AIR INTAKE PIPE 31417-066 15210 2 20 THERMO HOSE X 18" LG 18533-173 1 21 T‐BOLT CLAMP 3 IN 26518-163 2 22 EXHAUST CLAMP 29334-287 1 23 FLEX CONNECTOR 31782-004 1 24 MUFFLER CLAMP 3.50 S2227 1 25 HEX HEAD CAP SCREW B0806 15991 6 26 HEX NUT D08 15991 6 27 FLAT WASHER K08 15991 6 28 HEX HEAD CAP SCREW B0505 15991 10 29 LOCK WASHER J05 15991 23 30 FLAT WASHER K05 15991 23 31 1/0 POS. CABLE ASSY 47311-112 1 32 1/0 NEG. CABLE ASSY 47311-142 1 33 SQUARE HEAD BOLT A0506 15991 2 34 PUMP END ASSEMBLY 46186-187 1 35 HEX HEAD CAP SCREW B1010 15991 4 36 PUMP SPACER 33246-058 15120 2 37 PIPE NIPPLE T9654 15079 1 38 PIPE NIPPLE T9636 15079 1 39 CLOSE PIPE NIPPLE T16 15070 3 40 PIPE ELBOW R16 15070 1 41 PIPE TEE U16 11990 1 42 REDUCER PIPE BUSHING AP1604 15070 1 43 PIPE PLUG P04 15070 1 44 NAT GAS & LPG HOSE 29332-306 1 45 ENCLOSURE ASSY 42164-051 1 46 SOLAR CHARGER 27558-013 1 47 TAP SCREW #10 X 3/4 21281-446 6 48 MUFFLER 3" 29334-105 1 49 WEATHER CAP S2021 1 50 10" DIA MOUNTING BRKT 29334-288 2 51 HEX HEAD CAP SCREW B0505 15991 4 52 LOCK WASHER J05 15991 4 53 HOIST BAIL ASSY 44713-067 24150 1 54 HEAT SHIELD ASSY 42381-145 1 55 HEX HEAD CAP SCREW B0605 15991 20 56 LOCK WASHER J06 15991 20 57 HEX HEAD CAP SCREW B1006-1/2 15991 6

58 HEAT SHIELD 34167-015 15120 1 59 HEX NUT D06 15991 6 60 HEX HEAD CAP SCREW B0508 15991 2 61 SPACER 31141-037 13000 2 62 HEX NUT D05 15991 2 63 GASKET 33311-060 19460 1 64 CONTROL PANEL 29196-071 1 65 TRNSDCR HARNESS 29196-076 1 66 INTERFACE HARNESS 29196-075 1 67 STUD MOUNT 24631-014 4 68 HEX NUT D04 15991 4 69 LOCK WASHER J04 15991 4 70 MOUNTING BRACKET 34512-065 13000 1 71 FLAT WASHER K06 15991 4 72 MOUNTING ASS'Y 41881-788 1 73 THREADED INSERT 21769-160 8 74 HEX HEAD CAP SCREW B0504 15991 11 75 BATTERY BOX ASSY 42432-005 1 76 OPW ADAPTER 1 1/4 26531-404 1 77 REDUCER PIPE BUSHING AP2016 11999 2 78 STREET ELBOW RS16 11999 1 79 HOSE FITTING 26523-394 3 80 HOSE CLAMP 26518-666 4 81 HOSE 1" ID X 26" LG 18513-045 1 82 SUCTION TRANSDUCER 27780-988 1 83 PIPE ELBOW R16 15079 1 84 PIPE NIPPLE T1608 15079 1 85 REDUCER PIPE BUSHING AP2016 17040 1 86 CLOSE PIPE NIPPLE T16 15079 1 87 BALL VALVE 26631-025 1 88 HOSE 1" ID X 58" LG 18513-045 1 89 PIPE PLUG P20 10009 1 90 PIPE PLUG P32 14990 3 91 DSCHRG TRANSDUCER 27780-989 1 92 HOSE CLAMP 26518-641 2 93 HOSE .38 I.D. X 28" LG 18513-054 1 94 MALE HOSE END 26525-020 2 95 PIPE PLUG P08 15079 2 96 HOSE .38 I.D. X 24" LG 18513-054 1

NOT SHOWN:

ENG OPERATION DECAL 38816-347 1 ENGINE START‐UP TAG 38816-269 1 CAUTION DECAL 38816-169 1 WARNING DECAL 2613FE 1 PUMP DRAIN LABEL 38816-320 1 WARNING DECAL 38817-101 2 AIR RLSE DRAIN LABEL 38816-333 1 WARNING DECAL 38816-203 4 FOAM TAPE 279" LG 18668-003 1 RADIATOR DRAIN LABEL 38816-322 1 OIL DRAIN LABEL 38816-323 1 WARNING DECAL 38816-345 2 INSTRUCTION DECAL 38818-144 1 EXHAUST BLANKET 46241-018 1 EXHST INSULTN WRAP 29330-441 2 9" SNAP STRAP 29330-443 8 18" SNAP STRAP 29330-444 4

MAINTENANCE & REPAIR PAGE E - 3

Page 30

ILLUSTRATION

SUPER T SERIESOM-07174

79 77

868779

85 84 83

FUEL LINE CONNECTION

30 29

7778

7980

Figure 2. Pump Model T6A60S-ZPP857-ESP (cont'd)

MAINTENANCE & REPAIRPAGE E - 4

Page 31

SUPER T SERIES OM-07174

PARTS LIST

Pump Model T6A60S-ZPP857-ESP

ITEM

PART NAME PART

NO.

NUMBER

QTY ITEM

NO.

PART NAME PART

NUMBER

QTY

1 BASE WELDMENT 41565-603 24150 1

2 SUB BASE ASSY 41531-576 24150 1

3 COMPRESSION MOUNT 24631-104 6

4 LOCK WASHER J08 15991 24

5 HEX HEAD CAP SCREW B0805 15991 18

6 HEX HEAD CAP SCREW B1006 15991 4

7 LOCK WASHER J10 15991 14

8 HEX NUT D10 15991 14

NOT SHOWN:

MAINTENANCE & REPAIR PAGE E - 5

Page 32

ILLUSTRATION

SUPER T SERIESOM-07174

Figure 3. Pump End Assembly

MAINTENANCE & REPAIRPAGE E - 6

Page 33

SUPER T SERIES OM-07174

PARTS LIST

Pump End Assembly

ITEM

PART NAME PART

NO.

NUMBER

QTY ITEM

NO.

PART NAME PART

NUMBER

QTY

. 1 PUMP CASING SEE NOTE BELOW 1

2 SHIM 13131-3 17040 8

3 REPAIR ROTATING ASSY 44163-547 1

WEAR PLATE 46451-723 24150 1

5 BACK CVR PLATE ASSY 42111-803 1

-WARNING PLATE 2613EV 13990 1

-DRIVE SCREW BM#04-03 17000 4

-PRESS RELIEF VALVE 26662-005 1

. 6 PIPE PLUG P04 15079 2

6A PIPE PLUG P04 15079 1

7 LOCK WASHER J08 15991 8

8 HEX HEAD CAP SCREW B0806 15991 4

9 GASKET 25113-036 1 10 O‐RING 25152-453 1

11 LOCK WASHER J06 15991 6 12 HEX NUT D06 15991 4 13 O‐RING S1676 1

13A O‐RING S1676 1

.14 CASING DRAIN PLUG P20 10009 1

15 HANDLE 12354 13010 1 16 HEX HEAD CAP SCREW B0604 15991 2 17 LOCK COLLAR 38115-551 15001 4 18 HEX HEAD CAP SCREW B0804-1/2 15991 4 19 ADJUSTING SCREW 31871-070 1500G 4

.20 STUD C1213 15991 4

21 BACK COVER NUT 31871-073 15000 4 22 SUCT FLANGE GASKET 11402G 19370 1

23 SUCTION FLANGE 11402 10010 1

INDICATES PARTS RECOMMENDED FOR STOCK

24 CHECK VALVE PIN 11645 17010 1 25 LOCK WASHER J12 15991 8 26 HEX HEAD CAP SCREW B1211 15991 6

.27 PIPE PLUG P08 15079 1

28 FILL COVER ASSY 42111-344 1

-DRIVE SCREW BM#04-03 17000 2

-WARNING PLATE 38816-097 13990 1

-COVER GASKET 50G 19210 1

29 CLAMP BAR 38111-004 11010 1

.30 MACHINE BOLT A1014 15991 2

31 CLAMP BAR SCREW 31912-009 15000 1 32 FLAP VALVE ASSY 46411-064 1 33 CHK VLV/AIR REL ASSY 46421-100 1 34 MOUNTING BRKT ASSY 41888-286 1 35 HEX HEAD CAP SCREW B1212 15991 2 36 COUPLING KIT 48112-001 1

NOT SHOWN:

G‐R DECAL GR-06 1 INSTR TAG 38817-085 1 LUBRICATION DECAL 38817-084 1 WARNING DECAL 2613FE 1 SUCTION STICKER 6588AG 1 PRIMING STICKER 6588AH 1 DISCHARGE STICKER 6588BJ 1 SUPER "T" DECAL 38812-089 1 NAME PLATE 38819-002 13000 1 DRIVE SCREW BM#04-03 17000 4 STRAINER ASSY 7823A 24000 1

. INCLUDED WITH REPAIR 46472-722 1

PUMP CASING ASSY

MAINTENANCE & REPAIR PAGE E - 7

Page 34

ILLUSTRATION

SUPER T SERIESOM-07174

Figure 4. Repair Rotating Assembly

MAINTENANCE & REPAIRPAGE E - 8

Page 35

SUPER T SERIES OM-07174

PARTS LIST

Repair Rotating Assembly

ITEM NO.

1 IMPELLER SHAFT 38514-823 1706H 1 2 BALL BEARING S1030 1 3 BALL BEARING S616 1 4 OIL SEAL S1917 3 5 SNAP RING 24124-425 1 6 BEARING HOUSING 38251-517 10000 1 7 BEARING CAP GASKET 38683-478 18000 1 8 SIGHT GAUGE S1471 2

9 PIPE PLUG P12 15079 1 10 VENTED PIPE PLUG 4823A 15079 1 11 AIR VENT S1530 1 12 REDUCER PIPE BUSHING AP0802 15079 1 13 PIPE PLUG P04 15079 2 14 DRIVE FLANGE 38545-023 10000 1 15 LOCK WASHER J06 15991 8 16 GRADE 8 CAPSCREW 3/8 X 2 21632-938 8 17 SHAFT KEY N0607 15990 1 18 GASKET 10959G 20000 1 19 SHAFT SLEEVE O‐RING 25154-026 REF 20 SEAL PLATE 38272-254 10010 1 21 LOCK WASHER J08 15991 4 22 HEX HEAD CAP SCREW B0805-1/2 15991 4 23 1 7/8 CTG SEAL ASSY 46513-154 1 24 IMPELLER 38615-087 11010 1 25 ADJ SHIM SET 5091 17090 2 26 INTERMEDIATE GUARD 42381-509 24152 2 27 PIPE PLUG PC20 10009 1 28 ROTATING ASSY ADJ SHIM 13131-3 17040 8 29 O‐RING S1676 1 30 SHIPPING PLUG 11495B 15079 2

NOT SHOWN:

PART NAME

ASSEMBLY PLATE 2613GG 13990 1 DRIVE SCREW BM#04-03 17000 2 ROTATION DECAL 2613M 1 INSTRUCTION DECAL 6588U 1 WARNING DECAL 38817-102 1

PART NUMBER

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 9

Page 36

ILLUSTRATION

SUPER T SERIESOM-07174

MODEL T6A60S LOCATE COUPLING AS DIMENSIONED

Figure 5. Coupling Kit

PARTS LIST

ITEM NO.

1 BUSHING 24131-345 1

2 COUPLING ASSEMBLY 44165-011 1

3 . LOCKWASHER J06 15991 8

4 . SOCKET HD CAPSCREW BD0606-1/2 15991 8

3 ' LOCKWASHER 21171-536 8

4 ' SOCKET HD CAPSCREW 22644-220 8

PART NAME

PART NUMBER

QTY

. USE FOR SAE APPLICATIONS ' USE FOR METRIC APPLICATIONS

MAINTENANCE & REPAIRPAGE E - 10

Page 37

SUPER T SERIES

OM-07174

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Review all SAFETY information in Section A.

Follow the instructions on all tags, label and de cals attached to the pump.

This pump requires little service due to its rugged, minimum‐maintenance design. However, if it be comes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the illustrations (see Figures 1 through 5) and the accompanying parts lists.

This manual will alert personnel to known procedures which require spe cial attention, to those which could damage equipment, and to those which could be dangerous to personnel. How ever, this manual cannot possibly antici pate and provide detailed instructions and precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance personnel to ensure that only safe, established main tenance procedures are used, and that any procedures not addressed in this manual are performed only after estab lishing that neither personal safety nor pump integrity are compromised by such practices.

Many service functions may be performed by draining the pump and removing the back cover assembly. If major repair is required, the piping and/or engine must be disconnected. The follow ing instructions assume complete disassembly is required.

Before attempting to service the pump, disconnect or lock out the power source and take precautions to ensure that it will remain inoperative. Close all valves in the suction and discharge lines.

No instructions for removal and/or disassembly of the enclosure or its components are provided in

this manual. If removal of the enclosure is required for pump service, be sure to use safe shop practic es so as not to endanger personnel, and use cau tion to prevent damage to the enclosure.

For engine disassembly and repair, consult the lit erature supplied with the engine, or contact your local engine representative.

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.

MAINTENANCE & REPAIR PAGE E - 11

Page 38

OM-07174 SUPER T SERIES

Suction Check Valve Removal

(Figure 3)

If the check valve assembly (32) is to be serviced,

Use Only Genuine Gorman-Rupp re placement parts. Failure to do so may cre ate a hazard and damage the pump or di

remove the check valve pin (24), reach through the back cover opening and pull the complete assem bly from the suction flange (23).

minish optimal pump performance. Any such hazard, damage or diminished per formance is not covered by the warranty.

NOTE

When appropriate recycling facilities are available, the user should recycle components and fluids when doing any routine maintenance / repairs and also at the end of the pump’s useful life. All other components and fluids shall be disposed of ac cording to all applicable codes and regulations.

Back Cover and Wear Plate Removal

(Figure 3)

Further disassembly of the check valve is not re quired since it must be replaced as a complete unit. Individual parts are not sold separately.

Separating Intermediate and Coupling Assembly From Engine

(Figure 5)

Further disassembly requires separating the pump end and drive assembly from the engine. Remove the hardware securing the check valve/air release valve assembly (33, Figure 3) to the pump casing. Disengage and remove any additional compo nents necessary for the removal of the pump end.

NOTE

The wear plate (4) is easily accessible and may be serviced by removing the back cover assembly (5). Before attempting to service the pump, open the ball valve (87, Figure 2) and drain the pump. Close the valve after draining is complete.

Remove the back cover nuts (21) and pry the back cover and assembled wear plate from the pump casing (1).

NOTE

An alternate method of removing the back cover from the pump casing is to remove the back cover nuts (21) and two diagonally opposing locking col lars (17). Install two 1/2-16 UNC x 2 inch long screws in the tapped holes in the back cover and use them to press the back cover out of the pump casing.

Inspect the wear plate and replace it if badly scored or worn. To remove the wear plate, disengage the hardware (11 and 12).

Install a standard 5/8‐11 UNC lifting eye in the tapped hole in the top of the pump casing. Be sure to screw the eye into the casing until fully engaged. Support the pump using a suitable hoist and the lifting eye.

Do not attempt to lift the complete pump unit using the lifting eye. It is designed to facilitate removal or installation of in dividual components only. Additional weight may result in damage to the pump or failure of the eye bolt.

Remove the hardware securing the pump casing to the base.

Disengage the hardware (7 and 8, Figure 3) secur ing the drive flange to the engine bellhousing, and remove the guards (26, Figure 4). Separate the pump end and drive assembly from the engine by pulling the pump end straight away from the en gine.

Inspect the back cover and wear plate O‐rings (10 and 13) and replace them if damaged or worn.

As the assemblies separate, the flexible portion of the coupling assembly (2) will remain on the shaft.

MAINTENANCE & REPAIRPAGE E - 12

Page 39

SUPER T SERIES

OM-07174

To remove the coupling from the shaft, unscrew the two allen head setscrews from the bushing (1). Screw one of the setscrews into the puller hole on the circumference of the bushing. As the coupling and bushing separate, remove the bushing, and slide the coupling off the shaft. Remove the shaft key (17, Figure 4).

It is not necessary to remove the outer ring of the coupling from the engine flywheel unless the cou pling must be replaced. To remove the ring, disen gage the hardware (3 and 4) securing it to the fly wheel.

Remove any leveling shims used under the casing mounting feet. Tie and tag the shims for ease of reassembly.

Move the pump end to a clean, well equipped shop area for further disassembly.

shaft (1) with the “V” notch positioned over the shaft key.

With the impeller rotation still blocked, see Figure 6 and use a long piece of heavy bar stock to pry against the arm of the lathe dog in a counterclock wise direction (when facing the drive end of the shaft). Use caution not to damage the shaft or key way. When the impeller breaks loose, remove the lathe dog, key and wood block.

NOTE

Do not remove the impeller until the rotating assem bly has been removed from the pump casing.

Turn

Counterclockwise

Lathe Dog Arm

Loosening Impeller

(Figure 4)

Before attempting to loosen the impeller, remove the seal cavity drain plug (13) and drain the lubri cant. This will prevent the oil from escaping as the impeller is removed. Clean and reinstall the drain plug.

With the pump end separated from the engine and the back cover (5, Figure 3) removed, wedge a block of wood between the vanes of the impeller and the pump casing to prevent rotation.

If removed, install the shaft key (17) in the shaft keyway. Install a lathe dog on the drive end of the

“V” Notch

Heavy

Bar Stock

Figure 6. Loosening Impeller

Rotating Assembly Removal (Figure 3)

Remove the hardware (7 and 8) securing the rotat ing assembly to the pump casing. Separate the ro tating assembly by pulling straight away from the pump casing. Tie and tag the rotating assembly shims (2) for ease of reassembly.

Shaft Key

Impeller

Shaft

Lathe Dog

Setscrew

MAINTENANCE & REPAIR PAGE E - 13

Page 40

OM-07174 SUPER T SERIES

NOTE

An optional disassembly tool is available from the factory. If the tool is used, follow the instructions packed with it. A similar tool may be assembled us ing 1/2‐inch pipe (schedule 80 steel or malleable iron) and a standard tee (see Figure 7). All threads are 1/2‐inch NPT. Do not pre‐assemble the tool.

TEE

APPROX. 6 IN.

(152 MM) LONG

APPROX. 14 IN.

(356 MM) LONG

Seal Removal

(Figure 4)

Slide the integral shaft sleeve and rotating portion of the seal off the shaft as a unit.

Use a pair of stiff wires with hooked ends to remove the stationary element and seat.

An alternate method of removing the stationary seal components is to remove the hardware (21 and 22) and separate the seal plate (20) and gas ket (18) from the bearing housing (6). Position the seal plate on a flat surface with the impeller side down. Use a wooden dowel or other suitable tool to press on the back side of the stationary seat until the seat, O‐rings, and stationary element can be removed.

Remove the shaft sleeve O‐ring (19).

If no further disassembly is required, refer to Seal

Installation.

Figure 7. Rotating Assembly Tool

To install the tool, remove the vented plug (10, Fig ure 4) from the bearing housing, and screw the longest length of pipe into the vent hole until fully engaged. Install the tee, and screw the handles into the tee. Use caution when lifting the rotating assem bly to avoid injury to personnel or damage to the as sem bly.

Remove the bearing housing O‐ring (13A).

Impeller Removal

(Figure 4)

With the rotating assembly removed from the pump casing, unscrew the impeller from the shaft. Use caution when unscrewing the impeller; ten sion on the shaft seal spring will be released as the impeller is removed. Inspect the impeller and re place if cracked or badly worn.

Shaft and Bearing Removal and Disassembly

(Figure 4)

When the pump is properly operated and main tained, the bearing housing should not require dis assembly. Disassemble the shaft and bearings only when there is evidence of wear or damage.

Shaft and bearing disassembly in the field is not recommended. These operations should be performed only in a properly‐ equipped shop by qualified personnel.

Remove the bearing housing drain plug (13) and drain the lubricant. Clean and reinstall the drain plug.

Disengage the hardware (15 and 16) and slide the drive flange (14) and oil seal (4) off the shaft. Re move the flange gasket (7) and press the oil seal from the drive flange.

Remove the impeller adjusting shims (25); tie and tag the shims, or measure and record their thick ness for ease of reassembly.

Place a block of wood against the impeller end of the shaft and tap the shaft and assembled bear ings (2 and 3) from the bearing housing.

MAINTENANCE & REPAIRPAGE E - 14

Page 41

SUPER T SERIES

OM-07174

Pry or press the oil seals (4 ) from the bearing hous ing.

After removing the shaft and bearings, clean and inspect the bearings in place as follows.

To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place. It is strongly recommended that the bearings be replaced any time the shaft and bear ings are removed.

Clean the bearing housing, shaft and all compo nent parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage and replace as necessary.

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.

Clean the bearings thoroughly in fresh cleaning solvent. Dry the bearings with filtered compressed air and coat with light oil.

housing. Replace the bearings, shaft, or bearing housing if the proper bearing fit is not achieved.

If bearing replacement is required, remove the out board bearing snap ring (5) and use a bearing pull er to remove the bearings from the shaft.

Shaft and Bearing Reassembly and Installation

(Figure 4)

Clean the bearing housing, shaft and all compo nent parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage as necessary.

Inspect the shaft for distortion, nicks or scratches, or for thread damage on the impeller end. Dress small nicks and burrs with a fine file or emery cloth. Replace the shaft if defective.

Position the inboard oil seal (4) in the bearing hous ing bore with the lip positioned as shown in Figure

5. Press the oil seal into the housing until the face is just flush with the machined surface on the inside of the housing.

Bearings must be kept free of all dirt and foreign material. Failure to do so will great ly shorten bearing life. Do not spin dry bearings. This may scratch the balls or races and cause premature bearing fail ure.

Rotate the bearings by hand to check for rough ness or binding and inspect the bearing balls. If ro tation is rough or the bearing balls are discolored, replace the bearings.

The bearing tolerances provide a tight press fit onto the shaft and a snug slip fit into the bearing

MAINTENANCE & REPAIR PAGE E - 15

NOTE

Position the inboard bearing (3) on the shaft with the shielded side toward the impeller end of the shaft. Position the outboard bearing (2) on the shaft with the integral retaining ring on the bearing O.D. toward the drive end of the shaft.

Page 42

OM-07174 SUPER T SERIES

The bearings may be heated to ease installation. An induction heater, hot oil bath, electric oven, or hot plate may be used to heat the bearings. Bear ings should never be heated with a direct flame or directly on a hot plate.

NOTE

If a hot oil bath is used to heat the bearings, both the oil and the container must be absolutely clean. If the oil has been previously used, it must be thor oughly filtered.

Heat the bearings to a uniform temperature no higher than 250_F (120_C) and slide the bearings

onto the shaft, one at a time, until they are fully seated. This should be done quickly, in one con tinuous motion, to prevent the bearings from cool ing and sticking on the shaft.

After the bearings have been installed and allowed to cool, check to ensure that they have not moved away from the shaft shoulders in shrinking. If movement has occurred, use a suitably sized sleeve and a press to reposition the bearings against the shaft shoulders.

With the lip seal sleeve in place, lubricate the lip seal area of the shaft, and slide the shaft and as sembled bearings into the bearing housing until the retaining ring on the outboard bearing seats against the bearing housing. Remove the lip seal sleeve.

When installing the shaft and bearings into the bearing bore, push against the outer race. Never hit the balls or ball cage.

Position the outboard oil seal (4) on the lubricated shaft with the lip positioned as shown in Figure 4. Press the oil seal into the bearing housing until the face of the seal is just flush with the machined sur face on the bearing housing.

Press the oil seal (4) into the drive flange (14) with the lip positioned as shown in Figure 4. Replace the flange gasket (7) and secure the flange to the bearing housing with the hardware (15 and 16). Be careful not to damage the oil seal lip on the shaft keyway.

If heating the bearings is not practical, use a suit ably sized sleeve, and an arbor (or hydraulic) press to install the bearings on the shaft.

When installing the bearings onto the shaft, never press or hit against the outer race, balls, or ball cage. Press only on the inner race.

Secure the outboard bearing on the shaft with the bearing snap ring (5).

It is recommended that a sleeve be positioned against the inboard oil seal (4) to prevent the lip of the oil seal from rolling as the shaft and bearings are installed in the bearing housing. The O.D. of the sleeve should be just smaller than the bearing housing bore, while the I.D. of the sleeve should be just larger than the O.D. of the lip seal area of the shaft.

Lubricate the bearing housing as indicated in LU

BRICATION.

Seal Installation

(Figures 4, 8, 9 and 10)

Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent. Inspect the stationary seat bore in the seal plate for dirt, nicks and burrs, and remove any that exist. The stationary seat bore must be completely clean before installing the seal.

MAINTENANCE & REPAIRPAGE E - 16

Page 43

SUPER T SERIES

A new seal assembly should be installed any time the old seal is removed from the pump. Wear patterns on the finished faces

OM-07174

cannot be realigned during reassembly. Reusing an old seal could result in prema ture failure.

To ease installation of the seal, lubricate the shaft sleeve O‐ring (19) and the external stationary seat O‐ring with a very small amount of light lubricating oil. See Figure 8 for seal part identification.

SPRING

IMPELLER

SHIMS

IMPELLER

SHAFT

BELLOWS

SPRING

CENTERING

WASHER

RETAINER

DRIVE BAND

ROTATING

ELEMENT

STATIONARY

ELEMENT

SEAL PLATE

O‐RINGS

SLEEVE O‐RING

INTEGRAL

SHAFT

SLEEVE

SHEAR

RING

(SHEARED)

STATIONARY

SEAT

Figure 8. Cartridge Seal Assembly

tape covering the threads. Check to ensure that the shaft threads are free of any tape residue and clean as required before proceeding with seal installation.

This seal is not designed for operation at temperatures above 160_F (71_C). Do not

use at higher operating temperatures.

If the seal plate (20) was removed, install the seal plate gasket (18), position the seal plate over the shaft and secure it to the bearing housing with the hardware (21 and 22). Install the bearing housing O‐ring (29) and lubricate it with light grease.

To prevent damaging the shaft sleeve O‐ring (19) on the shaft threads, cover the threads with electri cal or duct tape. Slide the O‐ring over the shaft until it seats against the shaft shoulder. Remove the

MAINTENANCE & REPAIR PAGE E - 17

When installing a new cartridge seal assembly,

remove the seal from the container lubricate the ex ternal stationary seat O‐ring with light oil. Slide the seal assembly onto the shaft until the external sta tionary seat O‐ring engages the bore in the seal plate.

Clean and inspect the impeller as described in Im peller Installation and Adjustment. Install the full set of impeller shims (25) provided with the seal, and screw the impeller onto the shaft until it is seated against the seal (see Figure 9).

Page 44

OM-07174 SUPER T SERIES

Continue to screw the impeller onto the shaft. This will press the stationary seat into the seal plate bore.

O‐RING ENGAGED

WITH SEAL PLATE

BORE

SHEAR RING

(UNSHEARED)

Figure 9. Seal Partially Installed

NOTE

A firm resistance will be felt as the impeller presses the stationary seat into the seal plate bore.

As the stationary seat becomes fully seated, the seal spring compresses, and the shaft sleeve will break the nylon shear ring. This allows the sleeve to slide down the shaft until seated against the shaft shoulder. Continue to screw the impeller onto the shaft until the impeller, shims, and sleeve are fully seated against the shaft shoulder (see Figure

10).

STATIONARY SEAT

FULLY SEATED IN

SEAL PLATE BORE

proper clearance as described in Impeller Instal lation and Adjustment.

If necessary to reuse an old seal in an emer

gency, carefully separate the rotating and station ary seal faces from the bellows retainer and sta tionary seat.

A new seal assembly should be installed any time the old seal is removed from the pump. Wear patterns on the finished faces cannot be realigned during reassembly. Reusing an old seal could result in prema ture failure.

Handle the seal parts with extreme care to prevent damage. Be careful not to contaminate precision finished faces; even fingerprints on the faces can shorten seal life. If necessary, clean the faces with a non‐oil based solvent and a clean, lint‐free tissue. Wipe lightly in a concentric pattern to avoid scratching the faces.

Carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.

Do not attempt to separate the rotating portion of the seal from the shaft sleeve when reusing an old seal. The rubber bel lows will adhere to the sleeve during use, and attempting to separate them could damage the bellows.

SHEAR RING

(SHEARED)

Figure 10. Seal Fully Installed

Measure the impeller‐to‐seal plate clearance, and remove impeller adjusting shims to obtain the

Inspect the seal components for wear, scoring, grooves, and other damage that might cause leak age. Inspect the integral shaft sleeve for nicks or cuts on either end. If any components are worn, or the sleeve is damaged, replace the complete seal; never mix old and new seal parts.

Install the stationary seal element in the stationary seat. Press this stationary subassembly into the seal plate bore until it seats squarely against the bore shoulder. A push tube made from a piece of plastic pipe would aid this installation. The I.D. of the pipe should be slightly larger than the O.D. of the shaft sleeve.

MAINTENANCE & REPAIRPAGE E - 18

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SUPER T SERIES

OM-07174

Slide the rotating portion of the seal (consisting of the integral shaft sleeve, spring centering washer, spring, bellows and retainer, and rotating element) onto the shaft until the seal faces contact.

Proceed with Impeller Installation and Adjust

ment.

Impeller Installation and Adjustment

(Figure 4)

Inspect the impeller, and replace it if cracked or badly worn. Inspect the impeller and shaft threads for dirt or damage, and clean or dress the threads as required.

The shaft and impeller threads must be completely clean before reinstalling the im peller. Even the slightest amount of dirt on the threads can cause the impeller to seize to the shaft, making future removal difficult or impossible without damage to the im peller or shaft.

Install the same thickness of impeller adjusting shims (25) as previously removed. Apply `Never‐ Seez' or equivalent to the shaft threads and screw the impeller onto the shaft until tight. Be sure the seal spring seats squarely on the back side of the impeller.

Rotating Assembly Installation

(Figure 3)

NOTE

If the pump has been completely disassembled, it is recommended that the suction check valve and back cover assembly be reinstalled at this point. The back cover assembly must be in place to adjust the impeller face clearance.

NOTE

There is a 1‐1/2 inch diameter socket head pipe plug located in the side of the bearing housing. This hole is required for manufacturing purposes only; therefore the pipe plug should never require remov al.

Install the bearing housing O‐ring (13A) and lubri cate it with light grease. Ease the rotating assem bly into the pump casing using the installation tool. Be careful not to damage the O‐ring.

Install the rotating assembly adjusting shims (2) using the same thickness as previously removed. Secure the rotating assembly to the pump casing with the hardware (7 and 8).

To set the impeller and wear plate clearance refer to the Back Cover Installation And Adjustment.

Suction Check Valve Installation

(Figure 3)

NOTE

At the slightest sign of binding, immediately back the impeller off, and check the threads for dirt. Do

not try to force the impeller onto the shaft.

A clearance of .025 to .040 inch (0,64 to 1,02 mm) between the impeller and the seal plate is recom mended for maximum pump efficiency. Measure this clearance, and add or remove impeller adjust ing shims as required.

NOTE

If the rotating assembly has been installed in the pump casing, this clearance may be measured by reaching through the priming port with a feeler gauge.

MAINTENANCE & REPAIR PAGE E - 19

Inspect the check valve assembly (32) and replace it if badly worn.

NOTE

The check valve assembly must be replaced as a complete unit. Individual parts are not sold sepa rately.

Reach through the back cover opening with the check valve and position the check valve adaptor in the mounting slot in the suction flange (23). Align the adaptor with the flange hole and secure the as sembly with the check valve pin (24).

NOTE

If the suction or discharge flanges were removed, replace the respective gaskets, apply `Permatex

Page 46

OM-07174 SUPER T SERIES

Aviation No. 3 Form‐A‐Gasket' or equivalent com pound to the mating surfaces, and secure them to the pump casing with the attaching hardware.

Back Cover Installation and Adjustment

(Figures 3 and 11)

If the wear plate (4) was removed for replacement, carefully center it on the back cover and secure it with the hardware (11 and 12). The wear plate must be concentric to prevent binding when the back cover is installed.

The clearance between the impeller and wear plate is adjusted using four adjusting screws (19) and locking collars (17). There are 18 detents on the I.D. of each locking collar. Indexing the collars one detent on the adjusting screws represents approxi mately .005 inch (0,13 mm) of wear plate clear ance. The recommended clearance between the wear plate and the impeller is .010 to .020 inch (0,25 to 0,50 mm).

Replace the back cover and wear plate O‐rings (10 and 13) and lubricate them with a generous amount of No. 2 grease. Clean any scale or debris from the contacting surfaces in the pump casing that might interfere or prevent a good seal with the back cover.

USE TWO REMAINING ADJUSTING SCREWS AND LOCKING COLLARS TO SET FACE CLEARANCE

USE TWO OPPOSING BACK COVER NUTS TO PRESS BACK COVER INTO PUMP CASING

INDEX COLLARS 3 DETENTS COUNTER‐ CLOCKWISE, THEN TURN CLOCKWISE UNTIL SCREW HOLES ALIGN

just flush with the machined surface on the back

side of the cover plate.

Align the back cover plate over the studs (20) and slide it into the pump casing. Use two back cover nuts (21) on diagonally opposing studs to press the back cover into the pump casing until the wear plate just touches the impeller when the shaft is turned by hand. Tighten the back cover nuts

evenly to avoid binding.

With the wear plate just touching the impeller, turn the two free adjusting screws until they engage the pump casing. Position the locking collars over the adjusting screws so the holes in the collars for the locking screws align approximately with the holes in the cover plate.

Loosen the back cover nuts used to press the back cover into the pump casing one full turn.

Pull the collars off the adjusting screws, index them three detents counterclockwise, and reinstall the collars on the adjusting screws. Use the collars to turn the adjusting screws clockwise until the holes in the locking collars realign with the tapped screw holes in the back cover plate. Secure the locking collars to the back cover plate with the hardware (7 and 18). Install the two remaining back cover nuts snugly against the adjusting screws.

Remove the first two back cover nuts from their studs. Turn the adjusting screws clockwise until they engage the pump casing. Install the locking collars and hardware (7 and 18). Reinstall the back cover nuts.

Be sure the wear plate does not scrape against the impeller.

Over time it may be necessary to repeat the adjust ment process to compensate for normal wear be tween the impeller and wear plate. When all of the adjustment has been used on the back cover side of the pump, an additional 0.125 inch (3,2 mm) of adjustment may be obtained by removing the ro tating assembly adjusting shims (2).

Figure 11. Installing and Adjusting Back Cover

Screw the four adjusting screws (19) into the tapped holes in the back cover plate until they are

Allow an installed pump to completely cool before draining liquid from the pump casing. Remove the back cover. Remove the rotating assembly adjust ing shims, then reinstall the hardware securing the rotating assembly to the pump casing. Perform the back cover adjustment procedure described above to obtain the proper face clearance.

MAINTENANCE & REPAIRPAGE E - 20

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SUPER T SERIES

OM-07174

Securing Pump and Coupling Assembly to Engine

(Figure 5)

Install the shaft key (17, Figure 4) in the shaft key way. Position the flexible portion of the coupling as sembly (2) on the shaft as shown in Figure 5.

Align the keyway in the bushing (1) with the shaft key, and slide it onto the shaft to the dimension shown in Figure 8. Rotate the flexible portion of the coupling until the tapped holes for the two set screws align with those in the bushing, and install the setscrews.

Make certain that the flexible portion of the coupling is mounted as shown in Figure 5. This is critical. If the coupling is not prop erly positioned on the shaft, the coupling parts may not fully engage, or a pre‐load condition can cause premature bearing failure.

NOTE

To ease installation, lightly lubricate the rubber por tion of the coupling with a non‐petroleum based lubricant such as vegetable oil or glycerin, or a sili con‐based lubricant such as “WD40” or equivalent. Do not use petroleum‐based lubricants, or any oth er substance which may soften or otherwise dam age the rubber.

Install the intermediate guards (26, Figure 4), and secure the drive flange to the engine bellhousing with the hardware (7 and 8, Figure 3).

Secure the check valve/air release valve assembly (33, Figure 3) to the pump casing using the pre viously removed hardware. Reinstall any additional components removed at disassembly.

Install any leveling shims used under the casing mounting feet, and secure the casing to the base with the previously removed hardware.

If a lifting eye was used to move the pump casing, be sure to remove the lifting eye from the pump casing.

The end of the shaft must protrude 1.25 inch (32 mm) from the face of the bush ing. This will allow the two portions of the

coupling to fully engage when the drive flange is secured to the engine bellhous ing, without pre‐loading the bearings.

With the flexible portion of the coupling and the bushing properly positioned on the shaft, tighten the two setscrews in an alternating sequence until the bushing and coupling are fully secured. Torque the setscrews to 14.6 ft. lbs. (175 in. lbs. or 2 m. kg.).

If the complete coupling assembly is being re placed, apply `Loctite Retaining Compound No. 242' or equivalent to the threads of the hardware (3 and 4) and secure the outer ring of the coupling to the engine flywheel by torquing the hardware to 45 ft. lbs. (540 in. lbs. or 6,2 m. kg.).

Using a suitable lifting device, position the pump end so the flexible portion of the coupling seats in side the outer ring attached to the engine flywheel.

PRESSURE RELIEF VALVE MAINTENANCE

(Figure 3)

The back cover is equipped with a pressure relief valve (not shown) to provide additional safety for the pump and operator (refer to Liquid Tempera ture And Overheating in OPERATION).

It is recommended that the pressure relief valve as sembly be replaced at each overhaul, or any time the pump overheats and activates the valve. Never replace this valve with a substitute which has not

MAINTENANCE & REPAIR PAGE E - 21

Page 48

OM-07174 SUPER T SERIES

been specified or provided by the Gorman‐Rupp Company.

Periodically, the valve should be removed for in spection and cleaning. When reinstalling the relief valve, apply `Loctite Pipe Sealant With Teflon No. 592', or equivalent compound, on the relief valve threads. Position the valve as shown in Figure 3 with the discharge port pointing down.

Final Pump Assembly

Be sure the pump is secured to the base and en

gine. Be sure to install any guards used over the ro tating members.

Do not operate the pump without the guards in place over the rotating parts. Exposed rotating parts can catch cloth ing, fingers, or tools, causing severe in jury to personnel.

Install the suction and discharge lines and open all valves. Make certain that all piping connections are tight, properly supported and secure.

ounces (1,9 liter) of SAE No. 30 non‐detergent oil to the middle of the sight gauge (8) and maintain it at the middle of the gauge. Clean and reinstall the vented plug. Maintain the oil at this level.

Bearings

(Figure 4)

The bearing housing was fully lubricated when shipped from the factory. Check the oil level regu larly through the sight gauge (8) and maintain it at the middle of the gauge. When lubrication is re quired, add SAE No. 30 non‐detergent oil through the hole for the air vent (11). Do not over‐lubricate. Over‐lubrication can cause the bearings to over‐ heat, resulting in premature bearing failure.

Under normal conditions, drain the bearing hous ing once each year and refill with approximately 21 ounces (0,6 liter) clean oil. Change the oil more fre quently if the pump is operated continuously or in stalled in an environment with rapid temperature change.

Be sure the pump and engine have been properly lubricated, see LUBRICATION.

Remove the fill cover assembly (28, Figure 3) and fill the pump casing with clean liquid. Reinstall the fill cover and tighten it. Refer to OPERATION, Sec tion C, before putting the pump back into service.

LUBRICATION

Seal Assembly

(Figure 4)

Before starting the pump, remove the vented plug (10) and fill the seal cavity with approximately 64

Monitor the condition of the bearing lubri cant regularly for evidence of rust or mois ture condensation. This is especially im portant in areas where variable hot and cold temperatures are common.

For cold weather operation, consult the factory or a lubricant supplier for the recommended grade of oil.

Engine

Consult the literature supplied with the engine, or contact your local engine representative.

MAINTENANCE & REPAIRPAGE E - 22

Page 49

For Warranty Information, Please Visit

www.grpumps.com/warranty

or call:

U.S.: 419-755-1280

Canada: 519-631-2870

International: +1-419-755-1352

GORMAN‐RUPP PUMPS