Gorman-Rupp Pumps T10A60S-6068T User Manual

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Page 1

ACDEU

OM-05521−OE01

August 4, 2003

Rev. B 05-29-08

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

SUPER T SERIES PUMP

MODEL

T10A60S−6068T

THE GORMAN-RUPP COMPANY  MANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED  ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

www.grpumps.com

2003 The Gorman-Rupp Company

Page 2

Gorman-Rupp pump online at

www.grpumps.com

Valid serial number and e-mail address required.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

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 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

POSITIONING PUMP PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clearance PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION AND DISCHARGE PIPING PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Configuration PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections to Pump PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gauges PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION LINES PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fittings PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainers PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealing PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Lines In Sumps PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Line Positioning PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FLOAT SWITCHES PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONAL SUBMERSIBLE TRANSDUCER PAGE B − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISCHARGE LINES PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Siphoning PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bypass Lines PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTOMATIC AIR RELEASE VALVE PAGE B − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Theory of Operation PAGE B − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Release Valve Installation PAGE B − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALIGNMENT PAGE B − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION − SECTION C PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMING PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Starting PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Starting PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 4

TABLE OF CONTENTS

(continued)

Horn Delay PAGE C − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION PAGE C − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Leakage PAGE C − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Strainer Check PAGE C − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Vacuum Check PAGE C − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STOPPING PAGE C − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Stopping PAGE C − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Stopping PAGE C − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Shutdown System PAGE C − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION IN EXTREME HEAT PAGE C − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Preservation PAGE C − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING TEMPERATURE CHECK PAGE C − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING − SECTION D PAGE D − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREVENTIVE MAINTENANCE PAGE D − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

STANDARD PERFORMANCE CURVE PAGE E − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS LISTS:

Pump Model PAGE E − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Unit Kit PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump End Assembly PAGE E − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Rotating Assembly PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Assembly PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Cleanout Access And Suction Check Valve Removal PAGE E − 11. . . . . . . . . . . . . . . . . . . . . . .

Suction Head And Wear Plate Removal PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Separating Pump And Drive Assembly From Engine PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . .

Loosening Impeller PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotating Assembly Removal PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller And Wear Plate Removal PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Removal And Disassembly PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Shaft and Bearing Reassembly and Installation PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Reassembly And Installation PAGE E − 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Installation PAGE E − 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotating Assembly Installation PAGE E − 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Head And Wear Plate Installation PAGE E − 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Check Valve Installation PAGE E − 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing Pump End To Engine PAGE E − 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

LUBRICATION PAGE E − 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Assembly PAGE E − 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearings PAGE E − 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine PAGE E − 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 5

SUPER T SERIES

OM−05521

INTRODUCTION

Thank You for purchasing a Gorman-Rupp pump. Read this manual carefully to learn how to safely

install and operate your pump. Failure to do so could result in personal injury or damage to the pump.

This Installation, Operation, and Maintenance manual is designed to help you achieve the best performance and longest life from your GormanRupp pump.

This pump is a Super T Series, semi-open impeller, self-priming centrifugal model with a suction check valve. The pump also is designed with external shimless adjusters for setting the wear plate to impeller clearance. The pump is close coupled to a John Deere 6068T diesel engine, and is designed for handling dirty water containing specified entrained solids and slurries. The basic material of construction is gray iron, with ductile iron impeller and steel wearing parts.

If there are any questions regarding the pump or its application which are not covered in this manual or in other literature accompanying this unit, please contact your Gorman-Rupp distributor, or write:

The Gorman-Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901−1217

Phone: (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 engine, contact the engine manufacturer’s local dealer or representative.

neither operator safety nor pump integrity are compromised by the installation. Pumps and related equipment must be installed and operated according to all national, local and industry standards.

The following are used to alert maintenance personnel to procedures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel:

Immediate hazards which WILL result in severe personal injury or death. These instructions describe the procedure required and the injury which will result from failure to follow the procedure.

Hazards or unsafe practices which COULD result in severe personal injury or death. These instructions describe the procedure required and the injury which could result from failure to follow the procedure.

Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. These instructions describe the requirements and the possible damage which could result from failure to follow the procedure.

Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and precautions for every aspect of each specific application. Therefore, it is the responsibility of the owner/installer of the pump to ensure that applications not addressed in this manual are performed only after establishing that

NOTE

Instructions to aid in installation, operation, and maintenance or which clarify a procedure.

PAGE I − 1INTRODUCTION

Page 6

SUPER T SERIES

OM−05521

SAFETY - SECTION A

This information applies to Super T Series engine driven pumps. Refer to the manual accompanying the engine before attempting to begin operation.

Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and precautions for each specific application. Therefore, it is the owner/installer’s responsibility to ensure that applications not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity are compromised by the installation.

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

2. Switch off the engine ignition, 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 cautiously.

7. Drain the pump.

during automatic operation. Disconnect the positive battery cable before performing 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 personnel as a result of pump failure.

Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or damage to equipment. The bail is intended for use in lifting the pump assembly only. Suction and discharge hoses and piping must be removed from the pump before lifting.

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.

This pump is equipped with an automatic starting system, and is subject to automatic restart. Keep hands and clothing away from the unit to prevent injury

Do not operate the pump against a closed discharge valve for long periods of time. If operated against a closed discharge valve, pump components will deteriorate, and the liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode.

PAGE A − 1SAFETY

Page 7

SUPER T SERIESOM−05521

Do not remove plates, covers, gauges, pipe plugs, or fittings from an overheated pump. Vapor pressure within the pump can cause parts being disengaged to be ejected with great force. Allow 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 certain that exhaust fumes are piped to the outside. These fumes contain carbon monoxide, a deadly gas that is colorless, tasteless, and odorless.

Fuel used by internal combustion engines presents an extreme explosion and fire hazard. Make certain that all fuel lines are securely connected and free of leaks. Never refuel a hot or running engine. Avoid overfilling the fuel tank. Always use the correct type of fuel.

Never tamper with the governor to gain more power. The governor establishes safe operating limits that should not be exceeded. The maximum continuous operating speed for this pump is 1450 RPM.

PAGE A − 2 SAFETY

Page 8

SUPER T SERIES OM−05521

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 arrange 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

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 dimensions of this pump.

Figure 1. Pump Model T10A60S−6068T

PAGE B − 1INSTALLATION

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OM−05521 SUPER T SERIES

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested before shipment from the factory. Before installation, inspect the pump for damage which may have occurred during shipment. Check as follows:

a. Inspect the pump assembly for cracks, dents,

damaged threads, and other obvious damage.

b. Check for and tighten loose attaching hard-

ware. Since gaskets tend to shrink after drying, check for loose hardware at mating surfaces.

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 perform duties as instructed.

Table 1. Battery Specifications

Reserve

Capacity

@ 80

 F

(Minutes)

120

Amp/

Hr.

Rating

Approx.

Overall

Dims.

(Inches)

10.25L x

6.75W x

8.88H

Voltage

12 Volts

Cold Crank Amps

@ 0 F

850

Refer to the information accompanying the battery and/or electrolyte solution for activation and charging instructions.

Before installing the battery, clean the positive and negative cable connectors, and the battery terminals. Secure the battery by tightening the holddown brackets. The terminals and clamps may be coated with petroleum jelly to retard corrosion. Connect and tighten the positive cable first, then the negative cable.

POSITIONING PUMP

e. If the pump and engine have been stored for

more than 12 months, some of the components or lubricants may have exceeded their maximum shelf life. These must be inspected or replaced to ensure maximum pump service.

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

Battery Specifications And Installation

Unless otherwise specified on the pump order, the engine battery was not included with the unit. Refer to the following specifications when selecting a battery.

Lifting

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

The pump assembly can be seriously

PAGE B − 2 INSTALLATION

Page 10

SUPER T SERIES OM−05521

damaged if the cables or chains used to lift and move the unit are improperly wrapped around the pump.

Mounting

Locate the pump in an accessible place as close as practical to the liquid being pumped. Level mounting is essential for proper operation.

The pump may have to be supported or shimmed to provide for level operation or to eliminate vibration.

If the pump has been mounted on a moveable base, make certain the base is stationary by setting the brake and blocking the wheels before attempting to operate the pump.

To ensure sufficient lubrication and fuel supply to the engine, do not position the pump and engine more than 15 off horizontal for continuous operation. The pump and engine may be positioned up to 30 off horizontal for intermittent operation only; however, the engine manufacturer should be consulted for continuous operation at angles greater than 15.

ing piping couplings in suction lines is not recommended.

Line Configuration

Keep suction and discharge lines as straight as possible to minimize friction losses. Make minimum use of elbows and fittings, which substantially 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 exactly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or couplings.

Lines near the pump must be independently supported 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

Clearance

When positioning the pump, allow a minimum clearance of 18 inches (457,2 mm) in front of the back cover to permit removal of the cover and easy access to the pump interior.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by increased suction lift, discharge elevation, and friction losses. See the performance curve and notes on Page E-1 to be sure your overall application allows 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, reinforced type to prevent collapse under suction. Us-

Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges. If these gauges are desired for pumps that are not tapped, drill and tap the suction and discharge lines not less than 18 inches (457,2 mm) from the suction and discharge ports and install the lines. Installation closer to the pump may result in erratic readings.

SUCTION LINES

To avoid air pockets which could affect pump priming, 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-

PAGE B − 3INSTALLATION

Page 11

OM−05521 SUPER T SERIES

stalled with the flat part of the reducers uppermost to avoid creating air pockets. Valves are not normally used in suction lines, but if a valve is used, install it with the stem horizontal to avoid air pockets.

Strainers

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

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

This pump is designed to handle up to 3-inch (76,2 mm) diameter spherical solids.

sump at a distance equal to 1 1/2 times the diameter 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 suction inlet because the inflow will carry air down into the sump, and air entering the suction line will reduce pump efficiency.

If it is necessary to position inflow close to the suction inlet, install a baffle between the inflow and the suction inlet at a distance 1-1/2 times the diameter of the suction pipe. The baffle will allow entrained air to escape from the liquid before it is drawn into the suction inlet.

If two suction lines are installed in a single sump, the flow paths may interact, reducing the efficiency of one or both pumps. To avoid this, position the suction inlets so that they are separated by a distance equal to at least 3 times the diameter of the suction pipe.

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 airtight seal. Follow the sealant manufacturer’s recommendations 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

Suction Line Positioning

The depth of submergence of the suction line is critical to efficient pump operation. recommended minimum submergence vs. veloc-

ity.

Figure 2 shows

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 − 4 INSTALLATION

Page 12

SUPER T SERIES OM−05521

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

FLOAT SWITCHES

Installation

The standard pump is equipped with an auto-start control system, and can be conformed to start and stop as the liquid level in the wet well or sump rises and falls. The autostart unit employs either a single or double float switch system, where a bulb raises or lowers (floats) with the liquid level, thus activating an enclosed miniature switch. The floats are equipped with a socket type connector that plugs into a matching receptacle on the auto-start control box.

Standard floats are equipped with 50 feet (15,2 m) of cable.

When installing the floats, note the following:

a. Be sure to provide sufficient room in the wet

well or sump so that floats do not get obstructed or drawn into the suction line. If a flexible suction hose is used, it may be extended to lay along the bottom of the wet well or sump and the float can be attached to the hose

above the point where it bends along the bottom. Direct the suction line toward the flow, and the float(s) away from the flow. If a standpipe is available, attach the float switch cable to the standpipe in the sump at the approximate desired liquid level.

b. In a single float system, the cable can be teth-

ered to the suction line or standpipe approximately 6 inches (152 mm) above the float. This setting allows approximately 9 inches (229 mm) of liquid rise between pump start/ stop. The start/stop interval may be increased by extending the float end of the cable. The liquid level in the sump will increase approximately 8 inches (203 mm) between start/stop intervals for every 6 inches (152 mm) of cable increase.

c. If a double float switch system is used, posi-

tion the Start" float at the desired high water level in the sump, and the Stop" float at the desired low water level in the pump.

d. Refer to Figure 3 for additional float switch

data.

PAGE B − 5INSTALLATION

Page 13

OM−05521 SUPER T SERIES

ENGINE

CONTROL

BOX

(Emptying)

OFF

(Filling)

OPERATING

CABLE

TETHER

RANGE

(See Table Below)

POINT

OFF

(Emptying)

1.25" Pipe (Not Furnished)

(Filling)

Figure 3. Float Switch Data

OPTIONAL SUBMERSIBLE TRANSDUCER

This unit may be equipped with an optional Electronic Pressure Switch (EPS) that works in conjunction with a submersible transducer. The submersible transducer converts pressure to an electrical signal proportional to liquid level. This electrical signal is distributed to the digital display on the EPS through a scaling circuit which converts the electrical signal to feet of water".

3.0

(0.9)

2.5

(.76)

2.0

(0.6)

1.5

(.46)

1.0

(0.3)

0.5

(.15)

1.0

(0.3)

APPROXIMATE FREE CORD LENGTH IN FT. (M)

2.0

(0.6)

3.0

(0.9)

above the point where it bends along the bottom. See Figure B−4 for a typical installation.

c. The wet well or sump must be vented to atmo-

sphere.

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

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

4.0

(1.2)

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, suspend 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

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 cable; this will cause leakage and void

warranty.

PAGE B − 6 INSTALLATION

Page 14

SUPER T SERIES OM−05521

SUCTION

DISCHARGE

LINE

SIGNAL CABLE

(ATTACH TO

SUCTION LINE)

SUBMERSIBLE

TRANSDUCER

(DOWNSTREAM

FROM SUCTION)

SUCTION

STRAINER

Figure 4. 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 siphoning action causing damage to the pump could result.

Valves

If a throttling valve is desired in the discharge line, use a valve as large as the largest pipe to minimize friction losses. Never install a throttling valve in a suction line.

With high discharge heads, it is recommended that a throttling valve and a system check valve be installed in the discharge line to protect the pump from excessive shock pressure and reverse rotation when it is stopped.

FLOW

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

Bypass Lines

Self-priming pumps are not air compressors. During the priming cycle, air from the suction line must be vented to atmosphere on the discharge side. If the discharge line is open, this air will be vented through the discharge. However, if a check valve has been installed in the discharge line, the discharge side of the pump must be opened to atmospheric pressure through a bypass line installed between the pump discharge and the check valve. A self-priming centrifugal pump will not prime if there is sufficient static liquid head to hold the discharge check valve closed.

NOTE

The bypass line should be sized so that it does not

PAGE B − 7INSTALLATION

Page 15

OM−05521 SUPER T SERIES

affect pump discharge capacity; however, the bypass line should be at least 1 inch (25,4 mm) in diameter to minimize the chance of plugging.

In low discharge head applications (less than 30 feet (9,1 m)), it is recommended that the bypass line be run back to the wet well, and located 6 inches below the water level or cut-off point of the low level pump. In some installations, this bypass outline may be terminated with a six-to-eight foot (1,8 to 2,4 m) length of 1-1/4 inch (31,8 mm) I.D. smooth-bore hose; air and liquid vented during the priming process will then agitate the hose and break up any solids, grease, or other substances likely to cause clogging.

A bypass line that is returned to a wet well must be secured against being drawn into the pump suction inlet.

It is also recommended that pipe unions be installed at each 90 elbow in a bypass line to ease disassembly and maintenance.

In high discharge head applications (more than 30 feet (9,1 m), an excessive amount of liquid may be bypassed and forced back to the wet well under the full working pressure of the pump; this will reduce overall pumping efficiency. Therefore, it is

recommended that a Gorman-Rupp Automatic Air Release Valve be installed in the bypass line.

prevent flooding during service of an automatic air release valve in a below-ground lift station), if a manual shut-off valve is installed anywhere in a bypass line, it must be a full-opening, ball-type valve to pre- vent plugging by solids.

A manual shut-off valve should not be installed in any bypass line. A manual shut-off valve may inadvertently be left closed during operation. A pump which has lost prime may continue to operate without reaching prime, causing dangerous overheating and possible explosive rupture of the pump casing. Personnel could be severely injured.

Allow an over-heated pump to cool before servicing. Do not remove plates, covers, gauges, or fittings from an overheated pump. Liquid within the pump can reach boiling temperatures, and vapor pressure within the pump can cause parts being disengaged to be ejected with great force. After the pump cools, drain the liquid from the pump by removing the casing drain plug. Use caution when removing the plug to prevent injury to personnel from hot liquid.

AUTOMATIC AIR RELEASE VALVE

Gorman-Rupp Automatic Air Release Valves are reliable, and require minimum maintenance. See Automatic Air Release Valves in this section for installation and theory of operation of the Automatic Air Release Valve. Consult your GormanRupp distributor, or contact the Gorman-Rupp Company for selection of an Automatic Air Release Valve to fit your application.

Except in certain specific applications (to

PAGE B − 8 INSTALLATION

When properly installed and correctly adjusted to the specific hydraulic operating conditions of the application, the Gorman-Rupp Automatic Air Release Valve will permit air to escape through the bypass line, and then close automatically when the pump is fully primed and pumping at full capacity.

Theory of Operation

Figures 5 and 6 show a cross-sectional view of the Automatic Air Release Valve, and a corresponding description of operation.

Page 16

SUPER T SERIES OM−05521

Liters) per minute) will occur when the valve is fully closed. Be sure the bypass line is directed back to the wet well or tank to prevent hazardous spills.

When the pump shuts down, the spring returns the diaphragm to its original position. Any solids that may have accumulated in the diaphragm chamber settle to the bottom and are flushed out during the next priming cycle.

Figure 5. Valve in Open Position

During the priming cycle, air from the pump casing flows through the bypass line, and passes through the Air Release Valve to the wet well (Figure 5).

Figure 6. Valve in Closed Position

When the pump is fully primed, pressure resulting from flow against the valve diaphragm compresses the spring and closes the valve (Figure 6). The valve will remain closed, reducing the bypass of liquid to 1 to 5 gallons per minute, until the pump loses its prime or stops.

NOTE

The valve will remain open if the pump does not reach its designed capacity or head. Valve closing pressure is dependent upon the discharge head of the pump at full capacity. The range of the valve closing pressure is established by the tension rate of the spring as ordered from the factory. Valve closing pressure can be further adjusted to the exact system requirements by moving the spring retaining pin up or down the plunger rod to increase or decrease tension on the spring. Contact your Gorman-Rupp distributor or the Gorman-Rupp Company for information about an Automatic Air Release Valve for your specific application.

Air Release Valve Installation

The Automatic Air Release Valve must be independently mounted in a horizontal position and connected to the discharge line of the self-priming centrifugal pump (see Figure 7).

Some leakage (1 to 5 gallons (3,8 to 18,9

NOTE

If the Air Release Valve is to be installed on a staged pump application, contact the factory for specific installation instructions.

PAGE B − 9INSTALLATION

Page 17

OM−05521 SUPER T SERIES

INSTALL AIR RELEASE VALVE IN HORIZONTAL POSITION

90 LONG

RADIUS ELBOW

BLEED LINE 1" (25,4 MM) DIA. MIN. (CUSTOMER FURNISHED) EXTEND 6" (152 MM) BELOW PUMP OFF LIQUID LEVEL

SUPPORT BRACKET

CLEAN-OUT COVER

SUCTION LINE

WET WELL OR SUMP

DISCHARGE PIPE

DISCHARGE CHECK VALVE

PUMP DISCHARGE

SELF-PRIMING CENTRIFUGAL

PUMP

Figure 7. Typical Automatic Air Release Valve Installation

The valve inlet line must be installed between the pump discharge port and the non-pressurized side of the discharge check valve. The valve inlet is at the large end of the valve body, and is provided with standard 1 inch NPT pipe threads.

The valve outlet is located at the opposite end of the valve, and is also equipped with standard 1 inch NPT pipe threads. The outlet should be connected to a bleed line which slopes back to the wet well or sump. The bleed line must be the same size as the inlet piping, or larger. If piping is used for the bleed line, avoid the use of elbows whenever possible.

NOTE

It is recommended that each Air Release Valve be

fitted with an independent bleeder line directed back to the wet well. If multiple Air Release Valves are installed in a system, they must be fitted with in- dependent bleeder lines; never use a common manifold pipe. Contact your Gorman-Rupp distributor or the Gorman-Rupp Company for information about installation of an Automatic Air Release Valve for your specific application.

ALIGNMENT

The alignment of the pump and the engine is critical for trouble-free mechanical operation. See Section E, Securing Intermediate And Drive Assem-

bly To Engine for detailed information.

PAGE B − 10 INSTALLATION

Page 18

SUPER T SERIES

OM−05521

OPERATION − SECTION C

Review all SAFETY information in Section A.

Follow the instructions on all tags, labels and decals attached to the pump.

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

cated (see LUBRICATION in MAINTENANCE AND REPAIR).

This pump is self-priming, but the pump should never be operated unless there is liquid in the pump casing.

Never operate this pump unless there is liquid in the pump casing. The pump will not prime when dry. Extended operation of a dry pump will destroy the seal assembly.

Add liquid to the pump casing when:

1. The pump is being put into service for the first time.

2. The pump has not been used for a considerable length of time.

3. The liquid in the pump casing has evaporated.

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-

Never tamper with the governor to gain more power. The governor establishes safe operating limits that should not be exceeded. The maximum continuous operating speed for this pump is 1450 RPM.

PRIMING

Install the pump and piping as described in INSTALLATION. Make sure that the piping connec-

tions are tight, and that the pump is securely mounted. Check that the pump is properly lubri-

OPERATION PAGE C − 1

ing piping is securely installed. Otherwise, liquid in the pump forced out under pressure could cause injury to personnel.

To fill the pump, remove the pump casing fill cover or fill plug in the top of the casing, and add clean liquid until the casing is filled. Replace the fill cover or fill plug before operating the pump.

NOTE

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

Page 19

OM−05521 SUPER T SERIES

STARTING

This pump is equipped with an automatic starting system, and is subject to automatic restart. Keep hands and clothing away from the unit to prevent injury during automatic operation. Disconnect the positive battery cable before performing any maintenance. Failure to do so may result in serious personal injury.

Consult the operations manual furnished with the engine.

Manual Starting

On initial start-up, set the engine speed at the halfthrottle position. Turn the keyswitch on the control panel to the RUN" and press ENTER" button on the engine control panel.

After the engine starts and the unit is fully primed, adjust the engine RPM until the desired flow rate is achieved.

When the liquid level in the sump or wet well is sufficiently pumped down, the unit will automatically shut down.

NOTE

If the keyswitch is moved to the OFF" position while in the auto-start mode, the engine will stop. However, the auto-start process will continue as soon as the keyswitch is moved back to the AUTO" position. To cancel the auto-start process, turn the keyswitch to the OFF" positon for 8 seconds..

The control panel is equipped with high oil temperature, low oil pressure, and start failure (3 attempts) safety shutdowns. If any of these problems occur, the control panel will indicate the fault. When the problem is corrected, turn the keyswitch to the OFF" position to reset the control.

OPTIONAL EPS CONTROL

Features

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

 3 Output Relays: 1. A output, delayed

2. B output, no delay

3. Horn output, no delay

Pump speed and operating condition points must be within the continuous performance range shown on the curve on page E-1.

Automatic Starting

Install the float(s) or submersible transducer as described in INSTALLATION, Section B.

Follow the procedures outlined for manual starting and throttle adjustment, then turn the key to the AUTO" position.

In the auto-start mode, when the liquid level in the sump or wet well rises and activates the float(s), an audible alarm will sound for approximately 8 seconds before the unit starts.

 3 Inputs: 1. Horn silence

2, Pressure transducer

3. Low Temp Thermostat

 LCD screen with backlight for function moni-

toring

 Bright LEDs to indicate output status and dis-

play modes

 Three switches on front panel for all adjust-

ments

 Battery level indicator on LCD screen to alert

operator of low battery condition

 Microprocessor Control

 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,

OPERATIONPAGE C − 2

Page 20

SUPER T SERIES

OM−05521

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.

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 contacts.

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

used to decrease the smallest digit by bumping" the switch, or to continuously decrease the digit by pressing and holding 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 holding 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 adjustment, refer to the following instructions.

EPS Functions

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 output contacts will close in approximately 1 second 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 second.

NOTE

LED’s and all segments of the display are lighted 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

OPERATION PAGE C − 3

When the pressure decreases to a level equal to or less than the A.of" setpoint, A output contacts will open in approximately one second.

If an optional Low Temperature Thermostat is connected to the unit and the thermostat contacts close, the unit displays lo tpt" on the display. In approximately 1 second, the Horn output contacts close, then after the Hrn dLy" time, A output contacts close. A output contacts will remain closed as long as Low Temperature 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.

Page 21

OM−05521 SUPER T SERIES

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

tpt" unless some other information. Level is not viewable until the Low Temperature Thermostat contacts open.

The user may wish to check Setpoints Off/On

delay times. Bumping" the switch will display all of the information desired.

switch is pressed to display

NOTE

One second delays in contact opening/closing is a result of time sampling of the pressure signal to filter false signals that could cause nuisance" tripping of the contacts.

NOTE

If the Hrn dLy" is pre-set from the factory through the engine control panel, therefore this function is not utilized through the EPS.

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.

Press to accept the entry and advance to Calibrate Span".

Span Adjustment

Use caution to ensure that the --.on" setpoint (i.e. A.on") is not adjusted to a level less than the corresponding --.of" setpoint (i.e. A.of"). Improper adjustment of the off/on setpoints will render the unit nonfunctional, resulting in flooding.

EPS Calibration

NOTE

Zero offset and span adjustments are only necessary to calibrate a new unit, or when replacing the transducer. Once calibrated, ON" and OFF" setpoints 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 setpoints 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,

Span adjustment calibrates the unit to a known water 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 display equals the actual known depth of the transducer.

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".

OPERATIONPAGE C − 4

Page 22

SUPER T SERIES

OM−05521

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.

OPERATION

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

Lines With a Bypass

slowly and guard against excessive shock pressure which could damage pipe ends, gaskets, sprinkler heads, and any other fixtures connected to the line. When the discharge line is completely filled, adjust the throttling valve to the required flow rate.

Leakage

No leakage should be visible at pump mating surfaces, or at pump connections or fittings. Keep all line connections and fittings tight to maintain maximum pump efficiency.

Liquid Temperature And Overheating

The maximum liquid temperature for this pump is 160 F (71 C). Do not apply it at a higher operating temperature.

Overheating can occur if operated with the valves in the suction or discharge lines closed. Operating against closed valves could bring the liquid to a boil, build pressure, and cause the pump to rupture or explode. If overheating occurs, stop the pump and allow it to cool before servicing it. Refill

the pump casing with cool liquid.

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.

After the pump has been primed, partially close the discharge line throttling valve in order to fill the line

As a safeguard against rupture or explosion due to heat, this pump is equipped with a pressure relief valve which will open if vapor pressure within the pump casing reaches a critical point. If over-heating does occur, stop the pump immediately and allow it to cool before servicing it. Approach any over-heated pump cautiously. It is recommended that the pressure relief valve assembly be

OPERATION PAGE C − 5

Page 23

OM−05521 SUPER T SERIES

replaced at each overhaul, or any time the pump casing over-heats and activates the valve. Never replace this valve with a substitute which has not been specified or provided by the Gorman-Rupp Company.

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

Strainer Check

After stopping the pump, close and lock the control

If a suction strainer has been shipped with the pump or installed by the user, check the strainer regularly, and clean it as necessary. The strainer should also be checked if pump flow rate begins to drop. If a vacuum suction gauge has been installed, monitor and record the readings regularly to detect strainer blockage.

Never introduce air or steam pressure into the pump casing or piping to remove a blockage. This could result in personal injury or damage to the equipment. If backflushing is absolutely necessary, liquid pressure must be limited to 50% of the maximum permissible operating pressure shown on the pump performance curve.

Pump Vacuum Check

panel cover, or disconnect the positive battery cable to ensure that the pump will remain inoperative.

Automatic Stopping

In the automatic mode, the pump will stop when the liquid in the wet well or sump lowers and activates the Off" float switch(s) or Off" setpoint stored in the optional EPS. The pump will restart automatically when the liquid rises and activates the On" float switch(s) or On" setpoint stored in the optional EPS.

Safety Shutdown System

The unit is equipped with a safety system to automatically shut down the engine under certain conditions. The engine will automatically shut down:

With the pump inoperative, install a vacuum gauge in the system, using pipe dope on the threads. Block the suction line and start the pump. At operating speed the pump should pull a vacuum of 20 inches (508 mm) or more of mercury. If it does not, check for air leaks in the seal, gasket, or discharge valve.

Open the suction line, and read the vacuum gauge with the pump primed and at operation speed. Shut off the pump. The vacuum gauge reading will immediately drop proportionate to static suction lift, and should then stabilize. If the vacuum reading falls off rapidly after stabilization, an air leak exists. Before checking for the source of the leak, check the point of installation of the vacuum gauge.

STOPPING

Manual Stopping

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

1. If the engine exceeds its safe operating temperature.

2. If the engine oil pressure drops below design limits.

3. If the engine fails to start within a pre-set period of time.

4. If the engine speed exceeds the safe operating range.

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

Should any of the safety features cause the engine to shut down, the cause must be determined and corrected before putting the unit back into service. The engine will not restart until the keyswitch has been returned to the ‘OFF’ position for at least 10 seconds.

All safety shutdown features are pre-set at the factory for optimum performance and safety; do not attempt to adjust these settings.

OPERATIONPAGE C − 6

Page 24

SUPER T SERIES

Never disconnect any of the safety shutdown features; this will void the warranty and could result in serious damage to the unit and/or injury to personnel. Safety 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 additional information.

OPERATION IN EXTREME HEAT

The safety shutdown system will automatically stop the unit if engine operating temperature exceeds design limits. If engine over-temperature shutdown occurs, allow the unit to cool before restarting.

If engine overheating continues, check the engine lubricant level and viscosity. Consult the engine operation manual for the recommended lubricant for operation in extreme heat.

If the unit is equipped with the optional auto-start control, the float(s) may need to be adjusted to allow shorter run and longer cooling periods, if possible.

OM−05521

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 rotating parts. If the pump will be idle for more than a few hours, or if it has been pumping liquids containing 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 preventing 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.

BEARING TEMPERATURE CHECK

Bearings normally run at higher than ambient temperatures because of heat generated by friction. Temperatures up to 160F (71C) are considered normal for bearings, and they can operate safely to at least 180F (82C).

Checking bearing temperatures by hand is inaccurate. Bearing temperatures can be measured accurately 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

This pump is equipped with an automatic starting system, and is subject to automatic restart. Keep hands and cloth-

lubricant is of the proper viscosity and at the correct level (see LUBRICATION in Section E). Bearing overheating can also be caused by shaft misalignment and/or excessive vibration.

ing away from the unit to prevent injury during automatic operation. Disconnect the positive battery cable before performing any maintenance. Failure to do so may result in serious personal injury.

OPERATION PAGE C − 7

When pumps are first started, the bearings may seem to run at temperatures above normal. Continued operation should bring the temperatures down to normal levels.

Page 25

TROUBLESHOOTING − SECTION D

OM−05521SUPER T SERIES

Review all SAFETY information in Section A.

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

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.

Table 1. Trouble Shooting Chart

5. Close the suction and discharge valves.

6. Vent the pump slowly and cautiously.

7. Drain the pump.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO PRIME Not enough liquid in casing.

Suction check valve contaminated or damaged.

Air leak in suction line.

Lining of suction hose collapsed.

Leaking or worn seal or pump gasket.

Suction lift or discharge head too high.

Strainer clogged.

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE

Air leak in suction line.

Lining of suction hose collapsed.

Add liquid to casing. See PRIMING.

Clean or replace check valve.

Correct leak.

Replace suction hose.

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

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

Check strainer and clean if necessary.

Correct leak.

Replace suction hose.

TROUBLESHOOTING PAGE D − 1

Page 26

OM−05521 SUPER T SERIES

Table 1. Trouble Shooting Chart (cont.)

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

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

Leaking or worn seal or pump gasket.

Strainer clogged.

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

Check strainer and clean if necessary.

PUMP REQUIRES TOO MUCH POWER

PUMP CLOGS FREQUENTLY

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

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.

Discharge flow too slow.

Check installation and correct submergence as needed.

Replace worn or damaged parts. Check that impeller is properly centered and rotates freely.

Free impeller of debris.

Install bypass line.

Measure lift w/vacuum gauge. Reduce lift and/or friction losses in suction line.

Check engine output; consult engine 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).

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

Suction check valve or foot valve clogged or binding.

Liquid solution too thick.

EXCESSIVE NOISE Cavitation in pump.

Pumping entrained air.

Pump or drive not securely mounted.

Impeller clogged or damaged.

Clean valve.

Dilute if possible.

Reduce suction lift and/or friction losses in suction line. Record vacuum 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.

TROUBLESHOOTINGPAGE D − 2

Page 27

Table 1. Trouble Shooting Chart (cont.)

OM−05521SUPER T SERIES

TROUBLE

BEARINGS RUN TOO HOT

POSSIBLE CAUSE PROBABLE REMEDY

Bearing temperature is high, but within limits.

Low or incorrect lubricant.

Suction and discharge lines not properly supported.

Drive misaligned.

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 preventive maintenance schedule will help assure trouble-free performance and long life from your Gorman-Rupp pump. For specific questions concerning your application, contact your GormanRupp 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

Check bearing temperature regularly to monitor any increase.

Check for proper type and level of lubricant.

Check piping installation for proper support.

Align drive properly.

equipped) between regularly scheduled inspections can indicate problems that can be corrected before system damage or catastrophic failure occurs. 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 inspections should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently.

TROUBLESHOOTING PAGE D − 3

Page 28

OM−05521 SUPER T SERIES

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.

TROUBLESHOOTINGPAGE D − 4

Page 29

SUPER T SERIES OM−05521

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 T10A60S−6068T

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 different due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.

Contact the Gorman-Rupp Company to verify performance 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 performance range shown on the curve.

Page 30

PARTS PAGE

SUPER T SERIESOM−05521

SECTION DRAWING

Figure 1. Pump Model T10A60S−6068T

MAINTENANCE & REPAIRPAGE E − 2

Page 31

SUPER T SERIES OM−05521

PARTS LIST

Pump Model T10A60S−6068T

(From S/N 1268074 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 NO.

1 PUMP END ASSY T10A60S−(SAE 3/11.5) −−− 1 2 POWER UNIT KIT 46143−018 −−− 1 3 1000 RPM MIN DECAL 38816−169 −−− 1 4 G-R DECAL GR−06 −−− 4 5 PUMP MOUNTING KIT 48157−005 −−− 1

OPTIONAL:

INDICATES PARTS RECOMMENDED FOR STOCK

PART NAME

−SUCTION STAND BRACKET 34455−007 15080 1

−SUCTION BRACE ASSY 41818−653 24150 1

12V BATTERY 29331−515 −−− 1 WHEEL KIT GRP30−257 −−− 1

PART NUMBER

MAT’L CODE

QTY

MAINTENANCE & REPAIR PAGE E − 3

Page 32

PARTS PAGE

SUPER T SERIESOM−05521

SECTION DRAWING

Figure 2. 46143−018 John Deere Power Unit Kit

MAINTENANCE & REPAIRPAGE E − 4

Page 33

SUPER T SERIES OM−05521

PARTS LIST

46143−018 John Deere Power Unit Kit

ITEM NO.

1 JOHN DEERE 6068T ENGINE 29224−231 −−− 1 2 BASE/FUEL TANK 41553−008 24150 1 3 LIFTING BAIL KIT 48274−802 −−− 1 4 MUFFLER GUARD ASSY 42331−066 −−− 1 5 MALE CONNECTOR 26351−131 −−− 1 6 CONNECTOR S1447 −−− 2 7 HOSE ASSEMBLY 46341−789 −−− 1 8 BATTERY BOX KIT 42432−003 −−− 1

9 NEG. BATTERY CABLE 47311−215 −−− 1 10 OIL DRAIN ASSY 46342−031 −−− 1 11 POS. BATTERY CABLE 47311−214 −−− 1 12 FUEL PICKUP 29332−145 −−− 2 13 FUEL GAUGE 29332−135 −−− 1 14 HOSE BARB FITTING 26523−386 −−− 2 15 HOSE 11308G −−− 1 16 HOSE CLAMP 26518−641 −−− 2 17 HEX HD CAPSCREW B1007 15991 6 18 HEX NUT D10 15991 6 19 LOCKWASHER J10 15991 6 20 FLAT WASHER K10 15991 1

PART NAME

PART NUMBER

MAT’L CODE

QTY

NOT SHOWN:

FLOAT SWITCH KIT 48312−980 −−− 1 ENGINE STARTUP TAG 38816−269 −−− 1 INSTRUCTION DECAL 38818−144 −−− 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E − 5

Page 34

SECTION DRAWING

TOP VIEW

SUPER T SERIESOM−05521

Figure 3. T10A60S−(SAE 3/11.5) Pump End Assembly

MAINTENANCE & REPAIRPAGE E − 6

Page 35

SUPER T SERIES OM−05521

PARTS LIST

T10A60S−(SAE 3/11.5) Pump End Assembly

ITEM

PART NAME PART

NO.

NUMBER

MAT’L CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

MAT’L CODE

QTY

1 PUMP CASING 38222−701 10010 1 2 REPAIR ROTATING ASSY 44163−359 −−− 1 3 COVER PLATE GASKET 38688−008 20000 1

4 COVER PLATE ASSY 48271−018 −−− 1 5 CLAMP BAR 38111−004 11010 2 6 MACHINE BOLT A1014 15991 4 7 CLAMP BAR SCREW 31912−009 15000 2 8 PRIMING STICKER 6588AH −−− 1

9 PIPE PLUG P04 15079 1 10 DISCHARGE STICKER 6588BJ −−− 1 11 HEX HD CAPSCREW B1414 15991 12 12 HEX NUT D14 15991 12

13 DISCH ELBOW GASKET 2751GA 19370 1 14 NAME PLATE 38818−040 13990 1 15 DRIVE SCREW BM#04−03 17000 4 16 PUMP CASING RING 31281−016 15990 1 17 HEX HD CAPSCREW B0806 15991 6 18 LOCKWASHER J08 15991 6 19 HEX HD CAPSCREW B0805 15991 6 20 LOCKWASHER J08 15991 6

21 BEARING HSG O-RING S1914 −−− 1 22 ROT ASSY ADJ SHIM SET 48261−056 −−− 6 23 SEAL PLATE O-RING S1914 −−− 1 24 PIPE PLUG P08 15079 1 25 SUCTION HEAD GASKET 38682−811 2000 1 26 CASING DRAIN PLUG P24 10009 1 27 HEX HD CAPSCREW B1408 15991 2 28 LOCKWASHER J14 15991 2 29 HEX HD CAPSCREW B1207 15991 4 30 LOCKWASHER J12 15991 4 31 WEAR PLATE 38691−826 11010 1 32 SUCTION HEAD 38246−609 10010 1 33 PIPE PLUG P20 10009 1 34 REDUCING PIPE BUSHINGAP2008 11999 1

35 PRESSURE RELIEF VALVE 26662−005 −−− 1 36 VICTAULIC CLAMP 25552−213 −−− 1 37 HEX HD CAPSCREW B1414 15991 10 38 HEX NUT D14 15991 10

39 HEX HD CAPSCREW B1414 15991 12 40 HEX NUT D14 15991 12 41 SUCTION FLANGE 2751 10010 1

INDICATES PARTS RECOMMENDED FOR STOCK

 VITON IS A REGISTERED TRADEMARK OF THE DUPONT CORP.

42 SUCTION GASKET 2751GA 19370 1 43 SUCTION STICKER 6588AG −−− 1 44 45 SUCTION ELBOW 25512−077 −−− 1 45 HEX HD CAPSCREW B1410 15991 2 46 SUCT ELBOW GASKET 2751GA 19370 1 47 CHECK VALVE ASSY 46421−037 −−− 1 48 −HEX HD CAPSCREW B0606 17090 2 49 −PIPE PLUG P08 15079 1 50 −T TYPE LOCKWASHER AK06 17000 2 51 −FLAT WASHER KB08 17090 2 52 −PIVOT CAP 38141−003 11060 2 53 −CHK VALVE BODY 38341−805 10010 1

54 −FLAP VALVE 46411−082 24010 1 55 DISCHARGE FLANGE 2751 10010 1 56 DISCH FLG GASKET 2751GA 19370 1 57 HEX HD CAPSCREW B1414 15991 12 58 HEX NUT D14 15991 12 59 FLANGED ELBOW S5016 −−− 1 60 CLAMP BAR 38111−004 11010 1 61 MACHINE BOLT A1014 15991 2 62 CLAMP BAR SCREW 31912−009 15000 1 63 FILL COVER PLATE ASSY 42111−344 −−− 1 64 −COVER PLATE NOT AVAILABLE 1 65 −WARNING PLATE 38816−097 13990 1 66 −DRIVE SCREW BM#04−03 17000 2 67 −FILL COVER GASKET 50G 19210 1

NOT SHOWN:

STRAINER 46641−011 24150 1 WARNING DECAL 2613FE −−− 1 WARNING DECAL 38816−302 −−− 1 DRIVE ASSEMBLY 44162−172 −−− 1 ROTATION DECAL 2613M −−− 1 INSTRUCTION TAG 38817−023 −−− 1 SUPER T" DECAL 38812−089 −−− 1 INSTRUCTION TAG 38817−025 −−− 1 G-R DECAL GR−06 −−− 1 LUBE DECAL 38817−084 −−− 1

OPTIONAL:

AIR RELEASE VALVES:

−10# COMP SPRING GRP33−07A −−− 1

−25# COMP SPRING GRP33−07 −−− 1

−80# COMP SPRING GRP33−07B −−− 1

MAINTENANCE & REPAIR PAGE E − 7

Page 36

SECTION DRAWING

SUPER T SERIESOM−05521

DRIVE END VIEW

Figure 4. 44163−359 Repair Rotating Assembly

MAINTENANCE & REPAIRPAGE E − 8

Page 37

SUPER T SERIES OM−05521

PARTS LIST

44163−359 Repair Rotating Assembly

ITEM NO.

1 IMPELLER 38615−072 11010 1 2 CARTRIDGE SEAL ASSEMBLY 46513−154 −−− 1 3 SEAL PLATE 38272−423 10010 1 4 5 BEARING HOUSING O-RING S1874 −−− 1 6 HEX HD CAPSCREW 21632−945 −−− 4 7 LOCKWASHER J08 15991 4 8 BALL BEARING 23421−461 −−− 1

9 BEARING HOUSING 38251−515 10000 1 10 VENTED PLUG 4823A 15079 1 11 AIR VENT S1530 −−− 1 12 REDUCING PIPE BUSHING AP0802 15079 1 13 DRIVE FLANGE OIL SEAL S1917 −−− 1 14 DRIVE FLANGE 38545−007 11010 1 15 HEX HD CAPSCREW 21632−936 −−− 6 16 LOCKWASHER J06 15991 6 17 18 IMPELLER SHAFT 38515−590 1706H 1 19 THRUST WASHER 31134−113 15210 1 20 RETAINING RING S215 −−− 1 21 22 DRIVE FLANGE O-RING S333 −−− 1 23 INBOARD BEARING HOUSING OIL SEAL S1917 −−− 1 24 OUTBOARD BEARING HOUSING OIL SEAL S1917 −−− 1 25 LOCKWASHER J06 15991 4 26 HEX NUT D06 15991 4 27 WEAR PLATE ASSY 46451−722 24150 1 28 SEAL CAVITY SIGHT GUAGE S1471 −−− 1 29 BEARING HOUSING SIGHT GUAGE S1471 −−− 1 30 PIPE PLUG P04 15079 1

30A SEAL CAVITY DRAIN PLUG P04 15079 1

31 SOCKET HD PIPE PLUG PC04 15079 1 32 BEARING CAVITY DRAIN PLUG P12 15079 1 33 34 SHAFT SLEEVE O-RING 25154−026 −−− 1 35 INTERMEDIATE GUARD 42381−509 24152 2 36 HEX HD CAPSCREW B0603 15991 4 37 LOCKWASHER J06 15991 4 38 SOCKET HEAD PIPE PLUG PC20 10009 1 39 SEAL PLATE O-RING S1914 −−− 1 40 BEARING HOUSING O-RING S1914 −−− 1 41 SHIPPING PLUG 11495B 15079 2 42 DRIVE SCREW BM#04−03 17000 2 43 SERIAL NUMBER PLATE 2613GG 13990 1

NOT SHOWN:

PART NAME

SEAL PLATE GASKET 38684−302 19140 1

SHAFT KEY N0612 15990 1

BALL BEARING 23422−412 −−− 1

IMPELLER ADJUSTING SHIM SET 5091 17090 REF

ROTATING ASSY ADJUSTMENT SHIM SET 48261−056 −−− 1 ROTATION DECAL 2613M −−− 1 INSTRUCTION TAG 6588U −−− 1

PART NUMBER

MAT’L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E − 9

Page 38

SECTION DRAWING

SUPER T SERIESOM−05521

Figure 5. 44162−172 Drive Assembly

PARTS LIST

ITEM NO.

1 COUPLING KIT 48112−016 −−− 1 2 −BUSHING 24131−497 −−− 1 3 −COUPLING ASSEMBLY 24391−102 −−− 1 4 −LOCKWASHER 21171−536 −−− 8

SAE APPLICATION

5 SOCKET HD CAPSCREW BD0606 15991 8 6 HEX HD CAPSCREW B0605 15991 12 7 LOCKWASHER J06 15991 12

METRIC APPLICATION

5 SOCKET HD CAPSCREW 22644−218 −−− 8 6 HEX HD CAPSCREW 22645−164 −−− 12 7 LOCKWASHER 21171−511 −−− 12

PART NAME

PART NUMBER

MAT’L CODE

MAINTENANCE & REPAIRPAGE E − 10

QTY

Page 39

SUPER T SERIES

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Review all SAFETY information in Section A.

Follow the instructions on all tags, label and decals attached to the pump.

This pump requires little service due to its rugged, minimum-maintenance design. However, if it becomes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the sectional views (see Figures 1, 2, 3, 4 and 5) and the accompanying parts lists.

This manual will alert personnel to known procedures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel. However, this manual cannot possibly anticipate and provide detailed 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 establishing that neither personal safety nor pump integrity are compromised by such practices.

OM−05521

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

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 cautiously.

7. Drain the pump.

Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or damage to equipment.

Cleanout Access And Suction Check Valve Removal

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 power source must be disconnected. The following 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.

For engine disassembly and repair, consult the literature supplied with the engine, or contact your local John Deere engine representative.

MAINTENANCE & REPAIR PAGE E − 11

(Figure 3)

Before attempting to service the pump, remove the casing drain plug (26) and drain the pump. Clean and reinstall the drain plug.

For cleanout access, loosen the clamp screws (7) and clamp bars (5) securing the cleanout cover (4) to the suction head (32).

To remove the check valve assembly, reach through the cleanout opening and remove the hardware (48, 50 and 51) securing the check valve (54) to the valve body (53) and suction head.

NOTE

An alternate method of removing the check valve assembly is to remove the hardware securing the

Page 40

OM−05521 SUPER T SERIES

valve body to the suction piping. Disconnect the shoulder-type coupling (36) and separate the valve body and check valve from the suction head. Separate the check valve from the valve body as described above.

Make certain the chain or cable is positioned so that the pump will not be damaged, and so that the load will be balanced.

Replace the cleanout cover gasket (3) before reinstalling the cover.

Suction Head And Wear Plate Removal

(Figure 3)

To remove the suction head, support it with a suitable hoist and sling and remove the hardware (27, 28, 29 and 30) securing it to the pump casing. Remove the suction head gasket (25).

If the wear plate (31) does not slide easily from the casing bore, install capscrews (1/2-13 UNC X 1 inch long, not supplied) in the tapped holes in the suction head and use a suitable puller to remove the wear plate from the pump casing.

(Figure 5)

Disengage the hardware (6 and 7) securing the drive flange (14, Figure 2) to the engine bellhousing, and remove the guards (35, Figure 4). Separate the pump end and drive assembly from the engine by pulling the pump end straight away from the engine.

As the assemblies separate, the flexible portion of the coupling assembly (3) will remain on the shaft. To remove the coupling from the shaft, unscrew the two allen head setscrews from the bushing (2). 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.

NOTE

An alternate method of removing the wear plate is to position a wood or soft metal wedge between the impeller vanes and the wear plate, and tap the wedge with a hammer. Turn the impeller every 45_, repeating the process until the wear plate is walked" out of the pump casing.

If the pump is to be completely disassembled, the wear plate can also be easily removed after removing the rotating assembly (2). Use a suitably sized piece of wood to tap the wear plate out of the casing through the rotating assembly opening.

Separating Pump And Drive Assembly From Engine

(Figure 3)

Further disassembly requires separating the pump end and drive assembly from the engine. Remove the discharge elbow and gasket (10 and 13) and fill cover and gasket (64 and 67) from the pump casing. Loop a suitable chain or cable through the discharge port and back out the priming port and attach it to a hoist.

It is not necessary to remove the outer ring of the coupling from the engine flywheel unless the coupling must be replaced. To remove the ring, disengage the hardware (4 and 5) securing it to the flywheel.

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.

Loosening Impeller

(Figure 4)

Before attempting to loosen the impeller, remove the seal cavity drain plug (30A) and drain the lubricant. 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 suction head (32, 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

MAINTENANCE & REPAIRPAGE E − 12

Page 41

SUPER T SERIES

OM−05521

shaft (18) 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 counterclockwise direction (when facing the drive end of the shaft). Use caution not to damage the shaft or keyway. When the impeller breaks loose, remove the lathe dog, key and wood block.

NOTE

Do not remove the impeller until the rotating assembly has been removed from the pump casing.

Turn

Counterclockwise

Lathe Dog Arm

the inner hardware (19 and 20) and shim sets (22). Separate the casing ring from the pump casing. Tie and tag the shim sets for ease of reassembly.

Install hooks in the mounting holes in the drive flange (14, Figure 4) and attach the hooks to a three-legged sling and suitable lifting device. Carefully lift the rotating assembly out of the pump casing far enough to reach inside the casing and remove the seal plate O-ring (23). With the O-ring removed, the rotating assembly can be easily removed from the casing using the lifting device.

Move the rotating assembly to a suitable work area for further disassembly.

Impeller And Wear Plate Removal

(Figure 4)

Unscrew the impeller from the shaft in a counterclockwise direction (when facing the impeller). Use caution when unscrewing the impeller; tension on the shaft seal spring will be released as the impeller is removed.

V" Notch

Heavy

Bar Stock

Figure 6. Loosening Impeller

Rotating Assembly Removal

(Figure 3)

To ease removal of the rotating assembly, it is recommended that the pump be positioned on supporting blocks with the suction head opening down and the drive flange (14, Figure 4) up.

Remove the outer hardware (17 and 18) from the casing ring (16). Install three of the outer capscrews in the jacking holes in the casing ring, and use them to jack the rotating assembly loose from the pump casing.

After the rotating assembly is loosened, remove the jacking screws from the casing ring. Remove

Shaft Key

Impeller

Shaft

Lathe Dog

Setscrew

Remove the impeller adjusting shims (33). Tie and tag the shims or measure and record their thickness for ease of reassembly.

Inspect the wear plate (27) for excessive wear or scoring and, if replacement is required, remove the hardware (25 and 26) securing it to the seal plate (3).

Seal Removal And Disassembly

(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 portion of the seal is to remove the hardware (6 and

7) and separate the seal plate (3) and gasket (4) from the bearing housing (9). Remove the bearing housing O-ring (5).

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 sta-

MAINTENANCE & REPAIR PAGE E − 13

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OM−05521 SUPER T SERIES

tionary seat until the seat, O-rings, and stationary element can be removed.

If no further disassembly is required, refer to Seal

Installation.

Most cleaning solvents are toxic and flammable. Use them only in a well ven-

Shaft and Bearing Removal and Disassembly

tilated area free from excessive heat, sparks, and flame. Read and follow all

(Figure 4)

When the pump is properly operated and maintained, the bearing housing should not require disassembly. Disassemble the shaft and bearings

only when there is evidence of wear or damage.

precautions printed on solvent containers.

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

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 (32) and drain the lubricant. Clean and reinstall the drain plug.

Disengage the hardware (15 and 16) and remove the drive flange (14), O-ring (22) and oil seal (13) from the shaft. Press the oil seal from the drive flange.

Place a block of wood against the impeller end of the shaft (18) and tap the shaft and assembled bearings (8 and 21) from the bearing housing.

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

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

Rotate the bearings by hand to check for roughness or binding and inspect the bearing balls. If rotation 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 housing. Replace the bearings, shaft, or bearing housing if the proper bearing fit is not achieved.

If bearing replacement is required, remove the outboard bearing retaining ring (20) and thrust washer (19), and use a bearing puller or an arbor (or hydraulic) press to remove the bearings from the shaft.

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 component parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage and replace as necessary.

Press the oil seals (23 and 24) from the bearing housing bore.

Shaft and Bearing Reassembly and Installation

(Figures 4 and 7)

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

MAINTENANCE & REPAIRPAGE E − 14

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SUPER T SERIES

Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent containers.

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 (23) in the bearing housing bore with the lip positioned as shown in Figure 4. Press the oil seal into the housing until the face is just flush with the machined surface inside the housing.

OM−05521

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. Bearings 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 continuous motion, to prevent the bearings from cooling and sticking on the shaft.

BALL LOADING GROOVE POSITIONED AWAY FROM IMPELLER

LOADING GROOVE

DIRECTION OF

THRUST

INSTALLATION OF NEW DEPARTURE OR

BCA/FEDERAL MOGAL 5300W SERIES BEARINGS

(OPEN OR ENCLOSED IMPELLERS)

Figure 7. Inboard Bearing Positioning

Use caution when handling hot bearings to prevent burns.

NOTE

Position the inboard bearing (8) on the shaft as indicated by the following illustration.

BALL LOADING GROOVE POSITIONED

TOWARD IMPELLER

LOADING GROOVE

DIRECTION OF

THRUST

INSTALLATION OF MRC/SKF 5300M OR

FAFNIR 5300W SERIES BEARINGS

(OPEN OR ENCLOSED IMPELLERS)

NOTE

Position the outboard bearing (20) on the shaft with the retaining ring in the outer race toward the drive end of 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 suitable sized

MAINTENANCE & REPAIR PAGE E − 15

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OM−05521 SUPER T SERIES

sleeve and a press to reposition the bearings against the shaft shoulders.

If heating the bearings is not practical, use a suitable 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.

Install the thrust washer (19) and secure the outboard bearing (21) to the shaft with the bearing retaining ring (20).

It is recommended that a sleeve be positioned against the inboard oil seal (23) 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.

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

not to damage the lip of the oil seal (13) on the shaft keyway.

Lubricate the bearing housing as indicated in LU-

BRICATION at the end of this section.

Seal Reassembly And Installation

(Figures 4 and 8)

Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent.

Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent containers.

The seal is not normally reused because wear patterns on the finished faces cannot be realigned during reassembly. This could result in premature failure. If necessary to reuse an old seal in an emergency, carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.

Handle the seal parts with extreme care to prevent damage. Be careful not to contaminate precision finished faces; even fingerprints on the faces can 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.

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 (24) in the bearing housing with the lip positioned as shown in Figure

4. Press the oil seal into the bearing housing until it is just flush with the machined surface on the bearing housing.

Press the oil seal (13) into the drive flange (14) with the lip positioned as shown in Figure 4. Replace the drive flange O-ring (22), and secure the drive flange with the hardware (15 and 16). Be careful

Inspect the seal components for wear, scoring, grooves, and other damage that might cause leakage. Inspect the seal area of the impeller shaft, and replace it if badly damaged. Dress any small scratches with a fine file or emery cloth. If any components are worn, replace the complete seal; never mix old and new seal parts.

If a replacement seal is being used, remove it from the container and inspect the precision finished faces to ensure that they are free of any foreign matter.

To ease installation of the seal, lubricate the bellows and stationary seat O-rings with water or a very small amount of oil, and apply a drop of light

MAINTENANCE & REPAIRPAGE E − 16

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SUPER T SERIES

lubricating oil on the finished faces. Assemble the seal as follows, (see Figure 8).

OM−05521

IMPELLER

SHIMS

IMPELLER

SHAFT

BELLOWS

SPRING

CENTERING

WASHER

SPRING

RETAINER

DRIVE BAND

ROTATING

ELEMENT

STATIONARY

ELEMENT

SEAL PLATE

O-RINGS

SLEEVE O-RING

INTEGRAL

SHAFT

SLEEVE

SHEAR

RING

(SHEARED)

OIL SEAL

STATIONARY

SEAT

Figure 8. 46513−154 Seal Assembly

(38 mm x 45 mm x 51 mm). Slide the tube over the shaft threads, then slide the O-ring off the tube and onto the shaft. Remove the tube, and continue to slide the O-ring down the shaft until it seats against

This seal is not designed for operation at

the shaft shoulder.

temperatures above 160F (71C). Do not use at higher operating temperatures.

When installing a new cartridge seal assembly, re-

If the wear plate (27) was removed, secure it to the seal plate (3) with the hardware (25 and 26).

If the seal plate was removed, install the seal plate gasket (4) and bearing housing O-ring (5). Lubricate the O-ring with light grease. Position the seal plate over the shaft and secure it to the bearing housing with the hardware (6 and 7).

To prevent damaging the shaft sleeve O-ring (34) on the shaft threads, stretch the O-ring over a piece of tubing 1-1/2" I.D. x 1-3/4" O.D. x 2-inches long

MAINTENANCE & REPAIR PAGE E − 17

move the seal from the container, and lubricate the external stationary seat O-ring with light oil. Slide the seal assembly onto the shaft until the external stationary 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 (33) provided with the seal, and screw the impeller onto the shaft until it is seated against the seal (see Figure 9).

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OM−05521 SUPER T SERIES

O-RING ENGAGED

WITH SEAL PLATE

BORE

SHEAR RING

(UNSHEARED)

Figure 9. Seal Partially Installed

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

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 Installation and Adjustment.

If necessary to reuse an old seal in an emer-

gency, carefully separate the rotating and stationary seal faces from the bellows retainer and stationary 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 premature failure.

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 bellows 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 leakage. 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

Page 47

SUPER T SERIES

OM−05521

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

(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 impeller. 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 impeller or shaft.

Install the same thickness of impeller adjusting shims (33) as previously removed. Apply ‘NeverSeez’ or equivalent compound to the shaft threads and screw the impeller onto the shaft until tight. Be sure the seal spring seats squarely over the shoulder on the back side of the impeller.

NOTE

At the slightest sign of scraping, immediately back the impeller off, and check the threads for dirt. Do not try to force the impeller onto the shaft.

Rotating Assembly Installation

(Figure 3)

Install the bearing housing and seal plate O-rings (39 and 40), and lubricate them with light grease. Ease the rotating assembly into the pump casing. Be careful not to damage the O-rings.

Install the pump casing ring (16), and secure it to the rotating assembly with the inner hardware (19 and 20).

NOTE

The inner capscrews are 1/4 inch (3,2 mm) shorter than the outer capscrews.

Install an equal thickness of rotating assembly shims (22) under the pump casing ring, and secure the ring to the pump casing with the outer hardware (17 and 18).

NOTE

If the pump has been completely disassembled, it is recommended that the wear plate (31) and suction head (32) be reinstalled at this point. The suction head and wear plate must be in place to adjust the impeller face clearance.

A clearance of .020 to .025 inch (0,51 to 0,64 mm) between the impeller and the wear plate is also recommended for maximum pump efficiency. This clearance can be obtained by removing an equal amount of shims from each rotating assembly shim set (22) until the impeller scrapes against the wear plate when the shaft is turned by hand. After the impeller scrapes, add approximately .020 (0,51 mm) of shims to each shim set.

A clearance of .020 to .025 inch (0,51 to 0,64 mm) between the impeller and the wear plate is recommended for maximum pump efficiency. Measure this clearance, and add or remove impeller adjusting shims as required.

An alternate method of adjusting this clearance is to reach through the suction port with a feeler gauge and measure the gap. Add or subtract rotating assembly shims accordingly.

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

Suction Head And Wear Plate Installation

(Figure 3)

Clean any scale or debris from the contacting surfaces in the pump casing that might prevent a

Page 48

OM−05521 SUPER T SERIES

good seal with the suction head or interfere with the wear plate (31). Inspect the wear plate for wear or damage and replace as required. Slide the wear plate into the pump casing until fully seated.

Make certain that the flexible portion of the

Replace the suction head gasket (25) and lubricate it with a generous amount of No. 2 grease. Use a suitable hoist and sling to position the suction head against the pump casing, and secure it with the hardware (27, 28, 29 and 30).

coupling is mounted as shown in Figure 5. This is critical. If the coupling is not properly positioned on the shaft, the coupling parts may not fully engage, or a pre-load condition can cause premature bearing failure.

NOTE

To ease future disassembly, apply a film of grease or ‘Never-Seez’ on the suction head, or any surface which contacts the pump casing. This action will reduce rust and scale build-up.

The end of the shaft must be just flush with the face of the bushing. This will allow the two portions of the coupling to fully engage when the drive flange is secured to the engine bellhousing, without pre-loading the bearings.

Suction Check Valve Installation

(Figure 3)

Inspect the check valve components and replace if badly worn.

Reach through the cleanout cover opening with the check valve and secure it with the pivot caps (52) and hardware (48, 50 and 51).

NOTE

If the check valve body (53) was removed, install the check valve and secure the body to the suction head with the shoulder type clamp (36).

Securing Pump End To Engine

(Figure 5)

Install the shaft key (17, Figure 4) in the shaft keyway. Position the flexible portion of the coupling assembly (3) on the shaft as shown in Figure 5.

Align the keyway in the bushing (2) with the shaft key, and slide it onto the shaft until it is just flush with the end of the shaft. Rotate the flexible portion of the coupling until the tapped holes for the two setscrews align with those in the bushing, and install the setscrews.

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 23.3 ft. lbs. (280 in. lbs. or 3,2 m. kg.).

If the complete coupling assembly is being replaced, apply ‘Loctite Retaining Compound No. 242’ or equivalent to the threads of the hardware (4 and 5), 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 inside the outer ring attached to the engine flywheel.

NOTE

To ease installation, lightly lubricate the rubber portion of the coupling with a non-petroleum based lubricant such as vegetable oil or glycerin, or a silicon-based lubricant such as WD40" or equivalent. Do not use petroleum-based lubricants, or any other substance which may soften or otherwise damage the rubber.

Install the intermediate guards (35, Figure 4), and secure the drive flange to the engine bellhousing with the hardware (6 and 7).

MAINTENANCE & REPAIRPAGE E − 20

Page 49

SUPER T SERIES

OM−05521

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

PRESSURE RELIEF VALVE MAINTENANCE

(Figure 3)

The suction head is equipped with a pressure relief valve (35) to provide additional safety for the pump and operator (refer to Liquid Temperature And Overheating in OPERATION).

It is recommended that the pressure relief valve assembly 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 been specified or provided by the Gorman-Rupp Company.

Periodically, the valve should be removed for inspection 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.

Bearings

(Figure 4)

The bearing housing was fully lubricated when shipped from the factory. Check the oil level regularly through the sight gauge (29) and maintain it at the middle of the gauge. When lubrication is required, remove the air vent and bushing (11 and

12) and add SAE No. 30 non-detergent oil through the hole until the level is at the middle of the sight gauge. Do not over-lubricate. Over-lubrication can cause the bearings to over-heat, resulting in premature bearing failure.

NOTE

The white reflector in the sight gauge must be positioned horizontally to provide proper drainage.

Under normal conditions, drain the bearing housing once each year and refill with approximately 32 ounces (1 liter) clean oil. Change the oil more frequently if the pump is operated continuously or installed in an environment with rapid temperature change.

LUBRICATION

Seal Assembly

(Figure 4)

Before starting the pump, remove the vented plug (10) and fill the seal cavity with approximately 85 ounces (2,5 liters) of SAE No. 30 non-detergent oil, or to a level at the middle of the sight gauge (28). Clean and reinstall the vented plug. Maintain the oil at this level.

Monitor the condition of the bearing lubricant regularly for evidence of rust or moisture condensation. This is especially important 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 John Deere engine representative.

MAINTENANCE & REPAIR PAGE E − 21

Page 50

For U.S. and International Warranty Information,

Please Visit www.grpumps.com/warranty

or call:

U.S.: 419−755−1280

International: +1−419−755−1352

For Canadian Warranty Information,

Please Visit www.grcanada.com/warranty

or call:

519−631−2870

THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA