GORMAN-RUPP PUMPS T SERIES, T10A61-B Installation, Operation And Maintenance Manual

CDSW

OM---01936---OB03

August 15, 1984

Rev. K 11/22/02

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

TSERIESPUMP

MODEL

T10A61---B

INCLUDING: /FM, /WW

THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO

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

www.gormanrupp.com

ECopyright by the Gorman-Rupp Company

TABLE OF CONTENTS

INTRODUCTION PAGE I --- 1.................................................

SA FE TY --- SECTION A PA GE A --- 1...........................................

IN STALLAT ION --- SECTION B PA GE B --- 1....................................

Pump Dimensions PAGE B --- 1.....................................................

PREINSTALLATION INSPECTION PAGE B --- 1............................................

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

POSITIONING PUMP PA GE B --- 2.......................................................

Lifting PA GE B --- 2.................................................................

Mounting PA GE B --- 2.............................................................

SUCTION AND DISCHARGE PIPING PAGE B --- 2.........................................

Materials PA GE B --- 2..............................................................

Line Configuration PAGE B --- 2......................................................

Connections to Pump PAGE B --- 2..................................................

Gauges PA GE B --- 3...............................................................

SUCTION LINES PAGE B --- 3...........................................................

Fittings PA GE B --- 3...............................................................

Strainers PA GE B --- 3..............................................................

Sealing PAGE B --- 3...............................................................

Suction Lines In Sumps PAGE B --- 3.................................................

Suction Line Positioning PAGE B --- 3................................................

DISCHARGE LINE S PA GE B --- 4........................................................

Siphoning PA GE B --- 4.............................................................

Valves PA GE B --- 4................................................................

Bypass Lines PA GE B --- 4..........................................................

AUTOMATIC AIR RELEASE VALVE PAGE B --- 5...........................................

Theory of Operation PAGE B --- 6....................................................

Air Release V alve Installation P AGE B --- 6............................................

ALIGNMENT PAGE B --- 7..............................................................

Coupled Drives PA GE B --- 8........................................................

V-Belt Drives PA GE B --- 8...........................................................

OP E R ATION --- SE CTION C PAGE C --- 1......................................

PRIMING PA GE C --- 1.................................................................

STARTING PA GE C --- 1................................................................

OPERATION PA GE C --- 1..............................................................

Lines With a Bypass PAGE C --- 1....................................................

Lines Without a Bypass PAGE C --- 1.................................................

Leakage PAGE C --- 2..............................................................

Liquid Temperature And Overheating PAGE C --- 2.....................................

Strainer Check PAGE C --- 2.........................................................

Pump Vacuum Check PAGE C --- 2..................................................

STOPPING PA GE C --- 3................................................................

Cold Weather Preservation PAGE C --- 3..............................................

BEARING TEMPERATURE CHECK PAGE C --- 3..........................................

TROUBLESHOO T I N G --- S E C T I O N D PA G E D --- 1..............................

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

i

TABLE OF CONTENTS

(continued)

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

PERFORMANCE CURVE PA GE E --- 1...................................................

PARTS LISTS:

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

Repair Rotating Assembly PAGE E --- 5...............................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E --- 6.........................

Cleanout Access And Suction Check Valve Removal PAGE E --- 6.......................

Suction Head And Wear Plate Removal PAGE E --- 6...................................

Rotating Assembly Removal PAGE E --- 7.............................................

Impeller Removal P AGE E --- 8......................................................

Seal Removal And Disassembly PAGE E --- 8.........................................

Shaft and Bearing Removal and Disassembly PAGE E --- 8.............................

Shaft and Bearing Reassembly and Installation P AGE E - -- 9............................

Seal Reassembly and Installation P AGE E --- 10........................................

Impeller Installation PAGE E --- 12.....................................................

Rotating Assembly Installation PAGE E --- 13...........................................

Suction Head And Wear Plate Installation PAGE E --- 13.................................

Suction Check Valve Installation P AGE E - -- 13.........................................

PRESSURE RELIEF VALVE MAINTENANCE PAGE E --- 14..................................

LUBRICATION PA GE E --- 14.............................................................

Seal Assembly PAGE E --- 14.........................................................

Bearings PAGE E --- 14..............................................................

ii

TSERIES

OM--01936

INTRODUCTION

Thank You for purchasing a Gorman-Rupppump.
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 T Series, semi-open impeller, self­priming centrifugal model with a suction check
valve. The pump is designed for handling mild in­dustrial corrosives, residues and slurries contain­ing large entrained solids. The basic material of
construction is gray iron, with stainless steel impel­ler , impeller shaft and wearing parts.

Ifthereare anyquestionsregarding thepump orits
applicationwhichare not coveredin thismanualor
in other literature accompanying this unit, please
contact your Gorman -Rupp distributor, or write:

promised by the installation. Pumps and related
equipment must be installed and operated ac-
cording to all national, local and industry stan­dards.

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

Immediate hazardswhich 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.

The Gorman-Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901-- 1217

Phone: [phone]

or:

Gorman-Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: [phone]

Forinformationor technicalassistance onthepow­er source, contact the power source manufactur­er’s local dealer or representative.

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
neither operatorsafetynorpumpintegrity are com-

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

HazardsorunsafepracticeswhichCOULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possi­bledamagewhich couldresult fromfailure
to follow the procedure.

NOTE

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

PAGE I -- 1INTRODUCTION

TSERIES OM--01936

SAFETY --- SECTION A

This information applies to T Series ba­sic pumps. Gorman-Rupp has no con­trol over or particular knowledge of the
powersourcewhichwill be used. Refer
to the manual accompanying the power
source before attempting to begin op­eration.

Because pump installations are seldom
identical, this manual c annot 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.

This pump is designed to handle mild
industrial corrosives, mud and slurries
containing large entrained solids. Do
not attempt to pump volatile, flam­mable, or highly corrosive liquids
which may damage thepump or endan­ger personnel as a result of pump fail­ure.

After the pump has been positioned,
make certain that the pump and all pip­ing connections are tight, properlysup­ported and secure before operation.

Beforeattemptingto open orservice the
pump:

1. Familiarize yourself with this man­ual.

2. Disconnect or lock out the power
source, or take other action to en­sure that the pump will remain in­operative.

3. Allow the pump to completely cool
if overheated.

4. Vent the pump slowly and cau­tiously.

5. Close the suction and discharge
valves.

6. Check the temperature before
opening any covers, plates, or
plugs.

7. Drain the pump.

Do not operate the pump without
shields and /or guards in place over the
drive shafts, belts and/or couplings, or
other rotating parts. Exposed rotating
parts can catch clothing, fingers, or
tools. causing severe injury to person­nel.

Do not operate the pump against a
closed discharge valve for long periods
oftime.Ifoperatedagainstacloseddis­charge valve, pump components will
deteriorate, and the liquid could come
to a boil, build pressure, and cause the
pump casing to rupture or e xplode.

PAGE A -- 1SAFETY

TSERIESOM--01936

Use lifting and moving equipment in
good repair and with adequate capacity
toprevent injuries to personnelor dam­age to equipment.

Overheated pumps can cause severe
burns and injury. If overheating of the
pump occurs:

1. Stop the pump immediately.

2. Allowthepumpto completelycool.

3. Refer to instructions in thismanual
before restarting the pump.

Donotattempttodisengageanypartof
an overheated pump unit. Vapor pres ­sure within the pump casing can eject
these parts with great force when they
are disengaged. Allow the pump to
completely cool before servicing it.

Use lifting and moving equipment in
good repair and with adequate capacity
toprevent injuries to personnelor dam­age to equipment.

PAGE A -- 2 SAFETY

INSTALLATION --- SECTION B

OM--01936TSERIES

Review all SAFETY information in Section A.

Since pump installationsareseldomidentical,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 posi-
tionedabovethefreelevelofliquidto bepumped.

If installed ina floodedsuction application where
the liquid is supplied to the pump under pressure,
some of the information such as mounting, line

OUTLINE DRAWING

configuration, and priming must be tailored to the
specific application. Since the pressure supplied
to the pump is critical to performance and safety,
be sure to limit the incoming pressure to 50% of
the maximum permissible operating pressure as
shown on the pump performance curve.

Forfurtherassistance, contact yourGorman-Rupp
distributor or the Gorman-Rupp Company.

Pump Dimensions

SeeFigure1fortheapproximatephysicaldimen­sionsofthispump.

Figure 1. Pump Model T10A61--B

PREINSTALLATION INSPECTION

Thepump assemblywasinspected and tested be­foreshipment from the factory. Before installation,
inspect the pump fordamage which may have oc­curred during shipment. Check as follows:

a. Inspectthe pump forcracks, dents,damaged

threads, and other obvious damage.

b. Check for and t ighten loose attaching hard-

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

c. Carefully read all warnings and cautions con-

tained in this manual or affixed to the pump,
and perform all duties indicated. Note the di­rection of rotation indicated on the pump.

PAGE B -- 1INSTALLATION

OM--01936 TSERIES

Check that the pump shaft rotates counter­clockwise when facing the impeller.

Thepumpassemblycanbeseriously
damagedifthecablesor chainsused tolift
andmovetheunitareimproperlywrapped

Only operate this pump in the direction in­dicated by the arrow on the pump body
and on the accompanying decal. Refer to
Rotation in OPERATION,SectionC.

d. Checklevels and lubricate as necessary. Re-

fer to LUBRICATION in the MAINTENANCE
AND REPAIRsection of this manual and per­form duties as instructed.

e.Ifthepumpandpowersourcehavebeen

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 deter­minethe repair or updating policy. Do notputthe
pump into service until appropriate action has
been taken.

POSITIONING PUMP

Lifting

around the pump.

Mounting

Locatethepump inanaccessibleplaceas closeas
practicalto the liquid being pumped. Levelmount­ing is essential for proper operation.

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

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in­creased suction lift, discharge elevation, and fric­tion losses. See the performance curve and oper­ating range shown on Page E-1 to be sure your
overall application allows the pump to operate
within the safe operation range.

Materials

Either pipe or hose maybe used for suction and
discharge lines; however, the materials must be
compatiblewiththe liquidbeingpumped. If hoseis
used in suctionlines, it mustbe the rigid-wall, rein­forcedtype toprevent collapse under suction.Us­ing piping couplings in suction lines is not recom­mended.

Use lifting equipment with a capacity of at least

6,700 pounds. This pump weighs approximately
1,340 pounds, not including the weight of acces-

soriesor customerinstalledequipment. Customer
installed equipment such as suction and dis­chargepipingmust beremoved beforeattempting
to lift.

Make sure that hoists and other lifting equipment
areof sufficientcapacitytos afely handle thepump
assembly.Ifchains andcablesare used,make cer­tain that they are positioned so that they will not
damage thepump, andso that the load willbe bal­anced.

PAGE B -- 2 INSTALLATION

Line Configuration

Keep suction and discharge lines as straight as
possible to minimize friction losses. Make mini­mum use of elbows and fittings, which substan­tiallyincreasefriction loss.Ifelbowsarenecessary,
use the long-radius type to minimize friction loss.

Connections to Pump

Before tightening a connecting flange, align it ex­actlywith t he pump port. Never pulla pipeline into
place by tightening the flange bolts and/or cou ­plings.

OM--01936TSERIES

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
linesare used, theyshouldhave adequatesupport
to secure them when filled with liquid and under
pressure.

Gauges

Most pumps are drilled and tapped for installing
dischargepressureandvacuumsuctiongauges.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 mm) from the
suction and discharge ports and install the lines.
Installationcloserto the pump may result inerratic
readings.

SUCTION LINES

Toavoidair pockets whichcouldaffect pumpprim­ing, the suction line must be as short and direct as
possible.Whenoperationinvolvesasuctionlift,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

three or four times the cross section of the suction
line,and that the openings willnot permit passage
of solids larger than the solids handling capability
of the pump.

Thispump is designedto handleup to 3-inch (76,2
mm) diameter spherical solids.

Sealing

Since even a slight leak will affect priming, head,
and capacity, especially when operating with a
high suction lift, all connections in the suction line
should be sealed with pipe dope to ensure an 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
sumpat a distanceequalto 1-1/2timesthediame­ter 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 suc­tioninlet because the inflow willcarry air down into
the sump, and air entering the suction line will re­duce pump efficiency .

Suction lines shouldbethe same sizeas the pump
inlet. If reducers are used in suction lines, they
should be the eccentric type, and should be in­stalledwith 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 w ith the stem horizontal to avoid air pock­ets.

Strainers

If a s trainer is furnished with the pump, be certain
touse it;any sphericalsolidswhichpass througha
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

Ifitis necessary to positioninflowcloseto the suc­tioninlet, installa bafflebetween theinflow and the
suctioninlet 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,
theflow pathsmayinteract, reducingtheefficiency
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.

Suction Line Positioning

The depth of submergence of the suction line is
critical to efficient pump operation. Figure 2 shows
recommended minimum submergence vs. veloc-

ity.

PAGE B -- 3INSTALLATION

OM--01936 TSERIES

NOTE

The pipe submergence required may be reduced
byinstalling a standard pipe increaser fittingatthe
endof the suctionline.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).

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

DISCHARGE LINES

Siphoning

Donot terminate the dischargeline at a levellower
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

A check valve in the discharge lineis normallyrec­ommended, but it is not necessary in low dis­charge head applications.

If a throttling valve is desired in the discharge line,
useavalveaslargeasthelargestpipetominimize
friction losses. Never install a throttling valve in a
suction line.

Withhighdischarge heads,it isrecommendedthat
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.

Iftheapplicationinvolvesa highdischarge
head, gradually close the discharge
throttling valve before stopping the pump.

Bypass Lines

If it is mecessary to permit the escape of air to at­mosphere during initial priming or in the repriming
cycle, install a bypass line between th epump and
thedischarge check valve. Thebypasslineshould
be sized so that it does not affect pump discharge
capacity.

ItisrecommendedthataGorman---RuppAutomat­ic Air Release Valve be installed in the bypass line.

PAGE B -- 4 INSTALLATION

OM--01936TSERIES

Do Not install a manual shut---off valvein a bypass
line. If a manual shut---offvalve is installedto facili­tateservice ofthe AirReleaseValve,the valvemust
not be left closed during operation. See the sup­plement at the end of this section for additionalin­formationon bypass linesand the Gorman---Rupp
Automatic Air Release Valve.

NOTE

Thebypass line may clog occasionally, particularly
when pumping liquids containing large solids. If
clogging occurs, locate and remove theclog. Ifthe
clog is located between the discharge check valve
andtheAir ReleaseValve, thevalvewillnotclose. If
theclog is locatedin theReliefValveitself, or in the
line between the Relief Valve and the sump, the
valve will not open.

Donot terminate the dischargeline at a levellower
than that of the liquid being pumped unless a si­phon breaker is used in the line; otherwise, a si­phoning action could result, causing damage to
the pump.

Inlow discharge headapplications(less than30
feet or 9,1 meters), it is recommended that the by­pass line be run back to thewet well, and located 6
inches (152,4 mm) below the water level or cut-off
point of the low level pump. In some installations,
this bypass line may be terminated with a six-to­eight foot 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 wetwell
must be secured againstbeing d rawn into
the pump suction inlet.

this will reduce overall pumping efficiency. There-

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

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

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 dan­gerousoverheatingand 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,orfittings fromanover­heated pump. Liquid within the pump
canreachboilingtemperatures,andva­porpressure within the pumpcan cause
parts being disengaged to be ejected
with great force. After the pump cools
drain the liquid from the p ump by re­moving the casing drain plug. Use cau­tion when removing the plug to prevent
injury to personnel from hot liquid.

,

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 or 9,1 meters), an excessive amount of liq­uid may be bypassed and forced back to the wet
well under the full working pressure of the pump;

AUTOMATIC AIR RELEASE VALVE

When properly installed and correctly adjusted to
the specific hydraulic operating conditions of the
application, the Gorman-Rupp Automatic Air Re­leaseValvewillpermitairtoescapethroughtheby­pass line, and then close automatically when the
pump is fully primed and pumping at full capacity.

PAGE B -- 5INSTALLATION

OM--01936 TSERIES

Theory of Operation

Figures 3 and 4 show a cross-sectional view of the
AutomaticAir Release Valve, and a corresponding
description of operation.

Figure 3 Valve in Open Position

Duringthe primingcycle, airfromthe pump casing
flowsthroughthebypassline,andpassesthrough
theAirReleaseValvetothewetwell(Figure3).

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.

Whenthe pump shutsdown, thespring returnsthe
diaphragm to its original position. Any solids that
mayhave accumulatedin the diaphragm chamber
settle to the bottom and are flushedout during the
next priming cycle.

NOTE

The valve will remain open if the pump does not
reach its designed capacity or head. V alveclosing
pressureis dependentupon thedischargeheadof
the pump at full capacity. The range of the valve
closing pressure is established by the tensionrate
ofthespringasorderedfrom thefactory.Valveclos­ing 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.

Figure 4 Valve in Closed Position

When the pump is fully primed, pressure resulting
from flow against the valve diaphragm com­presses the spring and closesthe valve(Figure 4).
The valve will remain closed, reducing the bypass
ofliquidto 1to5 gallonsper minute,untilthepump
loses its prime or stops.

Some le akage (1 to 5 gallons [3.8 to 19

Air Release Valve Installation

The A utomatic Air Release Valve must be inde ­pendently mounted in a horizontal position and
connected to the discharge line of the self-priming
centrifugal pump (see Figure 5).

NOTE

IftheAirReleaseValveistobeinstalledonastaged
pump application, contact the factory for specific
installationinstructions.

PAGE B -- 6 INSTALLATION