Gorman-Rupp Pumps T10A61S-B-FM User Manual

Page 1
CDS OM‐05444-OB01
October 30, 2002
Rev. B 04‐23‐13
INSTALLATION, OPERATION,
WITH PARTS LIST
SUPER T SERIES PUMPS
MODELS
T10A61S-B
INCLUDING: /FM
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
2002 The Gorman‐Rupp Company
Page 2
Register your new
Gorman‐Rupp pump online at
www.grpumps.com
Valid serial number and e‐mail address required.
RECORD YOUR PUMP MODEL AND SERIAL NUMBER
Please record your pump model and serial number in the spaces provided below. Your Gorman‐Rupp distributor needs this information when you require parts or service.
Pump Model:
Serial Number:
Page 3
TABLE OF CONTENTS
INTRODUCTION PAGE I - 1.................................................
SAFETY - SECTION A PAGE A - 1...........................................
INSTALLATION - SECTION B PAGE B - 1....................................
Pump Dimensions PAGE B - 1.....................................................
PREINSTALLATION INSPECTION PAGE B - 1............................................
POSITIONING PUMP PAGE B - 2.......................................................
Lifting PAGE B - 2.................................................................
Mounting PAGE B - 2.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 2.........................................
Materials PAGE B - 2..............................................................
Line Configuration PAGE B - 2......................................................
Connections to Pump PAGE B - 2..................................................
Gauges PAGE B - 3...............................................................
SUCTION LINES PAGE B - 3...........................................................
Fittings PAGE B - 3...............................................................
Strainers PAGE B - 3..............................................................
Sealing PAGE B - 3...............................................................
Suction Lines In Sumps PAGE B - 3.................................................
Suction Line Positioning PAGE B - 3................................................
DISCHARGE LINES PAGE B - 4........................................................
Siphoning PAGE B - 4.............................................................
Valves PAGE B - 4................................................................
Bypass Lines PAGE B - 4..........................................................
AUTOMATIC AIR RELEASE VALVE PAGE B - 5...........................................
Theory of Operation PAGE B - 6....................................................
Air Release Valve Installation PAGE B - 6............................................
ALIGNMENT PAGE B - 7..............................................................
Coupled Drives PAGE B - 8........................................................
V‐Belt Drives PAGE B - 8...........................................................
OPERATION - SECTION C PAGE C - 1......................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 1................................................................
OPERATION PAGE 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 PAGE C - 3................................................................
Cold Weather Preservation PAGE C - 3..............................................
BEARING TEMPERATURE CHECK PAGE C - 3..........................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...............................................
i
Page 4
TABLE OF CONTENTS
(continued)
PUMP MAINTENANCE AND REPAIR - SECTION E PAGE E - 1................
PERFORMANCE CURVE PAGE 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 - 7...................................
Rotating Assembly Removal PAGE E - 7.............................................
Impeller Removal PAGE E - 8......................................................
Seal Removal And Disassembly PAGE E - 8.........................................
Shaft and Bearing Removal and Disassembly PAGE E - 8.............................
Shaft and Bearing Reassembly and Installation PAGE E - 9............................
Seal Reassembly and Installation PAGE E - 11........................................
Impeller Installation and Adjustment PAGE E - 13......................................
Rotating Assembly Installation PAGE E - 14...........................................
Suction Head And Wear Plate Installation PAGE E - 14.................................
Suction Check Valve Installation PAGE E - 14.........................................
PRESSURE RELIEF VALVE MAINTENANCE PAGE E - 14..................................
LUBRICATION PAGE E - 15.............................................................
Seal Assembly PAGE E - 15.........................................................
Bearings PAGE E - 15..............................................................
ii
Page 5
SUPER T SERIES OM-05444

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 Gorman‐ Rupp pump.
This pump is a Super T‐Series, semi‐open impeller, self‐priming centrifugal model with a suction check valve. It is designed for handling sewage, waste water, trash and slurries containing large entrained solids. The basic material of construction for wetted parts is gray iron, with stainless steel wear ing parts.
If there are any questions regarding the pump or its application which are not covered in this man ual or in other literature accompanying this unit, please contact your Gorman‐Rupp distributor, or 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 power source, contact the power source manufac turer's local dealer or representative.
Because pump installations are seldom identical, this manual cannot possibly provide detailed in structions and precautions for every aspect of each specific application. Therefore, it is the re sponsibility of the owner/installer of the pump to ensure that applications not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity are com promised by the installation. Pumps and related
equipment must be installed and operated ac cording to all national, local and industry stan dards.
The following are used to alert maintenance per sonnel to procedures which require special atten tion, to those which could damage equipment, and to those which could be dangerous to personnel:
Immediate hazards which WILL result in severe personal injury or death. These instructions describe the procedure re quired and the injury which will result from failure to follow the procedure.
Hazards or unsafe practices which COULD result in severe personal injury or death. These instructions describe the procedure required and the injury which could result from failure to follow the procedure.
Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. These instructions describe the requirements and the possi ble damage which could result from failure to follow the procedure.
NOTE
Instructions to aid in installation, operation, and maintenance or which clarify a procedure.
PAGE I - 1INTRODUCTION
Page 6
SUPER T SERIES OM-05444

SAFETY - SECTION A

This information applies to T Series ba sic pumps. Gorman‐Rupp has no con trol over or particular knowledge of the power source which will be used. Refer to the manual accompanying the power source before attempting to begin op eration.
Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and pre cautions for each specific application. Therefore, it is the owner/installer's re sponsibility to ensure that applications not addressed in this manual are per formed only after establishing that nei ther operator safety nor pump integrity are compromised by the installation.
Before attempting to open or service the pump:
highly corrosive liquids which may damage the pump or endanger person nel as a result of pump failure.
After the pump has been positioned, make certain that the pump and all pip ing connections are tight, properly sup ported and secure before operation.
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 person nel.
1. Familiarize yourself with this man ual.
2. Disconnect or lock out the power source, or take other action to en sure that the pump will remain in operative.
3. Allow the pump to completely cool if overheated.
4. Vent the pump slowly and cau tiously.
5. Close the suction and discharge valves.
6. Check the temperature before opening any covers, plates, or plugs.
7. Drain the pump.
This pump is designed to handle sew age, wastewater, trash and slurries con taining large entrained solids. Do not at tempt to pump volatile, flammable, or
Do not operate the pump against a closed discharge valve for long periods of time. If operated against a closed dis charge valve, pump components will deteriorate, and the liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode.
Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or dam age to equipment.
Overheated pumps can cause severe burns and injury. If overheating of the pump occurs:
PAGE A - 1SAFETY
Page 7
SUPER T SERIESOM-05444
1. Stop the pump immediately.
2. Allow the pump to completely cool.
3. Refer to instructions in this manual before restarting the pump.
Do not attempt to disengage any part of 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 com pletely cool before servicing it.
Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or dam age to equipment.
PAGE A - 2 SAFETY
Page 8

INSTALLATION - SECTION B

OM-05444SUPER T SERIES
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this section offers only general recommendations and practices required to inspect, position, and ar range the pump and piping.
Most of the information pertains to a standard
static lift application where the pump is posi tioned above the free level of liquid to be pumped.
If installed in a flooded suction application where the liquid is supplied to the pump under pressure, some of the information such as mounting, line
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.
For further assistance, contact your Gorman‐Rupp distributor or the Gorman‐Rupp Company.
Pump Dimensions
See Figure 1 for the approximate physical dimen sions of this pump.
Figure 1. Pump Model T10A61S-B
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be fore shipment from the factory. Before installation, inspect the pump for damage which may have oc curred during shipment. Check as follows:
a. Inspect the pump for cracks, dents, damaged
threads, and other obvious damage.
b. Check for and tighten loose attaching hard
ware. Since gaskets tend to shrink after dry ing, check for loose hardware at mating sur faces.
c. Carefully read all warnings and cautions con
tained in this manual or affixed to the pump, and perform all duties indicated. Note the di rection of rotation indicated on the pump.
PAGE B - 1INSTALLATION
Page 9
OM-05444 SUPER T SERIES
Check that the pump shaft rotates counter clockwise when facing the impeller.
The pump assembly can be seriously damaged if the cables or chains used to lift and move the unit are improperly wrapped
Only operate this pump in the direction in dicated by the arrow on the pump body
around the pump.
Mounting
and on the accompanying decal. Refer to Rotation in OPERATION, Section C.
d. Check levels and lubricate as necessary. Re
fer to LUBRICATION in the MAINTENANCE AND REPAIR section of this manual and per form duties as instructed.
e. If the pump and power source have been
stored for more than 12 months, some of the components or lubricants may have ex ceeded their maximum shelf life. These must be inspected or replaced to ensure maxi mum pump service.
If the maximum shelf life has been exceeded, or if anything appears to be abnormal, contact your Gorman‐Rupp distributor or the factory to deter mine the repair or updating policy. Do not put the pump into service until appropriate action has been taken.
POSITIONING PUMP
Lifting
Locate the pump in an accessible place as close as practical to the liquid being pumped. Level mount ing is essential for proper operation.
The pump may have to be supported or shimmed to provide for level operation or to eliminate vibra tion.
SUCTION AND DISCHARGE PIPING
Pump performance is adversely effected by in creased suction lift, discharge elevation, and fric tion losses. See the performance curve and oper ating 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 compatible with the liquid being pumped. If hose is used in suction lines, it must be the rigid‐wall, rein forced type to prevent collapse under suction. Us ing piping couplings in suction lines is not recom mended.
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.
Make sure that hoists and other lifting equipment are of sufficient capacity to safely handle the pump assembly. If chains and cables are used, make cer tain that they are positioned so that they will not damage the pump, and so that the load will be bal anced.
PAGE B - 2 INSTALLATION
Line Configuration
Keep suction and discharge lines as straight as possible to minimize friction losses. Make mini mum use of elbows and fittings, which substan tially increase friction loss. If elbows are necessary, use the long‐radius type to minimize friction loss.
Connections to Pump
Before tightening a connecting flange, align it ex actly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or cou plings.
Page 10
OM-05444SUPER T SERIES
Lines near the pump must be independently sup ported to avoid strain on the pump which could cause excessive vibration, decreased bearing life, and increased shaft and seal wear. If hose‐type lines are used, they should have adequate support to secure them when filled with liquid and under pressure.
Gauges
Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges. If these gauges are desired for pumps that are not tapped, drill and tap the suction and discharge lines not less than 18 inches (457 mm) from the suction and discharge ports and install the lines. Installation closer to the pump may result in erratic readings.
SUCTION LINES
To avoid air pockets which could affect pump prim ing, the suction line must be as short and direct as possible. When operation involves a suction lift, the line must always slope upward to the pump from the source of the liquid being pumped; if the line slopes down to the pump at any point along the suction run, air pockets will be created.
Fittings
three or four times the cross section of the suction line, and that the openings will not permit passage of solids larger than the solids handling capability of the pump.
This pump is designed to handle up to 3‐inch (76,2 mm) diameter spherical solids.
Sealing
Since even a slight leak will affect priming, head, and capacity, especially when operating with a high suction lift, all connections in the suction line should be sealed with pipe dope to ensure an air tight seal. Follow the sealant manufacturer's rec ommendations when selecting and applying the pipe dope. The pipe dope should be compatible with the liquid being pumped.
Suction Lines In Sumps
If a single suction line is installed in a sump, it should be positioned away from the wall of the sump at a distance equal to 1‐1/2 times the diame ter of the suction line.
If there is a liquid flow from an open pipe into the sump, the flow should be kept away from the suc tion inlet because the inflow will carry air down into the sump, and air entering the suction line will re duce pump efficiency.
Suction lines should be the same size as the pump inlet. If reducers are used in suction lines, they should be the eccentric type, and should be in stalled with the flat part of the reducers uppermost to avoid creating air pockets. Valves are not nor mally used in suction lines, but if a valve is used, install it with the stem horizontal to avoid air pock ets.
Strainers
If a strainer is furnished with the pump, be certain to use it; any spherical solids which pass through a strainer furnished with the pump will also pass through the pump itself.
If a strainer is not furnished with the pump, but is installed by the pump user, make certain that the total area of the openings in the strainer is at least
If it is necessary to position inflow close to the suc tion inlet, install a baffle between the inflow and the suction inlet at a distance 1‐1/2 times the diameter of the suction pipe. The baffle will allow entrained air to escape from the liquid before it is drawn into the suction inlet.
If two suction lines are installed in a single sump, the flow paths may interact, reducing the efficiency of one or both pumps. To avoid this, position the suction inlets so that they are separated by a dis tance equal to at least 3 times the diameter of the suction pipe.
Suction Line Positioning
The depth of submergence of the suction line is critical to efficient pump operation. Figure 2 shows recommended minimum submergence vs. veloc
ity.
PAGE B - 3INSTALLATION
Page 11
OM-05444 SUPER T SERIES
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).
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
DISCHARGE LINES
Siphoning
Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a si phon breaker is used in the line. Otherwise, a si phoning action causing damage to the pump could result.
Valves
A check valve in the discharge line is normally rec ommended, but it is not necessary in low dis charge head applications.
If a throttling valve is desired in the discharge line, use a valve as large as the largest pipe to minimize friction losses. Never install a throttling valve in a suction line.
With high discharge heads, it is recommended that a throttling valve and a system check valve be in stalled in the discharge line to protect the pump from excessive shock pressure and reverse rota tion when it is stopped.
If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.
Bypass Lines
If it is necessary to permit the escape of air to atmo sphere during initial priming or in the repriming cycle, install a bypass line between the pump and the discharge check valve. The bypass line should be sized so that it does not affect pump discharge capacity.
It is recommended that a Gorman‐Rupp Automatic Air Release Valve be installed in the bypass line.
PAGE B - 4 INSTALLATION
Page 12
OM-05444SUPER T SERIES
Do Not install a manual shut‐off valve in a bypass line. If a manual shut‐off valve is installed to facili tate service of the Air Release Valve, the valve must not be left closed during operation. See the sup plement at the end of this section for additional in formation on bypass lines and the Gorman‐Rupp Automatic Air Release Valve.
NOTE
The bypass line may clog occasionally, particularly when pumping liquids containing large solids. If clogging occurs, locate and remove the clog. If the clog is located between the discharge check valve and the Air Release Valve, the valve will not close. If the clog is located in the Relief Valve itself, or in the line between the Relief Valve and the sump, the valve will not open.
Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a si phon breaker is used in the line; otherwise, a si phoning action could result, causing damage to the pump.
In low discharge head applications (less than 30 feet or 9,1 meters), it is recommended that the by pass line be run back to the wet 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‐to‐ eight 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 wet well must be secured against being drawn 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 AUTOMATIC AIR RELEASE VALVE in this section for installation and theory of operation of the Auto matic Air Release Valve. Consult your Gorman‐ Rupp distributor, or contact the Gorman‐Rupp Company for selection of an Automatic Air Release Valve to fit your application.
A manual shut‐off valve should not be installed in any bypass line. A manual shut‐off valve may inadvertently be left closed during operation. A pump which has lost prime may continue to operate without reaching prime, causing dan gerous overheating and possible explo sive rupture of the pump casing. Per sonnel could be severely injured.
Allow an over‐heated pump to cool be fore servicing. Do not remove plates, covers, gauges, or fittings from an over‐ heated pump. Liquid within the pump can reach boiling temperatures, and va por 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 re moving the casing drain plug. Use cau tion when removing the plug to prevent injury to personnel from hot liquid.
It is also recommended that pipe unions be in stalled at each 90 elbow in a bypass line to ease disassembly and maintenance.
In high discharge head applications (more than 30 feet or 9,1 meters), an excessive amount of liq uid 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, a Gorman‐Rupp Auto matic Air Release Valve will permit air to escape through the bypass line and then close automati cally when the pump is fully primed and pumping at full capacity.
PAGE B - 5INSTALLATION
Page 13
OM-05444 SUPER T SERIES
Air Release Valve Installation
The Automatic Air Release Valve must be inde pendently mounted in a horizontal position be
Some leakage (1 to 5 gallons [3.8 to 19 liters] per minute) will occur when the valve is fully closed. Be sure the bypass line is directed back to the wet well or
tween the pump discharge port and the inlet side of the discharge check valve (see Figure 3). The inlet opening in the Air Release Valve is equipped with standard 1‐inch NPT pipe threads.
tank to prevent hazardous spills.
Consult the manual accompanying the Air Release Valve for additional information on valve installation and performance.
INSTALL AIR RELEASE VALVE IN HORIZONTAL POSITION
90 LONG
RADIUS ELBOW
BLEED LINE 1”
(25,4 MM) DIA. MIN.
(CUSTOMER FURNISHED) EXTEND 6”
(152,4 MM)
BELOW LIQUID
LEVEL SURFACE
SUPPORT BRACKET
CLEAN‐OUT COVER
SUCTION LINE
WET WELL OR SUMP
DISCHARGE PIPE
DISCHARGE CHECK VALVE
PUMP DISCHARGE
SELF‐PRIMING CENTRIFUGAL
PUMP
Figure 3. Typical Automatic Air Release Valve Installation
Connect the valve outlet to a bleed line which slopes back to the wet well or sump. The bleed line must be the same size as the outlet opening or
the Gorman‐Rupp Company for information about installation of an Automatic Air Release Valve for your specific application.
larger, depending on which Air Release Valve is be ing used. If piping is used for the bleed line, avoid the use of elbows whenever possible.
ALIGNMENT
NOTE
For multiple pump installations, it is recommended that each Air Release Valve be fitted with an inde pendent bleeder line directed back to the wet well. If multiple Air Release Valves are installed in a sys tem, do not direct bleeder lines to a common mani fold pipe. Contact your Gorman‐Rupp distributor or
PAGE B - 6 INSTALLATION
The alignment of the pump and its power source is critical for trouble‐free mechanical operation. In either a flexible coupling or belt‐driven system, the driver and pump must be mounted so that their shafts are aligned with and parallel to each other. It is imperative that alignment be checked after the
Page 14
pump and piping are installed, and before opera tion.
NOTE
Check Rotation, Section C, before final alignment of the pump.
OM-05444SUPER T SERIES
When mounted at the Gorman‐Rupp factory, driver and pump are aligned before shipment. Misalign ment will occur in transit and handling. Pumps must be checked and realigned before operation. Before checking alignment, tighten the foundation bolts. The pump casing feet and/or pedestal feet, and the driver mounting bolts should also be tightly secured.
When checking alignment, disconnect the power source to ensure that the pump will remain inoperative.
Adjusting the alignment in one direction may alter the alignment in another direc tion. check each procedure after altering alignment.
Coupled Drives
When using couplings, the axis of the power source must be aligned to the axis of the pump shaft in both the horizontal and vertical planes. Most couplings require a specific gap or clearance between the driving and the driven shafts. Refer to the coupling manufacturer's service literature.
Figure 4. Aligning Spider‐Type Couplings
Figure 5. Aligning Non‐Spider Type Couplings
Align non‐spider type couplings by using a feeler gauge or taper gauge between the coupling halves every 90. The coupling is in alignment when the hubs are the same distance apart at all points (see Figure 5).
Check parallel adjustment by laying a straightedge across both coupling rims at the top, bottom, and side. When the straightedge rests evenly on both halves of the coupling, the coupling is in horizontal parallel alignment. If the coupling is misaligned, use a feeler gauge between the coupling and the straightedge to measure the amount of misalign ment.
Drive Belts
Align spider insert type couplings by using calipers to measure the dimensions on the circumference of the outer ends of the coupling hub every 90. The coupling is in alignment when the hub ends are the same distance apart at all points (see Fig ure 4).
When using drive belts, the power source and the pump must be parallel. Use a straightedge along the sides of the pulleys to ensure that the pulleys are properly aligned (see Figure 6). In drive sys tems using two or more belts, make certain that the belts are a matched set; unmatched sets will cause accelerated belt wear.
PAGE B - 7INSTALLATION
Page 15
OM-05444 SUPER T SERIES
Do not operate the pump without the guard in place over the rotating parts. exposed rotating parts can catch cloth ing, fingers, or tools, causing severe in jury to personnel.
DRIVE BELT TENSIONING
MISALIGNED:
SHAFTS
NOT PARALLEL
Figure 6. Alignment of V‐Belt Driven Pumps
MISALIGNED:
SHAFTS
NOT IN LINE
ALIGNED: SHAFTS
PARALLEL AND
SHEAVES IN LINE
General Rules of Tensioning
For new drive belts, check the tension after 5, 20 and 50 hours of operation and re‐tension as re quired. Thereafter, check and re‐tension if required monthly or at 500 hour intervals, whichever comes first.
Tighten the belts in accordance with the belt manu facturer's instructions. If the belts are too loose, they will slip; if the belts are too tight, there will be excessive power loss and possible bearing failure. Select pulleys that will match the proper speed ra tio; overspeeding the pump may damage both pump and power source.
Ideal drive belt tension is the lowest tension at which the belt will not slip under peak load condi tions. Do not over‐tension drive belts. Over‐ten sioning will shorten both drive belt and bearing life. Under‐tensioning will cause belt slippage. Always keep belts free from dirt, grease, oil and other for eign material which may cause slippage.
PAGE B - 8 INSTALLATION
Page 16
SUPER T SERIES
OM-05444

OPERATION - SECTION C

Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and de cals attached to the pump.
This pump is designed to handle sew age, wastewater, trash and slurries con taining large entrained solids. Do not at tempt to pump volatile, corrosive, or flammable materials which may dam age the pump or endanger personnel as a result of pump failure.
Pump speed and operating condition points must be within the continuous per formance range shown on the curve. (See Section E, Page 1.)
1. The pump is being put into service for the first time.
2. The pump has not been used for a consider able length of time.
3. The liquid in the pump casing has evapo rated.
Once the pump casing has been filled, the pump will prime and reprime as necessary.
After filling the pump casing, reinstall and tighten the fill plug. Do not attempt to operate the pump unless all connect ing piping is securely installed. Other wise, liquid in the pump forced out 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.
PRIMING
Install the pump and piping as described in IN STALLATION. Make sure that the piping connec
tions are tight, and that the pump is securely mounted. Check that the pump is properly lubri cated (see LUBRICATION in MAINTENANCE AND REPAIR).
This pump is self‐priming, but the pump should never be operated unless there is liquid in the pump casing.
Never operate this pump unless there is liquid in the pump casing. The pump will not prime when dry. Extended operation of a dry pump will destroy the seal assembly.
Add liquid to the pump casing when:
STARTING
Consult the operations manual furnished with the power source.
OPERATION
Lines With a Bypass
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 power source. Priming is indicated by a positive
OPERATION PAGE C - 1
Page 17
reading on the discharge pressure gauge or by a quieter operation. The pump may not prime imme diately because the suction line must first fill with liquid. If the pump fails to prime within five minutes, stop it and check the suction line for leaks.
After the pump has been primed, partially close the discharge line throttling valve in order to fill the line slowly and guard against excessive shock pres sure which could damage pipe ends, gaskets, sprinkler heads, and any other fixtures connected to the line. When the discharge line is completely filled, adjust the throttling valve to the required flow rate.
Do not operate the pump against a closed discharge throttling valve for long periods of time. If operated against a closed discharge throttling valve, pump components will deteriorate, and the liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode.
Leakage
No leakage should be visible at pump mating sur faces, or at pump connections or fittings. Keep all line connections and fittings tight to maintain maxi mum pump efficiency.
Liquid Temperature And Overheating
SUPER T SERIESOM-05444
Do not remove plates, covers, gauges, pipe plugs, or fittings from an over heated pump. Vapor pressure within the pump can cause parts being disen gaged to be ejected with great force. Al low the pump to cool before servicing.
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 overheating 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 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 speci fied or provided by the Gorman‐Rupp Company.
Strainer Check
If a suction strainer has been shipped with the pump or installed by the user, check the strainer regularly, and clean it as necessary. The strainer should also be checked if pump flow rate begins to drop. If a vacuum suction gauge has been in stalled, monitor and record the readings regularly to detect strainer blockage.
Never introduce air or steam pressure into the pump casing or piping to remove a blockage. This could result in personal injury or damage to the equipment. If backflushing is absolutely neces sary, liquid pressure must be limited to 50% of the maximum permissible operating pressure shown on the pump performance curve.
The maximum liquid temperature for this pump is 160F (71C). Do not apply it at a higher operating temperature.
Overheating can occur if operated with the valves in the suction or discharge lines closed. Operating against closed valves could bring the liquid to a boil, build pressure, and cause the pump to rup ture or explode. If overheating occurs, stop the pump and allow it to cool before servicing it. Refill the pump casing with cool liquid.
Pump Vacuum Check
With the pump inoperative, install a vacuum gauge in the system, using pipe dope on the threads. Block the suction line and start the pump. At oper ating speed the pump should pull a vacuum of 20 inches (508 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.
OPERATIONPAGE C - 2
Page 18
SUPER T SERIES
OM-05444
Shut off the pump. The vacuum gauge reading will immediately drop proportionate to static suction lift, and should then stabilize. If the vacuum reading falls off rapidly after stabilization, an air leak exists. Before checking for the source of the leak, check the point of installation of the vacuum gauge.
STOPPING
Never halt the flow of liquid suddenly. If the liquid being pumped is stopped abruptly, damaging shock waves can be transmitted to the pump and piping system. Close all connecting valves slowly.
On engine driven pumps, reduce the throttle speed slowly and allow the engine to idle briefly be fore stopping.
If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.
After stopping the pump, disconnect or lock out the power source or take other action to ensure that the pump will remain inoperative.
Cold Weather Preservation
In below freezing conditions, drain the pump to prevent damage from freezing. Also, clean out any solids by flushing with a hose. Operate the pump for approximately one minute; this will remove any remaining liquid that could freeze the pump rotat
ing parts. If the pump will be idle for more than a few hours, or if it has been pumping liquids con taining a large amount of solids, drain the pump, and flush it thoroughly with clean water. To prevent large solids from clogging the drain port and pre venting the pump from completely draining, insert a rod or stiff wire in the drain port, and agitate the liquid during the draining process. Clean out any remaining solids by flushing with a hose.
BEARING TEMPERATURE CHECK
Bearings normally run at higher than ambient tem peratures because of heat generated by friction. Temperatures up to 160F (71C) are considered normal for bearings, and they can operate safely to at least 180F (82C).
Checking bearing temperatures by hand is inaccu rate. Bearing temperatures can be measured ac curately by placing a contact‐type thermometer against the housing. Record this temperature for future reference.
A sudden increase in bearing temperature is a warning that the bearings are at the point of failing to operate properly. Make certain that the bearing lubricant is of the proper viscosity and at the cor rect level (see LUBRICATION in MAINTENANCE AND REPAIR). Bearing overheating can also be caused by shaft misalignment and/or excessive vi bration.
When pumps are first started, the bearings may seem to run at temperatures above normal. Con tinued operation should bring the temperatures down to normal levels.
OPERATION PAGE C - 3
Page 19

TROUBLESHOOTING - SECTION D

Review all SAFETY information in Section A.
Before attempting to open or service 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 inopera tive.
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 open ing any covers, plates, or plugs.
7. Drain the pump.
OM-05444SUPER T SERIES
Table 1. Trouble Shooting Chart
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 gas ket.
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 leak ing or worn seal or gasket.
Check piping installation and install bypass line if needed. See INSTAL LATION.
Check strainer and clean if neces sary.
Correct leak.
Replace suction hose.
TROUBLESHOOTING PAGE D - 1
Page 20
OM-05444 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.)
PUMP REQUIRES TOO MUCH POWER
Leaking or worn seal or pump gas ket.
Strainer clogged.
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.
Pump speed too high.
Discharge head too low.
Check pump vacuum. Replace leaking or worn seal or gasket.
Check strainer and clean if neces sary.
Check installation and correct sub mergence as needed.
Replace worn or damaged parts. Check that impeller is properly cen tered and rotates freely.
Free impeller of debris.
Install bypass line.
Measure lift w/vacuum gauge. Re duce lift and/or friction losses in suction line.
Check engine output; consult en gine operation manual.
Check engine output.
Adjust discharge valve.
Liquid solution too thick.
Bearing(s) frozen.
PUMP CLOGS FREQUENTLY
EXCESSIVE NOISE Cavitation in pump.
Discharge flow too slow.
Suction check valve or foot valve clogged or binding.
Liquid solution too thick.
Pumping entrained air.
Pump or drive not securely mounted.
Impeller clogged or damaged.
Dilute if possible.
Disassemble pump and check bearing(s).
Open discharge valve fully to in crease flow rate, and run engine at maximum governed speed.
Clean valve.
Dilute if possible.
Reduce suction lift and/or friction losses in suction line. Record vacu um and pressure gauge readings and consult local representative or factory.
Locate and eliminate source of air bubble.
Secure mounting hardware.
Clean out debris; replace damaged parts.
TROUBLESHOOTINGPAGE D - 2
Page 21
Table 1. Trouble Shooting Chart (cont.)
OM-05444SUPER 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 pre ventive maintenance schedule will help assure trouble‐free performance and long life from your Gorman‐Rupp pump. For specific questions con cerning your application, contact your Gorman‐ Rupp distributor or the Gorman‐Rupp Company.
Record keeping is an essential component of a good preventive maintenance program. Changes in suction and discharge gauge readings (if so
Check bearing temperature regular ly 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 inspec tions can indicate problems that can be corrected before system damage or catastrophic failure oc curs. The appearance of wearing parts should also be documented at each inspection for comparison as well. Also, if records indicate that a certain part (such as the seal) fails at approximately the same duty cycle, the part can be checked and replaced before failure occurs, reducing unscheduled down time.
For new applications, a first inspection of wearing parts at 250 hours will give insight into the wear rate for your particular application. Subsequent inspec tions should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently.
TROUBLESHOOTING PAGE D - 3
Page 22
OM-05444 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
Annually
Legend: I = Inspect, Clean, Adjust, Repair or Replace as Necessary C = Clean R = Replace
* Service interval based on an intermittent 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 23
SUPER T SERIES
OM-05444
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 T10A61S-B, Including /FM
Based on 70F (21C) clear water at sea level
with minimum suction lift. Since pump installations are seldom identical, your performance may be dif ferent due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.
Contact the Gorman‐Rupp Company to verify per formance or part numbers.
Pump speed and operating condition
If your pump serial number is followed by an “N”, your pump is NOT a standard production model.
MAINTENANCE & REPAIR PAGE E - 1
points must be within the continuous per formance range shown on the curve.
Page 24
OM-05444 SUPER T SERIES
SECTION DRAWING

PARTS PAGE

Figure E-1. Pump Model T10A61S-B, /FM
MAINTENANCE & REPAIRPAGE E - 2
Page 25
SUPER T SERIES
OM-05444
PARTS LIST
Pump Model T10A61S-B, /FM
(From S/N 1255300 up)
If your pump serial number is followed by an “N”, your pump is NOT a standard production model. Contact the Gorman‐Rupp Company to verify part numbers.
ITEM
PART NAME PART
NO.
NUMBER
MAT'L CODE
QTY ITEM
NO.
PART NAME PART
NUMBER
MAT'L CODE
QTY
1 PUMP CASING SEE NOTE BELOW
2 REPAIR ROTATING ASSY 44163-351 --- 1 3 CHK VLV HSG ASSY 46421-037 --- 1 4 -CHECK VALVE BODY 38341-805 10010 1 5 -PIPE PLUG P08 15079 1 6 -CHECK VALVE 46411-082 24010 1 7 -PIVOT CAP 38141-003 11060 2 8 -HEX HD CAPSCREW B0606 17000 2
9 -LOCKWASHER AK06 17000 2 10 -FLAT WASHER KB08 17090 2 11 SHOULDER TYPE CPLG 25552-213 --- 1 12 CLEANOUT CVR GSKT 38688-008 20000 1 13 CLAMP BAR 38111-004 11010 2 14 MACHINE BOLT A1014 15991 4 15 CLAMP BAR SCREW 31912-009 15000 2 16 CLEANOUT CVR ASSY 48271-018 --- 1
-WARNING PLATE 38816-097 13990 1
-DRIVE SCREW BM#04-03 17000 1
-WARNING DECAL 2613FE --- 1
17 PIPE PLUG P04 15079 1
18 DISCH STICKER 6588BJ --- 1 19 NAMEPLATE 38818-040 13990 1 20 DRIVE SCREW BM#04-03 17000 4
21 SHIM SET 48261-056 --- REF 22 CASING RING 31281-016 15990 1 23 HEX HD CAPSCREW B0806 15991 6 24 LOCKWASHER J08 15991 6 25 HEX HD CAPSCREW B0805 15991 6 26 LOCKWASHER J08 15991 6 27 FILL CVR PLATE ASSY 42111-344 --- 1
28 -FILL CVR PLATE NOT AVAILABLE 1
29 -WARNING PLATE 38816-097 13990 1 30 -DRIVE SCREW BM#04-03 17000 2 31 -FILL COVER GASKET 50G 19210 1 32 CLAMP BAR SCREW 31912-009 15000 1
33 MACHINE BOLT A1014 15991 2
34 CLAMP BAR 38111-004 11010 1 35 ROTATION DECAL 2613M --- 1
36 BRG HSG O‐RING S1914 --- 1 37 SEAL PLATE O‐RING S1914 --- 1 38 FRONT WEAR PLATE 38691-826 17070 1
39 PIPE PLUG P08 15079 1
40 SUCTION HD GASKET 38682-811 20000 1
41 PIPE PLUG P24 10009 1
42 HEX HD CAPSCREW B1408 15991 2 43 LOCKWASHER J14 15991 2 44 HEX HD CAPSCREW B1207 15991 4 45 LOCKWASHER J12 15991 4
46 PRESS RELIEF VLV 46431-803 --- 1 47 RED PIPE BUSHING AP2008 11999 1 48 PIPE PLUG P20 10009 1 49 SUCTION HEAD 38246-609 10010 1 50 SUCTION STICKER 6588AG --- 1
NOT SHOWN:
PRIMING STICKER 6588AH --- 1 LUB DECAL 38817-084 --- 1 INSTRUC LABEL 2613DK --- 1 WARNING DECAL 2613FE --- 1 WARNING DECAL 38816-302 --- 1 G‐R DECAL GR-06 --- 1 INSTRUCTION TAG 38817-011 --- 1 INSTRUCTION TAG 38817-025 --- 1 SUPER T DECAL 38812-089 --- 1
OPTIONAL:
DISASSEMBLY TOOL 12858 24000 1 SPOOL FLANGE 38642-607 10000 1 /FM METRIC FLNG KIT 48213-084 --- 1
CASING HEATERS:
-120V 47811-014 --- 1
-240V 47811-015 --- 1
CHECK VALVE ASSYS:
-VITON MOLDED 46411-081 --- 1
PRESSURE RELIEF VALVES:
-BRASS SEWAGE TYPE 46431-628 --- 1
-STAINLESS STEEL 26662-101 --- 1
HI TEMP SHUT‐DOWN KITS:
-145ºF 48313-186 --- 1
-130ºF 48313-256 --- 1
-120ºF 48313-257 --- 1 HT SHUT DOWN 48313-172 --- 1 THERMOSTAT KIT 145ºF
AIR RELEASE VALVES:
-10# COMP SPRING GRP33-07A --- 1
-25# COMP SPRING GRP33-07 --- 1
-80# COMP SPRING GRP33-07B --- 1
SEAL PLATE/BRG HOUSING O‐RING:
-VITON 25154-458 --- 2
INDICATES PARTS RECOMMENDED FOR STOCK
OPTIONAL MECHANICAL SEAL(S) MUST BE USED WITH MECHANICAL SEAL SHAFT SLEEVE OR SOLID SST SHAFT.
KALREZ AND VITON ARE PRODUCTS OF THE DUPONT CORP PRODUCTS OF THE DUPONT CORP INCLUDED WITH REPAIR PUMP CASING ASSY 46472-709---1
MAINTENANCE & REPAIR PAGE E - 3
Page 26
OM-05444 SUPER T SERIES
SECTION DRAWING
DRIVE END VIEW
Figure E‐2. 44163-351 Repair Rotating Assembly
MAINTENANCE & REPAIRPAGE E - 4
Page 27
SUPER T SERIES
PARTS LIST
44163-351 Repair Rotating Assembly
ITEM
PART NAME PART
NO.
1 IMPELLER 38615-014 17070 1
2
SEAL ASSY 46512-192 --- 1
3 SEAL PLATE 38272-228 17070 1
SEAL PLATE GSKT 38684-302 19140 1
4
5 BEARING HSG O‐RING S1874 --- 1
6 HEX HD CAPSCREW 21632-945 --- 4
7 LOCKWASHER J08 15991 4
8 INBOARD BALL BEARING 23421-461 --- 1
9 BEARING HOUSING 38251-515 10000 1 10 VENTED PLUG 4823A 15079 1 11 AIR VENT S1530 --- 1 12 RED PIPE BUSHING AP0802 15079 1
13 BRG CAP OIL SEAL S1917 --- 1 14 BEARING CAP 38322-415 10010 1 15 HEX HD CAPSCREW B0605-1/2 15991 6 16 LOCKWASHER J06 15991 6
17 SHAFT KEY N0612 15990 1
18 IMPELLER SHAFT 38514-568 1706H 1 19 RETAINING RING S215 --- 1
20 OUTBOARD BALL BRG 23422-412 --- 1
21 BEARING CAP O‐RING S333 --- 1
22 OIL SEAL S1917 --- 1
23 OIL SEAL S1917 --- 1
24 IMPELLER WASHER 10278 17090 1
25 IMP CAP SCREW DM1004S 17090 1 26 SIGHT GAUGE S1471 --- 1 27 SIGHT GAUGE S1471 --- 1
NUMBER
MAT'L CODE
QTY ITEM
NO.
28 SEAL CVTY DRAIN PLUG P04 15079 1
28A BRG CVTY DRAIN PLUG P04 15079 1
29 SOC HD PIPE PLUG PC04 15079 1 30 PIPE PLUG P12 15079 1
31 IMP ADJ SHIM SET 5091 17090 1 32 SOC HD PIPE PLUG PC20 10009 1
33 SEAL PLATE O‐RING S1914 --- 1
34 BRG HSG O‐RING S1914 --- 1 35 SHIPPING PLUG 11495D 15079 2 36 S/N PLATE 2613GG 13990 1 37 DRIVE SCREW BM#04-03 17000 2
NOT SHOWN:
OPTIONAL:
-AFLAS 46512-193 --- 1
OM-05444
PART NAME PART
NUMBER
ROT ASSY SHIM SET 48261-056 --- 6 ROTATION DECAL 2613M --- 1 INSTRUCTION TAG 6588U --- 1
ADI IMPELLER 38615-014 1102H 1 ADI SEAL PLATE 38272-413 1102H 1
SEAL PLATE/BRG HOUSING O‐RING:
-VITON 25154-458 --- 2
PERMALON SEAL 46512-189 --- 1
METAL BELLOWS MECH SEAL ASSY
-KALREZ 46512-183 --- 1
MAT'L CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
OPTIONAL MECHANICAL SEAL MUST BE USED WITH MECHANICAL SEAL SHAFT SLEEVE OR /WWS SOLID SST SHAFT.
KALREZ AND VITON ARE PRODUCTS OF THE DUPONT CORP
AFLAS IS A PRODUCT OF THE 3M CORP
MAINTENANCE & REPAIR PAGE E - 5
Page 28
OM-05444 SUPER T SERIES

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Review all SAFETY information in Section A.
Follow the instructions on all tags, label and de cals attached to the pump.
This pump requires little service due to its rugged, minimum‐maintenance design. However, if it be comes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the sectional views (see Figures E‐1 and E‐2) and the accompanying parts lists.
This manual will alert personnel to known proce dures 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 per sonnel to ensure that only safe, established main tenance procedures are used, and that any proce dures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such prac tices.
Many service functions may be performed by draining the pump and removing the suction head. If major repair is required, the piping and/or engine must be disconnected. The following instructions assume complete disassembly is required.
sure that the pump will remain in operative.
3. Allow the pump to completely cool if overheated.
4. Check the temperature before opening any covers, plates, or plugs.
5. Close the suction and discharge valves.
6. Vent the pump slowly and cau tiously.
7. Drain the pump.
Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or dam age to equipment. Suction and dis charge hoses and piping must be re moved from the pump before lifting.
Cleanout Access And Suction Check Valve Removal
(Figure E‐1)
Before attempting to service the pump, remove the casing drain plug (41) and drain the pump. Clean and reinstall the drain plug.
For cleanout access, loosen the clamp screws (15) and clamp bars (13) securing the cleanout cover (16) to the suction head (49).
Before attempting to service the pump, switch off the engine ignition and disconnect the positive bat tery cable to ensure that the pump will remain inop erative. Close all valves in the suction and dis charge lines.
Before attempting to open or service the pump:
1. Familiarize yourself with this man ual.
2. Disconnect or lock out the power source, or take other action to en
To remove the check valve assembly, reach through the cleanout opening and remove the hardware (8, 9 and 10) securing the check valve (6) to the valve body (4) and suction head.
NOTE
An alternate method of removing the check valve assembly is to remove the hardware securing the valve body (4) to the suction piping. Disconnect the shoulder‐type coupling (11) and separate the valve body (4) and check valve from the suction head. Separate the check valve from the valve body as de scribed above.
Replace the cleanout cover gasket (12) before re installing the cover.
MAINTENANCE & REPAIRPAGE E - 6
Page 29
SUPER T SERIES
OM-05444
Suction Head And Wear Plate Removal
(Figure E‐1)
To remove the suction head, support it with a suit able hoist and sling and remove the hardware (42,43, 44 and 45) securing it to the pump casing. Remove the suction head gasket (40).
If the wear plate (38) does not slide easily from the casing bore, position a wood or soft metal wedge between the impeller vanes and the wear plate, and tap the wedge with a hammer. Turn the impel ler every 45, repeating the process until the wear plate is “walked” out of the pump casing.
Rotating Assembly Removal
(Figure E‐2)
The rotating assembly (2, Figure 1) may be re moved from either side of the casing; however, it is recommended that it be removed through the suc tion head opening.
The impeller (1) should be loosened while the rotat ing assembly is still secured to the pump casing. Before loosening the impeller, remove the seal cav ity drain plug (28) and drain the seal lubricant. This will prevent the oil in the seal cavity from escaping as the impeller is loosened. Clean and reinstall the seal cavity drain plug.
Immobilize the impeller by wedging a block of wood between the vanes and remove the impeller capscrew and washer (24 and 25). Install a lathe dog on the drive end of the shaft (18) with the “V” notch positioned over the shaft keyway. Strike the lathe dog sharply in a counterclockwise direction (when facing the drive end of the shaft). When the
impeller breaks loose, remove the wood block and lathe dog. Do not fully unscrew the impeller from the shaft at this time.
(Figure E‐1)
An optional disassembly tool for removing and in stalling the rotating assembly is available from the factory. If improvised tools are used, be sure they are heavy enough for safe use and will not damage the pump.
Remove the inner hardware (25 and 26) from the casing ring (22). If the removal tool is used, follow the instructions packaged with it, and pull the rotat ing assembly from the pump casing (see Figure E‐3 for removal tool use). If the removal tool is not used, install three of the inner capscrews in the jacking holes in the casing ring, and use them to press the rotating assembly into the pump casing until the bearing housing is free.
Remove the jacking screws from the casing ring. Remove the outer hardware (23 and 24) and shim sets (21). Separate the casing ring from the pump casing. Tie and tag the shim sets for ease of reas sembly.
After the rotating assembly is loosened, screw a 5/8‐11 UNC X 16 inch long threaded rod into the hole in the impeller shaft. Support the drive end of the shaft with a 1‐13/16” (46 mm) minimum I.D. piece of pipe or a set of handles as shown in Figure E‐3, and slide the complete rotating assembly through the suction head opening. Once free, use a suitable hoist and sling and attach it to the lifting eye provided at the top of the bearing housing to move the rotating assembly to a suitable work area for further disassembly.
MAINTENANCE & REPAIR PAGE E - 7
Page 30
OM-05444 SUPER T SERIES
ADD PIPE
AS REQUIRED
Figure E‐3. Rotating Assembly Removal With Tool
Impeller Removal
(Figure E‐2)
Unscrew the impeller from the shaft in a counter clockwise 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.
Remove the impeller adjusting shims (31). Tie and tag the shims or measure and record their thick ness for ease of reassembly.
Seal Removal And Disassembly
(Figure E‐2)
Remove the seal spring. Apply oil to the shaft and work it up under the bellows. Slide the rotating por tion of the seal off the shaft as a unit.
Use two stiff wires with hooked ends to remove the stationary portion of the seal.
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 seal plate and bearing housing O‐rings (33 and 34).
tionary seat until the seat, O‐rings, and stationary element can be removed.
If no further disassembly is required, refer to Seal
Installation.
Shaft and Bearing Removal and Disassembly
(Figure E‐2)
When the pump is properly operated and main tained, the bearing housing should not require dis assembly. Disassemble the shaft and bearings only when there is evidence of wear or damage.
Shaft and bearing disassembly in the field is not recommended. These operations should be performed only in a properly equipped shop by qualified personnel.
Remove the bearing housing drain plug (28A) and drain the lubricant. Clean and reinstall the drain plug.
Disengage the hardware (15 and 16) and remove the bearing cap (14), O‐ring (21) and oil seal (13) from the shaft. Press the oil seal from the bearing cap.
Position the seal plate on a flat surface with the im peller side down. Use a wooden dowel or other suitable tool to press on the back side of the sta
Place a block of wood against the impeller end of the shaft (18) and tap the shaft and assembled bearings (8 and 20) from the bearing housing.
MAINTENANCE & REPAIRPAGE E - 8
Page 31
SUPER T SERIES
OM-05444
After removing the shaft and bearings, clean and inspect the bearings in place as follows.
To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place. It is strongly recommended that the bearings be replaced any time the shaft and bear ings are removed.
Clean the bearing housing, shaft and all compo nent parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage and replace as necessary.
Most cleaning solvents are toxic and flammable. Use them only in a well ven tilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent contain ers.
Clean the bearings thoroughly in fresh cleaning solvent. Dry the bearings with filtered compressed air and coat with light oil.
If bearing replacement is required, remove the out board bearing retaining ring (19), and use a bear ing puller or an arbor (or hydraulic) press to remove the bearings from the shaft.
Press the oil seals (22 and 23) from the bearing housing bore.
Shaft and Bearing Reassembly and Installation
(Figures E‐2 and E‐4)
Clean the bearing housing, shaft and all compo nent parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage as necessary.
Most cleaning solvents are toxic and flammable. Use them only in a well ven tilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent contain ers.
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 (22) in the bearing housing bore with the lip positioned as shown in Figure E‐2. Press the oil seal into the housing until the face is just flush with the machined surface in side the housing.
Bearings must be kept free of all dirt and foreign material. Failure to do so will great ly shorten bearing life. Do not spin dry bearings. This may scratch the balls or races and cause premature bearing fail ure.
To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place. It is
Rotate the bearings by hand to check for rough ness or binding and inspect the bearing balls. If ro tation is rough or the bearing balls are discolored, replace the bearings.
The bearing tolerances provide a tight press fit onto the shaft and a snug slip fit into the bearing housing. Replace the bearings, shaft, or bearing housing if the proper bearing fit is not achieved.
MAINTENANCE & REPAIR PAGE E - 9
strongly recommended that the bearings
be replaced any time the shaft and bear ings are removed.
The bearings may be heated to ease installation. An induction heater, hot oil bath, electric oven, or hot plate may be used to heat the bearings. Bear ings should never be heated with a direct flame or directly on a hot plate.
Page 32
OM-05444 SUPER T SERIES
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 250F (120C), and slide the bearings
onto the shaft, one at a time, until they are fully seated. This should be done quickly, in one con
BALL LOADING GROOVE POSITIONED AWAY FROM IMPELLER
LOADING GROOVE
DIRECTION OF
THRUST
tinuous motion, to prevent the bearings from cool ing and sticking on the shaft.
Use caution when handling hot bearings to pre vent burns.
NOTE
Position the inboard bearing (8) on the shaft as indi cated by the following illustration.
BALL LOADING GROOVE POSITIONED
TOWARD IMPELLER
LOADING GROOVE
DIRECTION OF
THRUST
INSTALLATION OF NEW DEPARTURE OR
BCA/FEDERAL MOGAL 5300W SERIES BEARINGS
(OPEN OR ENCLOSED IMPELLERS)
Figure E‐4. Inboard Bearing Positioning
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 sleeve and a press to reposition the bearings against the shaft shoulders.
If heating the bearings is not practical, use a suit able sized sleeve, and an arbor (or hydraulic) press to install the bearings on the shaft.
INSTALLATION OF MRC/SKF 5300M OR
FAFNIR 5300W SERIES BEARINGS
(OPEN OR ENCLOSED IMPELLERS)
Secure the outboard bearing (20) on the shaft with the bearing retaining ring (19).
It is recommended that a sleeve be positioned against the inboard oil seal (22) 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 as sembled bearings into the bearing housing until the retaining ring on the outboard bearing seats against the bearing housing. Remove the lip seal sleeve.
When installing the bearings onto the shaft, never press or hit against the outer race, balls, or ball cage. Press only on the inner race.
When installing the shaft and bearings into
MAINTENANCE & REPAIRPAGE E - 10
Page 33
SUPER T SERIES
OM-05444
the bearing bore, push against the outer race. Never hit the balls or ball cage.
Position the outboard oil seal (23) in the bearing housing with the lip positioned as shown in Figure E‐2. 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 bearing cap (14) with the lip positioned as shown in Figure E‐2. Replace the bearing cap O‐ring (21), and secure the bear ing cap with the hardware (15 and 16). Be careful not to damage the oil seal lip on the shaft keyway.
Lubricate the bearing housing as indicated in LU
BRICATION at the end of this section.
Seal Reassembly and Installation
(Figures E‐2 and E‐5)
Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent.
The seal is not normally reused because wear pat terns on the finished faces cannot be realigned during reassembly. This could result in premature failure. If necessary to reuse an old seal in an emer gency, carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.
Handle the seal parts with extreme care to prevent damage. Be careful not to contaminate precision finished faces; even fingerprints on the faces can 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.
Inspect the seal components for wear, scoring, grooves, and other damage that might cause leak age. 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 com ponents are worn, replace the complete seal;
never mix old and new seal parts.
Most cleaning solvents are toxic and flammable. Use them only in a well ven tilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent contain ers.
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 bel lows and stationary seat O‐rings with water or a very small amount of oil, and apply a drop of light lubricating oil on the finished faces. Assemble the seal as follows, (see Figure E‐5).
MAINTENANCE & REPAIR PAGE E - 11
Page 34
OM-05444 SUPER T SERIES
SPRING
IMPELLER
SHIMS
BELLOWS
IMPELLER
RETAINER
DRIVE BAND
ROTATING
ELEMENT
SEAL PLATE
O‐RINGS
IMPELLER
SHAFT
STATIONARY
ELEMENT
STATIONARY
SEAT
Figure E‐5. 46512-192 Seal Assembly
This seal is not designed for operation at temperatures above 160F (71C). Do not use at higher operating temperatures.
Lubricate the stationary seat O‐rings with water or light oil, and install them in the stationary seat. In stall the stationary seal element in the stationary seat. Press this stationary subassembly into the front of the seal end plate (3) until it seats squarely against the bore shoulder. Be careful not to dam age the seal face.
Install the seal plate gasket (4) and seal plate O‐ ring (33). Position the seal plate and stationary seat over the shaft. Position the seal plate so that the cast word “TOP” is upper most and secure it to the bearing housing (9) with the hardware (6 and 7). Torque the hardware to 90 ft. lbs. (1,080 in. lbs. or 12,4 m. kg.). Be careful not to damage the station ary element on the shaft threads.
NOTE
It is recommended that a tapered sleeve be in stalled over the threads of the impeller shaft to ease installation of the rotating seal components.
Lubricate the shaft with a small amount of light oil and slide the rotating subassembly (consisting of rotating element, bellows and retainer), onto the shaft. Apply firm, steady pressure on the seal re tainer as it slides onto the shaft until the seal faces contact.
Install the seal spring. Lubricate the seal as indi cated in LUBRICATION after the impeller is in stalled.
If necessary to reuse an old seal in an emer gency, carefully separate the rotating and station ary seal faces from the bellows retainer and sta tionary seat.
A new seal assembly should be installed
MAINTENANCE & REPAIRPAGE E - 12
Page 35
SUPER T SERIES
OM-05444
any time the old seal is removed from the
pump. Wear patterns on the finished faces cannot be realigned during reassembly. Reusing an old seal could result in prema ture failure.
Handle the seal parts with extreme care to prevent damage. Be careful not to contaminate precision finished faces; even fingerprints on the faces can shorten seal life. If necessary, clean the faces with a non‐oil based solvent and a clean, lint‐free tissue. Wipe lightly in a concentric pattern to avoid scratching the faces.
Carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.
Do not attempt to separate the rotating portion of the seal from the shaft sleeve when reusing an old seal. The rubber bel lows will adhere to the sleeve during use, and attempting to separate them could damage the bellows.
Inspect the seal components for wear, scoring, grooves, and other damage that might cause leak age. Inspect the integral shaft sleeve for nicks or cuts on either end. If any components are worn, or the sleeve is damaged, replace the complete seal; never mix old and new seal parts.
Install the stationary seal element in the stationary seat. Press this stationary subassembly into the seal end 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 about the same as the I.D. of the seal spring.
Slide the rotating portion of the seal (consisting of rotating element, bellows and retainer) onto the shaft until the seal faces contact.
Impeller Installation and Adjustment
(Figure E‐2)
Inspect the impeller, and replace it if cracked or badly worn. Inspect the impeller and shaft threads for dirt or damage, and clean or dress the threads as required.
The shaft and impeller threads must be completely clean before reinstalling the im peller. Even the slightest amount of dirt on the threads can cause the impeller to seize to the shaft, making future removal difficult or impossible without damage to the im peller or shaft.
Install the same thickness of impeller adjusting shims (31) as previously removed. Apply `Never‐ Seez' 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 shoul der 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.
A clearance of .020 to .025 inch (0,51 to 0,64 mm) between the impeller and the wear plate is recom mended for maximum pump efficiency. Measure this clearance, and add or remove impeller adjust ing shims as required.
NOTE
If the rotating assembly has been installed in the pump casing, this clearance may be measured by reaching through the priming port with a feeler gauge.
Install the seal spring. Lubricate the seal as indi cated in LUBRICATION after the impeller is in stalled.
Proceed with Impeller Installation and Adjust
ment.
MAINTENANCE & REPAIR PAGE E - 13
After the rotating assembly is installed in the pump casing, coat the threads of the impeller capscrew (25) with `Never‐Seez' or equivalent compound, and install the impeller washer (24) and capscrew; torque the capscrew to 90 ft. lbs. (1080 in. lbs. or 12,4 m. kg.).
Page 36
OM-05444 SUPER T SERIES
Rotating Assembly Installation
(Figure E‐1)
Install the bearing housing and seal plate O‐rings (36 and 37) and lubricate them with light grease. Ease the rotating assembly into the pump casing using the installation tool. Be careful not to dam age the O‐rings.
Install the pump casing ring (22), and secure it to the rotating assembly with the inner hardware (25 and 26).
NOTE
The inner capscrews are 1/4 inch (3,2 mm) shorter than the outer capscrews.
Install an equal thickness of rotating assembly shims (21) under the pump casing ring, and secure the ring to the pump casing with the outer hard ware (23 and 24).
Suction Head And Wear Plate Installation
(Figure E‐1)
Clean any scale or debris from the contacting sur faces in the pump casing that might prevent a good seal with the suction head or interfere with the wear plate (38). Inspect the wear plate for wear or damage and replace as required. Slide the wear plate into the pump casing until fully seated.
Replace the suction head gasket (40) 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 (42, 43, 44 and 45).
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 re duce rust and scale build‐up.
Suction Check Valve Installation
(Figure E‐1)
NOTE
If the pump has been completely disassembled, it is recommended that the wear plate (38) and suc tion head (49) be reinstalled at this point. The suc tion 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 rec ommended for maximum pump efficiency. This clearance can be obtained by removing an equal amount of shims from each rotating assembly shim set (21) 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.
NOTE
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 as sembly shims accordingly.
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 (7) and hardware (8, 9 and 10).
NOTE
If the check valve body (4) was removed, install the check valve and secure the body to the suction head with the shoulder type clamp (11).
PRESSURE RELIEF VALVE MAINTENANCE
(Figure E‐1)
The suction head is equipped with a pressure relief valve (46) 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 as sembly be replaced at each overhaul, or any time the pump overheats and activates the valve. Never replace this valve with a substitute which has not
MAINTENANCE & REPAIRPAGE E - 14
Page 37
SUPER T SERIES
OM-05444
been specified or provided by the Gorman‐Rupp Company.
Periodically, the valve should be removed for in spection and cleaning. When reinstalling the relief valve, apply `Loctite Pipe Sealant With Teflon No. 592', or equivalent compound, on the relief valve threads. Position the valve as shown in Figure E‐1, with the discharge port pointing down.
LUBRICATION
Seal Assembly
(Figure E‐2)
Check the oil level regularly through the sight gauge (26) and maintain it at the middle of the gauge. When lubrication is required, remove the vented plug (10) and add SAE No. 30 non‐deter gent oil through the hole until the level is at the middle of the sight gauge.
larly through the sight gauge (27) the middle of the gauge. When lubrication is re quired, remove the air vent and bushing (11 and
12) and add SAE No. 30 non‐detergent 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 pre mature bearing failure.
and maintain it at
oil through
NOTE
The white reflector in the sight gauge must be posi tioned horizontally to provide proper drainage.
Under normal conditions, drain the bearing hous ing once each year and refill with clean oil. Change the oil more frequently if the pump is operated con tinuously or installed in an environment with rapid temperature change.
NOTE
The white reflector in the sight gauge must be posi tioned horizontally to provide proper drainage.
Bearings
(Figure E‐2)
The bearing housing was fully lubricated when shipped from the factory. Check the oil level regu
Monitor the condition of the bearing lubri cant regularly for evidence of rust or mois ture condensation. This is especially im portant in areas where variable hot and cold temperatures are common.
For cold weather operation, consult the factory or a lubricant supplier for the recommended grade of oil.
MAINTENANCE & REPAIR PAGE E - 15
Page 38
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 MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA
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