Page 1
D
OM-06610-01
May 1, 2013
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
SUPER T SERIES
ENVIRONMENTAL SILENT PUMP
MODEL
T6A60S-5.7 NG-ESP
THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
www.grpumps.com
E2010 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 - 2............................................
Battery Specifications And Installation PAGE B - 2....................................
SAFETY AND CONFORMANCE PAGE B - 2.............................................
POSITIONING PUMP PAGE B - 3.......................................................
Lifting PAGE B - 3.................................................................
Mounting PAGE B - 3.............................................................
Clearance PAGE B - 3.............................................................
FUEL SUPPLY PAGE B - 3.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 3.........................................
Materials PAGE B - 3..............................................................
Line Configuration PAGE B - 4......................................................
Connections to Pump PAGE B - 4..................................................
Gauges PAGE B - 4...............................................................
SUCTION LINES PAGE B - 4...........................................................
Fittings PAGE B - 4...............................................................
Strainers PAGE B - 4..............................................................
Sealing PAGE B - 4...............................................................
Suction Lines In Sumps PAGE B - 4.................................................
Suction Line Positioning PAGE B - 5................................................
FLOAT SWITCHES PAGE B - 5.........................................................
Installation PAGE B - 5............................................................
OPTIONAL SUBMERSIBLE TRANSDUCER PAGE B - 6...................................
DISCHARGE LINES PAGE B - 7........................................................
Siphoning PAGE B - 7.............................................................
Valves PAGE B - 7................................................................
Bypass Lines PAGE B - 8..........................................................
AUTOMATIC AIR RELEASE VALVE PAGE B - 9...........................................
OPERATION - SECTION C PAGE C - 1......................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 2................................................................
Manual Starting PAGE C - 2........................................................
Automatic Starting PAGE C - 2.....................................................
OPTIONAL EPS CONTROL PAGE C - 2.................................................
Features PAGE C - 2..............................................................
Functional Description PAGE C - 3..................................................
EPS Functions PAGE C - 3.........................................................
EPS Calibration PAGE C - 4........................................................
Zero Adjustment PAGE C - 4.......................................................
Span Adjustment PAGE C - 4......................................................
Level Adjustment PAGE C - 4......................................................
Horn Delay PAGE C - 5............................................................
i
Page 4
TABLE OF CONTENTS
(continued)
OPERATION PAGE C - 5..............................................................
Lines With a Bypass PAGE C - 5....................................................
Lines Without a Bypass PAGE C - 5.................................................
Leakage PAGE C - 5..............................................................
Liquid Temperature And Overheating PAGE C - 5.....................................
Strainer Check PAGE C - 6.........................................................
Pump Vacuum Check PAGE C - 6..................................................
STOPPING PAGE C - 6................................................................
Manual Stopping PAGE C - 6.......................................................
Automatic Stopping PAGE C - 6....................................................
Safety Shutdown System PAGE C - 6...............................................
OPERATION IN EXTREME HEAT PAGE C - 7............................................
Cold Weather Preservation PAGE C - 7..............................................
BEARING TEMPERATURE CHECK PAGE C - 7..........................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...............................................
PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................
STANDARD PERFORMANCE CURVE PAGE E - 1........................................
PARTS LISTS:
Pump Model PAGE E - 3..........................................................
Pump Model (Cont'd) PAGE E - 5...................................................
Pump Model (Cont'd) PAGE E - 7...................................................
Pump End Assembly PAGE E - 9...................................................
Repair Rotating Assembly PAGE E - 11...............................................
Check Valve/Air Release Valve Assembly PAGE E - 13..................................
Check Valve Assembly PAGE E - 14..................................................
Drive Assembly PAGE E - 15........................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 16.........................
Back Cover And Wear Plate Removal PAGE E - 16.....................................
Suction Check Valve Removal PAGE E - 17...........................................
Separating Intermediate and Drive Assembly From Engine PAGE E - 17..................
Loosening Impeller PAGE E - 17.....................................................
Rotating Assembly Removal PAGE E - 18.............................................
Impeller Removal PAGE E - 18......................................................
Seal Removal PAGE E - 18..........................................................
Shaft and Bearing Removal and Disassembly PAGE E - 19.............................
Shaft and Bearing Reassembly and Installation PAGE E - 20............................
Seal Installation PAGE E - 21........................................................
Impeller Installation PAGE E - 24.....................................................
Rotating Assembly Installation PAGE E - 24...........................................
Suction Check Valve Installation PAGE E - 24.........................................
Back Cover Installation And Adjustment PAGE E - 24..................................
Securing Pump and Drive Assembly to Engine PAGE E - 25............................
PRESSURE RELIEF VALVE MAINTENANCE PAGE E - 26..................................
Final Pump Assembly PAGE E - 27..................................................
LUBRICATION PAGE E - 27.............................................................
Seal Assembly PAGE E - 27.........................................................
Bearings PAGE E - 27..............................................................
ii
Page 5
TABLE OF CONTENTS
(continued)
Engine PAGE E - 26................................................................
iii
Page 6
SUPER T SERIES
OM-06610
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. The pump is designed with external shim
less adjusters for setting the wear plate to impeller
clearance. The pump is close coupled to a General
Motors natural gas powered engine, and is de
signed for handling dirty water containing speci
fied entrained solids and slurries. The basic materi
al of construction is gray iron, with ductile iron im
peller and steel wearing parts. The pump is
mounted on a spill‐containment base and sur
rounded by a sound‐attenuating enclosure.
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.
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 en
gine, contact the engine manufacturer'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
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 7
SUPER T SERIES
SAFETY ‐ SECTION A
This information applies to Super T Se
ries engine driven pumps. Refer to the
manual accompanying the engine be
fore attempting to begin operation.
This manual will alert personnel to
known procedures which require spe
cial attention, to those which could
damage equipment, and to those which
could be dangerous to personnel. How
ever, this manual cannot possibly pro
vide detailed instructions and precau
tions for each specific application or for
every situation that might occur during
maintenance of the unit. Therefore, it is
the responsibility of the owner, installer
and/or maintenance personnel to en
sure that applications and/or mainte
nance procedures not addressed in this
manual are performed only
lishing that neither personal safety nor
pump integrity are compromised by
such applications or procedures.
after estab
OM-06610
This pump is equipped with an automat
ic starting system, and is subject to au
tomatic restart. Keep hands and cloth
ing away from the unit to prevent injury
during automatic operation. Disconnect
the positive battery cable before per
forming any maintenance. Failure to do
so may result in serious personal injury.
This pump is designed to handle dirty
water containing specified entrained
solids. Do not attempt to pump volatile,
corrosive, or flammable liquids which
may damage the pump or endanger per
sonnel as a result of pump failure.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Shut down the engine, remove the
key and disconnect the positive
battery cable to ensure that the
pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau
tiously.
7. Drain the pump.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment. The bail is intended
for use in lifting the pump assembly
only. Suction and discharge hoses and
piping must be removed from the pump
before lifting.
After the unit has been installed, make
certain that the pump and all piping or
hose connections are tight, properly
supported and secure before operation.
Do not operate the pump against a
PAGE A - 1SAFETY
Page 8
SUPER T SERIESOM-06610
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.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over
heated pump. Vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Al
low the pump to cool before servicing.
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating internal combustion
engines in an enclosed area, make cer
tain that exhaust fumes are piped to the
outside. These fumes contain carbon
monoxide, a deadly gas that is color
less, tasteless, and odorless.
precautions outlined by the National
Fire Protection Association when de
signing and installing the system. Make
certain that the regulators and fuel lines
are of the proper size and capacity for
the system, and that all fuel lines are se
curely connected and free of leaks.
Fuel used by internal combustion en
gines presents an extreme explosion
and fire hazard. Make certain that all
fuel lines are securely connected and
free of leaks.
Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. Refer to the performance
curve in Section E for the maximum con
tinuous operating speed for this pump.
Pumps and related equipment must be in
Natural gas presents an extreme explo
sion and fire hazard. Follow all safety
PAGE A - 2 SAFETY
stalled and operated according to all na
tional, local and industry standards.
Page 9
SUPER T SERIES OM-06610
INSTALLATION - SECTION B
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this
section offers only general recommendations and
practices required to inspect, position, and ar
range the pump and piping.
Most of the information pertains to a standard
static lift application where the pump is positioned
above the free level of liquid to be pumped.
If installed in a flooded suction application where
the liquid is supplied to the pump under pressure,
some of the information such as mounting, line
configuration, and priming must be tailored to the
OUTLINE DRAWING
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 T6A60S-5.7 NG-ESP
PAGE B - 1INSTALLATION
Page 10
OM-06610 SUPER T SERIES
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 assembly for cracks, dents,
damaged threads, and other obvious dam
age.
b. Check for and tighten loose attaching hard
ware. Since gaskets tend to shrink after dry
ing, check for loose hardware at mating sur
faces.
c. Carefully read all tags, decals, and markings
on the pump assembly, and perform all duties
indicated.
d. Check levels and lubricate as necessary. Re
fer to LUBRICATION in the MAINTENANCE
AND REPAIR section of this manual and per
form duties as instructed.
e. If the pump and engine have been stored for
more than 12 months, some of the compo
nents or lubricants may have exceeded their
maximum shelf life. These must be inspected
or replaced to ensure maximum pump serv
ice.
If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Gorman‐Rupp distributor or the factory to deter
mine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.
Battery Specifications And Installation
Before installing the battery, clean the positive and
negative cable connectors, and the battery termi
nals. Secure the battery by tightening the
holddown brackets. The terminals and clamps
may be coated with petroleum jelly to retard corro
sion. Connect and tighten the positive cable first,
then the negative cable.
SAFETY AND CONFORMANCE
All aspects of the design and installation of the fuel
supply system must be evaluated in terms of safety
to personnel and equipment, and conformance to
all applicable codes.
Natural gas presents an extreme explo
sion and fire hazard. Follow all safety
precautions outlined by the National
Fire Protection Association when de
signing and installing the system. Make
certain that the regulators and fuel lines
are of the proper size and capacity for
the system, and that all fuel lines are se
curely connected and free of leaks.
Before installing the system:
1. Check all state and local codes pertaining to
installations of stationary combustion engines
and fuel systems.
Unless otherwise specified on the pump order, the
engine battery was not included with the unit. Re
2. Consult the following National Fire Protection
Association pamphlet:
fer to the following specifications when selecting a
battery.
NFPA No. 37 - Stationary Combustion
Engines/Gas Turbines
Table 1. Battery Specifications
Copies may be ordered from:
National Fire Protection Association
1 Batterymarch Park
Quincy, Massachusets 02269
Voltage
12 Volts
Cold
Crank
Amps
@ 0_ F
950
Reserve
Capacity
@ 80_ F
(Minutes)
175
Amp/
Hr.
Rating
95
Approx.
Overall
Dims.
(Inches)
13L
x
7W
x
9.5H
PAGE B - 2 INSTALLATION
Page 11
SUPER T SERIES OM-06610
POSITIONING PUMP
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment. The bail is intended
for use in lifting the pump assembly
only. Suction and discharge hoses and
piping must be removed from the pump
before lifting.
Lifting
Pump unit weights will vary depending on the
mounting and drive provided. Check the shipping
tag on the unit packaging for the actual weight, and
use lifting equipment with appropriate capacity.
Drain the pump and remove all customer‐installed
equipment such as suction and discharge hoses
or piping before attempting to lift existing, installed
units.
and engine may be positioned up to 30
zontal for intermittent operation only; however,
the engine manufacturer should be consulted for
continuous operation at angles greater than 15
Clearance
When positioning the pump, allow a minimum
clearance of 18 inches (457,2 mm) in front of the
enclosure suction cover to permit removal of the
cover and easy access to the pump.
_
off hori
_
FUEL SUPPLY
The amount of fuel required for the engine is meas
ured in cubic feet per hour. This is calculated from
the BTU (British Thermal Unit) content of the natu
ral gas supplied, and the horsepower required to
drive the pump. This unit requires 826 cubic feet
of natural gas per hour with 1000 BTU content at
10 inches of water column. The BTU content of
gas varies in the United States, therefore, it will be
necessary to contact your local gas supplier to de
termine the BTU content of the natural gas in your
area.
.
The pump assembly can be seriously
damaged if the cables or chains used to lift
and move the unit are improperly wrapped
around the pump.
Mounting
Locate the pump in an accessible place as close as
practical to the liquid being pumped. Level 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.
If the pump has been mounted on a moveable
base, make certain the base is stationary by setting
the brake and blocking the wheels before attempt
ing to operate the pump.
To ensure sufficient lubrication to the engine, do
not position the pump and engine more than 15
off horizontal for continuous operation. The pump
Natural gas suppliers typically provide 2 psi of gas
to commercial accounts. To provide the optimal
gas supply to the engine, this must be reduced to
10 inches of water column. Install the pressure reg
ulator supplied with the unit in the line supplying
the engine.
There is a 1‐inch pipe tee in the engine fuel line.
The tee is equipped with a reducer and a 1/4‐inch
pipe plug. Remove the pipe plug and install a pres
sure gauge rated in inches of water column.
Open the fuel supply to the regulator and observe
the pressure gauge. If the reading is less or greater
than 10 inches of water column, remove the cap on
the regulator to expose the adjusting screw plug
beneath it. Turn the adjusting plug clockwise to in
crease the fuel supply or counter‐clockwise to de
crease the fuel supply.
When the supply is properly adjusted to 10 inches
of water column, reinstall the protective cap over
the adjusting screw on the regulator. Remove the
pressure gauge from the fuel line and reinstall the
_
1/4‐inch pipe plug to avoid vibration damage to the
gauge.
PAGE B - 3INSTALLATION
Page 12
OM-06610 SUPER T SERIES
SUCTION AND DISCHARGE PIPING
Pump performance is adversely effected by in
creased suction lift, discharge elevation, and fric
tion losses. See the performance curve and notes
on Page E‐1 to be sure your overall application al
lows pump to operate within the safe operation
range.
Materials
Either pipe or hose maybe used for suction and
discharge lines; however, the materials must be
compatible with the liquid being pumped. If hose is
used in suction lines, it must be the rigid‐wall, rein
forced type to prevent collapse under suction. Us
ing piping couplings in suction lines is not recom
mended.
Line Configuration
Keep suction and discharge lines as straight as
possible to minimize friction losses. Make mini
mum use of elbows and fittings, which 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.
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.
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
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
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
Gauges
Most pumps are drilled and tapped for installing
discharge pressure and vacuum suction gauges.
If these gauges are desired for pumps that are not
tapped, drill and tap the suction and discharge
lines not less than 18 inches (457,2 mm) from the
suction and discharge ports and install the lines.
PAGE B - 4 INSTALLATION
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.
Page 13
SUPER T SERIES OM-06610
Suction Lines In Sumps
If a single suction line is installed in a sump, it
should be positioned away from the wall of the
sump at a distance equal to 1 1/2 times the diame
ter of the suction line.
If there is a liquid flow from an open pipe into the
sump, the flow should be kept away from the suc
tion inlet because the inflow will carry air down into
the sump, and air entering the suction line will re
duce pump efficiency.
If it is necessary to position inflow close to the suc
tion inlet, install a baffle between the inflow and the
suction inlet at a distance 1‐1/2 times the diameter
of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into
the suction inlet.
If 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.
recommended minimum submergence vs. veloc
ity.
Figure 2 shows
NOTE
The pipe submergence required may be reduced
by installing a standard pipe increaser fitting at the
end of the suction line. The larger opening size will
reduce the inlet velocity. Calculate the required
submergence using the following formula based
on the increased opening size (area or diameter).
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
FLOAT SWITCHES
Installation
The standard pump is equipped with an auto‐start
control system, and can be conformed to start and
stop as the liquid level in the wet well or sump rises
and falls. The autostart unit employs either a single
or double float switch system, where a bulb raises
or lowers (floats) with the liquid level, thus activat
ing an enclosed miniature switch. The floats are
PAGE B - 5INSTALLATION
Page 14
OM-06610 SUPER T SERIES
equipped with a socket type connector that plugs
into a matching receptacle on the auto‐start control
box.
Standard floats are equipped with 50 feet (15,2 m)
of cable.
When installing the floats, note the following:
a. Be sure to provide sufficient room in the wet
well or sump so that floats do not get ob
structed or drawn into the suction line. If a flex
ible suction hose is used, it may be extended
to lay along the bottom of the wet well or sump
and the float can be attached to the hose
above the point where it bends along the bot
tom. Direct the suction line toward the flow,
and the float(s) away from the flow. If a stand
pipe is available, attach the float switch cable
to the standpipe in the sump at the approxi
mate desired liquid level.
ENGINE
CONTROL
BOX
ON
(Emptying)
OFF
(Filling)
OPERATING
CABLE
TETHER
RANGE
(See Table Below)
POINT
OFF
(Emptying)
1.25” Pipe
(Not Furnished)
ON
(Filling)
b. In a single float system, the cable can be teth
ered to the suction line or standpipe approxi
mately 6 inches (152 mm) above the float.
This setting allows approximately 9 inches
(229 mm) of liquid rise between pump start/
stop. The start/stop interval may be increased
by extending the float end of the cable. The
liquid level in the sump will increase approxi
mately 8 inches (203 mm) between start/stop
intervals for every 6 inches (152 mm) of cable
increase.
c. If a double float switch system is used, posi
tion the “Start” float at the desired high water
level in the sump, and the “Stop” float at the
desired low water level in the pump.
d. Refer to Figure 3 for additional float switch
data.
3.0
(0.9)
2.5
(.76)
2.0
(0.6)
1.5
(.46)
1.0
(0.3)
0.5
(.15)
1.0
(0.3)
APPROXIMATE FREE CORD LENGTH IN FT. (M)
2.0
(0.6)
3.0
(0.9)
4.0
(1.2)
Figure 3. Float Switch Data
OPTIONAL SUBMERSIBLE
TRANSDUCER
When installing the submersible transducer, note
the following:
a. Handle the signal cable and transducer with
care during installation. Carefully lower the
transducer into the wet well or sump; do not
This unit may be equipped with an optional Elec
tronic Pressure Switch (EPS) that works in con
drop it to the bottom. To avoid clogging, sus
pend the transducer off the bottom.
junction with a submersible transducer. The sub
mersible transducer converts pressure to an elec
trical signal proportional to liquid level. This electri
cal signal is distributed to the digital display on the
EPS through a scaling circuit which converts the
electrical signal to “feet of water”.
b. Be sure to provide sufficient room in the wet
well or sump so that the transducer does not
get drawn into the suction line. To prevent this,
a flexible suction hose may be extended to lay
along the bottom of the wet well or sump. The
PAGE B - 6 INSTALLATION
Page 15
SUPER T SERIES OM-06610
transducer can then be attached to the hose
above the point where it bends along the bot
tom. See Figure B-4 for a typical installation.
c. The wet well or sump must be vented to atmo
sphere.
d. The EPS is scaled in feet of water column. If
the measured medium is other than 1.0 spe
cific gravity, the reading on the EPS should be
divided by the specific gravity of the mea
sured medium to obtain the actual level.
SUCTION
DISCHARGE
LINE
LINE
e. Thoroughly clean the transducer after each
use to prevent clogging.
Do not disassemble the transducer or
loosen the compression nut at the signal
cable entry. This will void warranty. There
are no user‐serviceable parts inside. Do
not nick or cut the jacket of the signal
cable; this will cause leakage and void
warranty.
SIGNAL CABLE
(ATTACH TO
SUCTION LINE)
SUBMERSIBLE
TRANSDUCER
(DOWNSTREAM
FROM SUCTION)
SUCTION
STRAINER
Figure 4. Typical Submersible Transducer Installation
DISCHARGE LINES
Siphoning
Do not terminate the discharge line at a level lower
than that of the liquid being pumped unless a si
phon breaker is used in the line. Otherwise, a si
phoning action causing damage to the pump
could result.
FLOW
Valves
If a throttling valve is desired in the discharge line,
use a valve as large as the largest pipe to minimize
friction losses. Never install a throttling valve in a
suction line.
With high discharge heads, it is recommended that
a throttling valve and a system check valve be in
stalled in the discharge line to protect the pump
PAGE B - 7INSTALLATION
Page 16
OM-06610 SUPER T SERIES
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
Self‐priming pumps are not air compressors. Dur
ing the priming cycle, air from the suction line must
be vented to atmosphere on the discharge side. If
the discharge line is open, this air will be vented
through the discharge. However, if a check valve
has been installed in the discharge line, the dis
charge side of the pump must be opened to atmos
pheric pressure through a bypass line installed be
tween the pump discharge and the check valve. A
self‐priming centrifugal pump will not prime if
there is sufficient static liquid head to hold the dis
charge check valve closed.
NOTE
The bypass line should be sized so that it does not
affect pump discharge capacity; however, the by
pass line should be at least 1 inch (25,4 mm) in di
ameter to minimize the chance of plugging.
It is also recommended that pipe unions be in
stalled at each 90
disassembly and maintenance.
In high discharge head applications (more than
30 feet (9,1 m), an excessive amount of liquid may
be bypassed and forced back to the wet well under
the full working pressure of the pump; this will re
duce overall pumping efficiency. Therefore, 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 Valves 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.
_
elbow in a bypass line to ease
Except in certain specific applications (to
prevent flooding during service of an auto
matic air release valve in a below‐ground
lift station), if a manual shut‐off valve is in
stalled anywhere in a bypass line, it must
be a full‐opening, ball‐type valve to pre
vent plugging by solids.
In low discharge head applications (less than 30
feet (9,1 m)), it is recommended that the bypass
line be run back to the wet well, and located 6
inches below the water level or cut‐off point of the
low level pump. In some installations, this bypass
outline may be terminated with a six‐to‐eight foot
(1,8 to 2,4 m) length of 1‐1/4 inch (31,8 mm) I.D.
smooth‐bore hose; air and liquid vented during
the priming process will then agitate the hose and
break up any solids, grease, or other substances
likely to cause clogging.
A 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 com
pletely cool before servicing. Do not re
move plates, covers, gauges, or fittings
A bypass line that is returned to a wet well
must be secured against being drawn into
the pump suction inlet.
PAGE B - 8 INSTALLATION
from an over‐heated pump. Liquid with
in the pump can reach boiling tempera
tures, and vapor pressure within the
Page 17
SUPER T SERIES OM-06610
pump can cause parts being disen
gaged to be ejected with great force. Af
ter the pump completely cools, drain the
liquid from the pump by removing the
casing drain plug. Use caution when re
moving the plug to prevent injury to per
sonnel from hot liquid.
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.
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
tank to prevent hazardous spills.
Consult the Air Release Valve manual accompany
ing the pump for additional information on valve
installation and performance.
PAGE B - 9INSTALLATION
Page 18
SUPER T SERIES
OM-06610
OPERATION - SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and
decals attached to the pump.
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating internal combustion
engines in an enclosed area, make cer
tain that exhaust fumes are piped to the
outside. These fumes contain carbon
monoxide, a deadly gas that is color
less, tasteless, and odorless.
This pump is designed to handle dirty
water containing specified entrained
solids and slurries. Do not attempt to
pump volatile, corrosive, or flammable
liquids which may damage the pump or
endanger personnel as a result of pump
failure.
cated (see LUBRICATION in MAINTENANCE
AND REPAIR).
This pump is self‐priming, but the pump should
never be operated unless there is liquid in the
pump casing.
Never operate this pump unless there is
liquid in the pump casing. The pump will
not prime when dry. Extended operation of
a dry pump will destroy the seal assembly.
Add liquid to the pump casing when:
1. The pump is being put into service for the
first time.
2. The pump has not been used for a 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
Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. Refer to the performance
curve in Section E for the maximum con
tinuous operating speed for this pump.
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
OPERATION PAGE C - 1
ing piping is securely installed. Other
wise, liquid in the pump forced out un
der pressure could cause injury to per
sonnel.
To fill the pump, remove the pump casing fill cover
or fill plug in the top of the casing, and add clean
liquid until the casing is filled. Replace the fill cover
or fill plug before operating the pump.
NOTE
If the suction or discharge piping is open, a hose
can be used to fill the casing through the piping.
Page 19
OM-06610 SUPER T SERIES
STARTING
This pump is equipped with an automat
ic starting system, and is subject to au
tomatic restart. Keep hands and cloth
ing away from the unit to prevent injury
during automatic operation. Disconnect
the positive battery cable before per
forming any maintenance. Failure to do
so may result in serious personal injury.
Consult the operations manual furnished with the
engine.
Manual Starting
On initial start‐up, set the engine speed at the half‐
throttle position. Turn the keyswitch on the control
box to the “START” position until the engine starts.
Release the key and the switch will return to the
“RUN” position.
After the engine starts and the unit is fully primed,
adjust the engine RPM until the desired flow rate is
achieved.
Press the “ENTER” button on the engine control
panel. The auto‐start system is now armed.
In the auto‐start mode, an audible alarm will sound
for approximately 8 seconds before the unit starts
when the liquid level in the sump or wet well rises
and activates the float(s).
When the liquid level in the sump or wet well is suffi
ciently pumped down, the unit will automatically
shut down.
NOTE
If the keyswitch is moved to the “OFF” position
while in the auto‐start mode, the engine will stop.
However, the auto‐start process will continue as
soon as the keyswitch is moved back to the “RUN”
position.
The control panel is equipped with high oil temper
ature, low oil pressure and start failure (5 attempts)
safety shutdowns. If any of these problems occur,
the control panel display will indicate a system
fault. When the problem is corrected, turn the key
switch to “OFF” and then back to “RUN” to reset
the control.
OPTIONAL EPS CONTROL
Pump speed and operating condition
points must be within the continuous per
formance range shown on the curve on
page E‐1.
Automatic Starting
Install the float(s) or submersible transducer as de
scribed in INSTALLATION, Section B.
Follow the procedures outlined for manual starting
and throttle adjustment, then turn the key to the
“RUN” position.
NOTE
For security purposes, the key can be removed with
the switch in the “AUTO START” position.
Features
The optional EPS Control is equipped with a
12VDC Electronic Pressure Switch which includes
the following features:
S 3 Output Relays: 1. A output, delayed
2. B output, no delay
3. Horn output, no delay
S 3 Inputs: 1. Horn silence
2, Pressure transducer
3. Low Temp Thermostat
S LCD screen with backlight for function moni
toring
S Bright LEDs to indicate output status and dis
play modes
S Three switches on front panel for all adjust
ments
S Battery level indicator on LCD screen to alert
operator of low battery condition
S Microprocessor Control
S Error display to alert user of errors in calibra
tion
OPERATIONPAGE C - 2
Page 20
SUPER T SERIES
OM-06610
Functional Description
Front Panel Controls/Displays
1. The LCD screen displays level information,
A and B setpoint off/on levels, Horn delay,
and calibration information.
Typical Messages on the display:
a) EEP bAd... Eeprom memory is not cor
rect, user must recalibrate
unit.
b) USr CAL... User calibrate mode, i.e.,
user wants to calibrate unit.
c) SEt a.oF... A OFF setpoint, units of lev
el.
d) SEt a.on... A ON setpoint, units of level.
e) SEt b.oF... B OFF setpoint, units of lev
el.
f) SEt b.on... B ON setpoint, units of level.
g) Hrn dLy... Horn on, A output delay
time, 5-30 seconds, in
5‐second increments.
h) LO BAT... Indicator, shows battery
voltage level is below
12VDC.
i) Lo tpt... Shows status of Low Tem
perature Thermostat con
tacts.
2. LEDs:
a) When the green LED is lighted, the unit is
showing level on the LCD display.
cause the unit to show the next selection
in the order listed above.
b) The switch functions to decrease the
selection showing. This switch can be
used to decrease the smallest digit by
“bumping” the switch, or to continuously
decrease the digit by pressing and hold
ing for at least one second and releasing
when desired setting is reached.
c. The switch functions to increase the
selection showing. This switch can be
used to increase the smallest digit by
“bumping” the switch, or to continuously
increase the digit by pressing and hold
ing for at least one second and releasing
when desired setting is reached.
Liquid level adjustment of the Electronic Pressure
Switch is accomplished using the three buttons on
the control. For EPS functions and level adjust
ment, refer to the following instructions.
EPS Functions
Actual functions of the control occur as follows:
Power is applied to the unit.
Unit performs display test for approximately 4
seconds.
When the pressure level showing is equal to or
greater than the “A.on” setpoint, the Horn out
put contacts will close in approximately 1 sec
ond and a delay, equal to the “Hrn dLy” time,
will occur before the A output contacts close.
b) When the A output LED is lighted, the A
output relay is closed.
c) When the B output LED is lighted, the B
output relay is closed
NOTE
LED's and all segments of the display are lighted
upon connection of power as a lamp test feature.
However, no relay outputs are closed during test.
3. Switches:
a) The switch functions as a “round rob
in” type switch. Pressing this switch will
OPERATION PAGE C - 3
When the level showing is equal to or greater
than the “B.on” setpoint, the B output contacts
will close in approximately 1 second.
When the pressure decreases to a level equal
to or less than the “B.of” setpoint, B output
contacts will open in approximately one sec
ond.
When the pressure decreases to a level equal
to or less than the “A.of” setpoint, A output con
tacts will open in approximately one second.
If an optional Low Temperature Thermostat is
connected to the unit and the thermostat con
tacts close, the unit displays “lo tpt” on the dis
play. In approximately 1 second, the Horn out
Page 21
OM-06610 SUPER T SERIES
put contacts close, then after the “Hrn dLy”
time, A output contacts close. A output con
tacts will remain closed as long as Low Tem
perature Thermostat contacts are closed.
When the Low Temperature Contacts open, A
output contact will open only if the level is
equal to or less than the “A.off” setpoint.
As long a the Low Temperature Thermostat
contacts are closed, the display will show “lo
tpt” unless
some other information. Level is not viewable
until the Low Temperature Thermostat con
tacts open.
The user may wish to check Setpoints Off/On
and Horn output/A output delay times. “Bump
ing” the switch will display all of the informa
tion desired.
switch is pressed to display
NOTE
One second delays in contact opening/closing is a
result of time sampling of the pressure signal to fil
ter false signals that could cause “nuisance” trip
ping of the contacts.
level adjustments will be used whenever “ON” and
“OFF” liquid levels must be reset.
There are two reasons for the user to calibrate the
unit. When power is applied, the unit confirms set
points and other calibration information for validity.
If the setpoints are not valid, the LCD screen shows
“EEP bAd” and the unit must be recalibrated. Also,
if the unit is moved, or some other external change
takes place, the unit must be recalibrated.
Zero Adjustment
Zero adjustment tells the unit when the transducer
is exposed to zero water (atmospheric) pressure.
When recalibration is desired, hold the transducer
in hand and apply power to the unit. The LCD
screen will display “Level ABC”. Press and hold
for 5 seconds. The LCD screen displays “Input?
External XDUCR”. Perform the following calibration
procedures.
Press 3 times and the LCD screen will display
“Calibrate Zro”. Press or until a character or
number on the display changes.
NOTE
If the “Hrn dLy” is changed during the actual A out
put delay cycle, the current cycle is not changed;
the change becomes effective on the next A output
delay cycle.
Use caution to ensure that the “‐‐.on” set
point (i.e. “A.on”) is not adjusted to a level
less than the corresponding “‐‐.of” set
point (i.e. “A.of”). Improper adjustment of
the off/on setpoints will render the unit non‐
functional, resulting in flooding.
EPS Calibration
NOTE
Zero offset and span adjustments are only neces
sary to calibrate a new unit, or when replacing the
transducer. Once calibrated, “ON” and “OFF” set
points will be stored in the unit's memory. Liquid
Press to accept the entry and advance to “Cali
brate Span”.
Span Adjustment
Span adjustment calibrates the unit to a known wa
ter pressure (depth). To set:
Submerge the transducer to an exact known
depth. At “Calibrate Span”, the span setting in the
unit's memory will display. Press to increase or
to decrease the value unitl the LCD screen dis
play equals the actual known depth of the trans
ducer.
Level Adjustment
Level adjustment tells the unit when to turn the
pump on and off. To set:
From “Level ABC” display, press once and
“Pump Setpt A On” will display. Press to in
crease or to decrease to the desired level at
which the pump turns on. Press to advance to
OPERATIONPAGE C - 4
Page 22
SUPER T SERIES
OM-06610
“Pump Setpt A Off”. Press to increase or to
decrease to the desired level at which the pump
turns off.
Press again to advance to “Pump Setpt B On”. If
“B” is to be used, repeat the procedure described
above for adjusting level “A”.
Horn Delay
The horn delay is pre‐set from the factory through
the engine control panel, therefore this function is
not utilized through the EPS.
OPERATION
A Gorman‐Rupp automatic air release valve may
be installed in a bypass line, or the bypass line may
be left open.
Lines Without a Bypass
Open all valves in the discharge line and start the
engine. Priming is indicated by a positive reading
on the discharge pressure gauge or by a quieter
operation. The pump may not prime immediately
because the suction line must first fill with liquid. If
the pump fails to prime within five minutes, stop it
and check the suction line for leaks.
After the pump has been primed, partially close the
discharge line throttling valve in order to fill the line
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.
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.
A manual shut‐off valve should not be
installed in any bypass line. A manual
shut‐off valve may inadvertently be left
closed during operation. A pump which
has lost prime may continue to operate
without reaching prime, causing dan
gerous overheating and possible explo
sive rupture of the pump casing. Per
sonnel could be severely injured.
Lines With a Bypass
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.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
160_F (71_C). Do not apply it at a higher operating
temperature.
Overheating can occur if operated with the valves
in the suction or discharge lines closed. Operating
against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to 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.
Allow an over‐heated pump to com
pletely cool before servicing. Do not re
move plates, covers, gauges, or fittings
from an over‐heated pump. Liquid with
in the pump can reach boiling tempera
tures, and vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Af
ter the pump completely cools, drain the
OPERATION PAGE C - 5
Page 23
OM-06610 SUPER T SERIES
liquid from the pump by removing the
casing drain plug. Use caution when re
moving the plug to prevent injury to per
sonnel from hot liquid.
As a safeguard against rupture or explosion due to
heat, this pump is equipped with a pressure relief
valve which will open if vapor pressure within the
pump casing reaches a critical point. If over‐heat
ing does occur, stop the pump immediately and al
low it to cool before servicing it. Approach any
over‐heated pump cautiously. It is recom
mended 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 specified 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.
Pump Vacuum Check
falls off rapidly after stabilization, an air leak exists.
Before checking for the source of the leak, check
the point of installation of the vacuum gauge.
STOPPING
Manual Stopping
In the manual mode, reduce the throttle speed
slowly, and allow the engine to idle briefly before
turning the kewswitch to `OFF'.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
After stopping the pump, close and lock the control
panel cover, or disconnect the positive battery
cable to ensure that the pump will remain inopera
tive.
Automatic Stopping
In the automatic mode, the pump will stop when
the liquid in the wet well or sump lowers and acti
vates the “Off” float switch(s) or “Off” setpoint
stored in the optional EPS. The pump will restart
automatically when the liquid rises and activates
the “On” float switch(s) or “On” setpoint stored in
the optional EPS.
Safety Shutdown System
The unit is equipped with a safety system to auto
matically shut down the engine under certain con
ditions. The engine will automatically shut down:
With the pump inoperative, install a vacuum gauge
in the system, using pipe dope on the threads.
Block the suction line and start the pump. At 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.
Shut off the pump. The vacuum gauge reading will
immediately drop proportionate to static suction
lift, and should then stabilize. If the vacuum reading
1. If the engine exceeds its safe operating tem
perature.
2. If the engine oil pressure drops below design
limits.
3. If the engine fails to start in five attempts.
The control panel display will indicate which of the
safety features has caused the engine to shut
down.
Should any of the safety features cause the engine
to shut down, the cause must be determined and
OPERATIONPAGE C - 6
Page 24
SUPER T SERIES
OM-06610
corrected before putting the unit back into service.
The engine will not restart until the keyswitch has
been returned to the `OFF' position for at least 10
seconds.
All safety shutdown features are pre‐set at the fac
tory for optimum performance and safety; do not
attempt to adjust these settings.
Never disconnect any of the safety shut
down features; this will void the warran
ty and could result in serious damage to
the unit and/or injury to personnel. Safe
ty shutdown features are pre‐set at the
factory; do not attempt to adjust any of
the settings. Determine the cause of
shutdown before putting the unit back
into service. Consult the factory for ad
ditional information.
during automatic operation. Disconnect
the positive battery cable before per
forming any maintenance. Failure to do
so may result in serious personal injury.
Cold Weather Preservation
In below freezing conditions, drain the pump to
prevent damage from freezing. Also, clean out any
solids by flushing with a hose. Operate the pump
for approximately one minute; this will remove any
remaining liquid that could freeze the pump rotat
ing parts. If the pump will be idle for more than a
few hours, or if it has been pumping liquids con
taining a large amount of solids, drain the pump,
and flush it thoroughly with clean water. To prevent
large solids from clogging the drain port and pre
venting the pump from completely draining, insert
a rod or stiff wire in the drain port, and agitate the
liquid during the draining process. Clean out any
remaining solids by flushing with a hose.
OPERATION IN EXTREME HEAT
The safety shutdown system will automatically
stop the unit if engine operating temperature ex
ceeds design limits. If engine over‐temperature
shutdown occurs, allow the unit to cool before re
starting.
If engine overheating continues, check the engine
lubricant level and viscosity. Consult the engine
operation manual for the recommended lubricant
for operation in extreme heat.
If the unit is equipped with the optional auto‐start
control, the float(s) may need to be adjusted to al
low shorter run and longer cooling periods, if pos
sible.
This pump is equipped with an automat
ic starting system, and is subject to au
tomatic restart. Keep hands and cloth
ing away from the unit to prevent injury
BEARING TEMPERATURE CHECK
Bearings normally run at higher than ambient tem
peratures because of heat generated by friction.
Temperatures up to 160_F (71_C) are considered
normal for bearings, and they can operate safely to
at least 180_F (82_C).
Checking bearing temperatures by hand is inaccu
rate. Bearing temperatures can be measured ac
curately by placing a contact‐type thermometer
against the housing. Record this temperature for
future reference.
A sudden increase in bearing temperatures is a
warning that the bearings are at the point of failing
to operate properly. Make certain that the bearing
lubricant is of the proper viscosity and at the cor
rect level (see LUBRICATION in Section E). Bear
ing overheating can also be caused by shaft
misalignment and/or excessive vibration.
When pumps are first started, the bearings may
seem to run at temperatures above normal. Con
tinued operation should bring the temperatures
down to normal levels.
OPERATION PAGE C - 7
Page 25
TROUBLESHOOTING - SECTION D
OM-06610SUPER T SERIES
Review all SAFETY information in Section A.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Shut down the engine, remove the
key and disconnect the positive
battery cable to ensure that the
pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO PRIME Not enough liquid in casing.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau
tiously.
7. Drain the pump.
This pump is equipped with an automat
ic starting system, and is subject to au
tomatic restart. Keep hands and cloth
ing away from the unit to prevent injury
during automatic operation. Disconnect
the positive battery cable before per
forming any maintenance. Failure to do
so may result in serious personal injury.
Add liquid to casing. See PRIMING.
PUMP STOPS OR FAILS
TO DELIVER RATED
FLOW OR PRESSURE
Suction check valve contaminated or
damaged.
Air leak in suction line.
Lining of suction hose collapsed.
Leaking or worn seal or pump gas
ket.
Suction lift or discharge head too
high.
Strainer clogged.
Air leak in suction line.
Lining of suction hose collapsed.
Leaking or worn seal or pump gas
ket.
Strainer clogged.
Clean or replace check valve.
Correct leak.
Replace suction hose.
Check pump vacuum. Replace leak
ing or worn seal or gasket.
Check piping installation and install
bypass line if needed. See INSTAL
LATION.
Check strainer and clean if neces
sary.
Correct leak.
Replace suction hose.
Check pump vacuum. Replace
leaking or worn seal or gasket.
Check strainer and clean if neces
sary.
Suction intake not submerged at
proper level or sump too small.
TROUBLESHOOTING PAGE D - 1
Check installation and correct sub
mergence as needed.
Page 26
OM-06610 SUPER T SERIES
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP STOPS OR FAILS
TO DELIVER RATED
FLOW OR PRESSURE
(cont.)
PUMP REQUIRES TOO
MUCH POWER
Impeller or other wearing parts
worn or damaged.
Impeller clogged.
Discharge head too high.
Suction lift too high.
Pump speed too slow.
EPS limit switches set improperly or
submersible transducer clogged.
Pump speed too high.
Discharge head too low.
Liquid solution too thick.
Bearing(s) frozen.
Replace worn or damaged parts.
Check that impeller is properly cen
tered and rotates freely.
Free impeller of debris.
Install bypass line.
Measure lift w/vacuum gauge. Re
duce lift and/or friction losses in
suction line.
Check engine output; consult en
gine operation manual.
Check EPS limit settings; check and
clean submersible transducer.
Check engine output.
Adjust discharge valve.
Dilute if possible.
Disassemble pump and check
bearing(s).
PUMP CLOGS
FREQUENTLY
EXCESSIVE NOISE Cavitation in pump.
BEARINGS RUN TOO
HOT
Discharge flow too slow.
Suction check valve or foot valve
clogged or binding.
Liquid solution too thick.
Pumping entrained air.
Pump or drive not securely
mounted.
Impeller clogged or damaged.
Bearing temperature is high, but
within limits.
Open discharge valve fully to in
crease flow rate, and run engine at
maximum governed speed.
Clean valve.
Dilute if possible.
Reduce suction lift and/or friction
losses in suction line. Record vacu
um and pressure gauge readings
and consult local representative or
factory.
Locate and eliminate source of air
bubble.
Secure mounting hardware.
Clean out debris; replace damaged
parts.
Check bearing temperature regular
ly to monitor any increase.
Low or incorrect lubricant.
Suction and discharge lines not
properly supported.
Drive misaligned.
Check for proper type and level of
lubricant.
Check piping installation for proper
support.
Align drive properly.
TROUBLESHOOTINGPAGE D - 2
Page 27
OM-06610SUPER T SERIES
PREVENTIVE MAINTENANCE
Since pump applications are seldom identical, and
pump wear is directly affected by such things as
the abrasive qualities, pressure and temperature
of the liquid being pumped, this section is intended
only to provide general recommendations and
practices for preventive maintenance. Regardless
of the application however, following a routine pre
ventive maintenance schedule will help assure
trouble‐free performance and long life from your
Gorman‐Rupp pump. For specific questions con
cerning your application, contact your Gorman‐
Rupp distributor or the Gorman‐Rupp Company.
Record keeping is an essential component of a
good preventive maintenance program. Changes
in suction and discharge gauge readings (if so
equipped) between regularly scheduled inspec
tions can indicate problems that can be corrected
before system damage or catastrophic failure oc
curs. The appearance of wearing parts should also
be documented at each inspection for comparison
as well. Also, if records indicate that a certain part
(such as the seal) fails at approximately the same
duty cycle, the part can be checked and replaced
before failure occurs, reducing unscheduled down
time.
For new applications, a first inspection of wearing
parts at 250 hours will give insight into the wear rate
for your particular application. Subsequent inspec
tions should be performed at the intervals shown
on the chart below. Critical applications should be
inspected more frequently.
Preventive Maintenance Schedule
Service Interval*
Item
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.) I
Pump Performance (Gauges, Speed, Flow) I
Bearing Lubrication I R
Seal Lubrication (And Packing Adjustment,
If So Equipped) I R
V‐Belts (If So Equipped) I
Air Release Valve Plunger Rod (If So Equipped) I C
Front Impeller Clearance (Wear Plate) I
Rear Impeller Clearance (Seal Plate) I
Check Valve I
Pressure Relief Valve (If So Equipped) C
Pump and Driver Alignment I
Shaft Deflection I
Bearings I
Bearing Housing I
Piping I
Driver Lubrication - See Mfgr's Literature
Daily Weekly Monthly Semi‐
Annually
Annually
Legend:
I = Inspect, Clean, Adjust, Repair or Replace as Necessary
C = Clean
R = Replace
* Service interval based on an intermittant duty cycle equal to approximately 4000 hours annually.
Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.
TROUBLESHOOTING PAGE D - 3
Page 28
SUPER T SERIES OM-06610
PUMP MAINTENANCE AND REPAIR ‐ SECTION E
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK
OPERATING PERFORMANCE.
STANDARD PERFORMANCE FOR PUMP MODEL T6A60S‐5.7 NG-ESP
Based on 70_F (21_C) clear water at sea level
with minimum suction lift. Since pump installations
are seldom identical, your performance may be 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 29
PARTS PAGE
SUPER T SERIESOM-06610
ILLUSTRATION
Figure 1. Pump Model T6A60S-5.7 NG-ESP
MAINTENANCE & REPAIRPAGE E - 2
Page 30
SUPER T SERIES OM-06610
PARTS LIST
Pump Model T6A60S-5.7 NG-ESP
(From S/N 1544458 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 BASE WELDMENT 41565-603 24150 1
2 COMPRESSION MOUNT 24631-104 --- 6
3 SUB BASE ASSY 41531-571 24150 1
4 PUMP END ASSY 46186-187 --- 1
5 GM 5.7L NG ENGINE 29161-018 --- 1
6 ' ENCLOSURE ASSY 42164-036 --- 1
7 GRADE SILENCER 29334-105 --- 1
8 MOUNTING BRKT 29334-288 --- 2
9 WEATHER CAP S1706 --- 1
10 HOIST BAIL ASSY 44715-045 24150 1
11 GASKET 33311-060 19460 1
12 PIPE NIPPLE T9636 15079 1
13 PIPE NIPPLE T9654 15070 1
14 REDUCING ELBOW 29284-041 --- 1
15 AIR INTAKE PIPE 31417-069 15210 1
16 CONTROL PANEL 29284-067 --- 1
17 GASKET 38687-560 19460 1
18 COVER PLATE 34851-317 13000 1
19 BATTERY BOX ASSY 42432-005 --- 1
20 RADIATOR FRAME ASSY 41437-086 24130 1
21 BULKHEAD CVR PLATE 34851-614 13000 1
22 CVR PLT INSULATION 33188-138 19460 2
23 MOUNTING ASSY 41881-788 --- 1
24 INSERT 29334-042 --- 1
25 PUMP SPACER 33246-058 15120 2
26 HEX HEAD CAP SCREW B0806 15991 4
27 FLAT WASHER K08 15991 4
28 LOCK WASHER J08 15991 22
29 HEX NUT D08 15991 4
30 HEX HEAD CAP SCREW B0805 15991 18
31 HEX HEAD CAP SCREW B1006-1/2 15991 6
32 LOCK WASHER J10 15991 10
33 HEX NUT D10 15991 10
34 HEX HEAD CAP SCREW B1010 15991 4
35 THREADED INSERT 21769-160 --- 8
36 LOCK WASHER J06 15991 22
37 HEX HEAD CAP SCREW B0605 15991 18
38 HEX HEAD CAP SCREW B0604 15991 4
39 FLAT WASHER K05 15991 21
40 LOCK WASHER J05 15991 21
41 HEX HEAD CAP SCREW B0504 15991 11
42 HEX HEAD CAP SCREW B0505 15991 10
43 24” LG HOSE 18533-173 --- 1
44 BAND CLAMP 29334-287 --- 1
45 EXHAUST BLANKET 29334-285 --- 1
46 MALE HOSE END 26525-020 --- 1
47 HOSE FITTING 26523-335 1
48 CONT PANEL MTG BRKT 34512-055 13000 1
49 FLAT WASHER K06 15991 4
50 HEX NUT D06 15991 4
51 RED PIPE BUSHING AP2016 17040 1
52 PIPE NIPPLE T1608 15079 1
53 PIPE ELBOW R16 15079 1
54 RED PIPE BUSHING AP2016 11999 2
55 HOSE FITTING 26523-394 --- 3
56 FLEX CONNECTOR 31782-004 --- 1
57 BALL VALVE 26631-025 --- 1
58 1” ID X 14" LG HOSE 18513-045 --- 1
59 HOSE CLAMP 26518-666 --- 4
60 3/8” I.D. X 87" LG HOSE 18513-054 --- 1
61 BATTERY 29331-527 --- 1
62 1/2” I.D. X 32" LG HOSE 18513-056 --- 1
63 HEAT SHIELD ASSY 42381-145 --- 1
' CONSULT FACTORY FOR ADDITIONAL ENCLOSURE PARTS
64 BELT GUARD 34851-615 15120 1
65 STREET ELBOW RS16 11999 1
66 OPW ADAPTER 1 1/4 26531-404 --- 1
67 1” ID X 40" LG HOSE 18513-045 --- 1
68 NATURAL GAS HOSE 29332-306 --- 1
69 T‐BOLT CLAMP 26518-164 --- 5
70 T‐BOLT CLAMP 26518-166 --- 1
71 POS. CABLE ASSY 47311-112 --- 1
72 NEG. CABLE ASSY 47311-142 --- 1
73 46" LG STARTER CABLE 18124-004 --- 1
74 29 1/2" LG POS BATT CBL 18124-009 --- 1
75 CLOSE PIPE NIPPLE T16 15070 3
76 PIPE ELBOW R16 15070 1
76 PIPE ELBOW R16 15070 1
77 PIPE TEE U16 11999 1
78 RED PIPE BUSHING AP1604 15070 1
79 PIPE PLUG P04 15070 1
80 PRESSURE GAUGE 26853-721 --- 1
81 PRESSURE GAUGE 26851-363 --- 1
82 PIPE TEE U04 11999 2
83 STREET ELBOW RS04 11999 4
84 BALL VALVE 26631-053 --- 2
85 CONNECTOR S1447 --- 2
86 HOSE BARB FTG 26523-015 2
87 PIPE PLUG P04 15079 2
88 MALE NPT HOSE BARB 26523-388 --- 2
89 3/8” I.D. X 48" LG HOSE 18513-054 --- 1
90 3/8” I.D. X 43" LG HOSE 18513-054 --- 1
91 ELBOW 29284-039 --- 1
92 EXHAUST TUBING 31417-076 15210 2
93 SPACER 31141-037 13000 2
94 HEX HEAD CAP SCREW BD0507 15991 2
95 WASHER J05 15991 2
NOT SHOWN:
PIPE PLUG P08 15079 2
BATT MAINTENANCE KIT 48313-814 --- 1
PIPE PLUG P20 10009 1
PIPE PLUG P32 14990 3
PUMP DRAIN LABEL 38816-320 --- 1
RADIATOR DRAIN LABEL 38816-322 --- 1
OIL DRAIN LABEL 38816-323 --- 1
LEVEL CONTROL LABEL 38816-332 --- 1
WARNING DECAL 2613FE --- 1
SUCTION STICKER 6588AG --- 1
DISCHARGE STICKER 6588BJ --- 1
CAUTION DECAL 2613FJ --- 1
DECAL KIT RELIAPRIME 48154-820 --- 1
SUPER "T" DECAL 38812-089 --- 1
INSTRUCTION TAG 38817-085 --- 1
WARNING DECAL 38816-203 --- 1
ENGINE START‐UP TAG 38816-269 --- 1
WARNING DECAL 38816-345 --- 1
INSTRUCTION DECAL 38818-144 --- 1
168" LG FOAM TAPE 18668-003 --- 1
FLOAT SWITCH 48312-980 --- 1
NAT GAS ONLY DECAL 38816-258 --- 1
AIR RELEASE DRAIN 38816-333 --- 1
COVER PLATE 33273-262 13000 1
SLOTTED MACH SCREW X#08-04 15991 4
LOCK WASHER J#08 15991 4
NUT D#08 15991 4
PRESS REGULATOR 29332-329 --- 1
MAINTENANCE & REPAIR PAGE E - 3
Page 31
ILLUSTRATION
SUPER T SERIESOM-06610
Figure 2. Pump Model T6A60S-5.7 NG-ESP (Cont'd)
MAINTENANCE & REPAIRPAGE E - 4
Page 32
SUPER T SERIES OM-06610
PARTS LIST
Pump Model T6A60S-5.7 NG-ESP
(From S/N 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 BASE WELDMENT 41565-603 24150 1
2 COMPRESSION MOUNT 24631-104 --- 6
3 SUB BASE ASSY 41531-571 24150 1
4 PUMP END ASSY 46186-187 --- 1
5 GM 5.7L NG ENGINE 29161-018 --- 1
6 ' ENCLOSURE ASSY 42164-036 --- 1
7 GRADE SILENCER 29334-105 --- 1
8 MOUNTING BRKT 29334-288 --- 2
9 WEATHER CAP S1706 --- 1
10 HOIST BAIL ASSY 44715-045 24150 1
11 GASKET 33311-060 19460 1
12 PIPE NIPPLE T9636 15079 1
13 PIPE NIPPLE T9654 15070 1
14 REDUCING ELBOW 29284-041 --- 1
15 AIR INTAKE PIPE 31417-069 15210 1
16 CONTROL PANEL 29284-067 --- 1
17 GASKET 38687-560 19460 1
18 COVER PLATE 34851-317 13000 1
19 BATTERY BOX ASSY 42432-005 --- 1
20 RADIATOR FRAME ASSY 41437-086 24130 1
21 BULKHEAD CVR PLATE 34851-614 13000 1
22 CVR PLT INSULATION 33188-138 19460 2
23 MOUNTING ASSY 41881-788 --- 1
24 INSERT 29334-042 --- 1
25 PUMP SPACER 33246-058 15120 2
26 HEX HEAD CAP SCREW B0806 15991 4
27 FLAT WASHER K08 15991 4
28 LOCK WASHER J08 15991 22
29 HEX NUT D08 15991 4
30 HEX HEAD CAP SCREW B0805 15991 18
31 HEX HEAD CAP SCREW B1006-1/2 15991 6
32 LOCK WASHER J10 15991 10
33 HEX NUT D10 15991 10
34 HEX HEAD CAP SCREW B1010 15991 4
35 THREADED INSERT 21769-160 --- 8
36 LOCK WASHER J06 15991 22
37 HEX HEAD CAP SCREW B0605 15991 18
38 HEX HEAD CAP SCREW B0604 15991 4
39 FLAT WASHER K05 15991 21
40 LOCK WASHER J05 15991 21
41 HEX HEAD CAP SCREW B0504 15991 11
42 HEX HEAD CAP SCREW B0505 15991 10
43 24” LG HOSE 18533-173 --- 1
44 BAND CLAMP 29334-287 --- 1
45 EXHAUST BLANKET 29334-285 --- 1
46 MALE HOSE END 26525-020 --- 1
47 HOSE FITTING 26523-335 1
48 CONT PANEL MTG BRKT 34512-055 13000 1
49 FLAT WASHER K06 15991 4
50 HEX NUT D06 15991 4
51 RED PIPE BUSHING AP2016 17040 1
52 PIPE NIPPLE T1608 15079 1
53 PIPE ELBOW R16 15079 1
54 RED PIPE BUSHING AP2016 11999 2
55 HOSE FITTING 26523-394 --- 3
56 FLEX CONNECTOR 31782-004 --- 1
57 BALL VALVE 26631-025 --- 1
58 1” ID X 14" LG HOSE 18513-045 --- 1
59 HOSE CLAMP 26518-666 --- 4
60 3/8” I.D. X 87" LG HOSE 18513-054 --- 1
61 BATTERY 29331-527 --- 1
62 1/2” I.D. X 32" LG HOSE 18513-056 --- 1
63 HEAT SHIELD ASSY 42381-145 --- 1
' CONSULT FACTORY FOR ADDITIONAL ENCLOSURE PARTS
64 BELT GUARD 34851-615 15120 1
65 STREET ELBOW RS16 11999 1
66 OPW ADAPTER 1 1/4 26531-404 --- 1
67 1” ID X 40" LG HOSE 18513-045 --- 1
68 NATURAL GAS HOSE 29332-306 --- 1
69 T‐BOLT CLAMP 26518-164 --- 5
70 T‐BOLT CLAMP 26518-166 --- 1
71 POS. CABLE ASSY 47311-112 --- 1
72 NEG. CABLE ASSY 47311-142 --- 1
73 46" LG STARTER CABLE 18124-004 --- 1
74 29 1/2" LG POS BATT CBL 18124-009 --- 1
75 CLOSE PIPE NIPPLE T16 15070 3
76 PIPE ELBOW R16 15070 1
76 PIPE ELBOW R16 15070 1
77 PIPE TEE U16 11999 1
78 RED PIPE BUSHING AP1604 15070 1
79 PIPE PLUG P04 15070 1
80 PRESSURE GAUGE 26853-721 --- 1
81 PRESSURE GAUGE 26851-363 --- 1
82 PIPE TEE U04 11999 2
83 STREET ELBOW RS04 11999 4
84 BALL VALVE 26631-053 --- 2
85 CONNECTOR S1447 --- 2
86 HOSE BARB FTG 26523-015 2
87 PIPE PLUG P04 15079 2
88 MALE NPT HOSE BARB 26523-388 --- 2
89 3/8” I.D. X 48" LG HOSE 18513-054 --- 1
90 3/8” I.D. X 43" LG HOSE 18513-054 --- 1
91 ELBOW 29284-039 --- 1
92 EXHAUST TUBING 31417-076 15210 2
93 SPACER 31141-037 13000 2
94 HEX HEAD CAP SCREW BD0507 15991 2
95 WASHER J05 15991 2
NOT SHOWN:
PIPE PLUG P08 15079 2
BATT MAINTENANCE KIT 48313-814 --- 1
PIPE PLUG P20 10009 1
PIPE PLUG P32 14990 3
PUMP DRAIN LABEL 38816-320 --- 1
RADIATOR DRAIN LABEL 38816-322 --- 1
OIL DRAIN LABEL 38816-323 --- 1
LEVEL CONTROL LABEL 38816-332 --- 1
WARNING DECAL 2613FE --- 1
SUCTION STICKER 6588AG --- 1
DISCHARGE STICKER 6588BJ --- 1
CAUTION DECAL 2613FJ --- 1
DECAL KIT RELIAPRIME 48154-820 --- 1
SUPER "T" DECAL 38812-089 --- 1
INSTRUCTION TAG 38817-085 --- 1
WARNING DECAL 38816-203 --- 1
ENGINE START‐UP TAG 38816-269 --- 1
WARNING DECAL 38816-345 --- 1
INSTRUCTION DECAL 38818-144 --- 1
168" LG FOAM TAPE 18668-003 --- 1
FLOAT SWITCH 48312-980 --- 1
NAT GAS ONLY DECAL 38816-258 --- 1
AIR RELEASE DRAIN 38816-333 --- 1
COVER PLATE 33273-262 13000 1
SLOTTED MACH SCREW X#08-04 15991 4
LOCK WASHER J#08 15991 4
NUT D#08 15991 4
PRESS REGULATOR 29332-329 --- 1
MAINTENANCE & REPAIR PAGE E - 5
Page 33
ILLUSTRATION
SUPER T SERIESOM-06610
Figure 3. Pump Model T6A60S-5.7 NG-ESP
MAINTENANCE & REPAIRPAGE E - 6
Page 34
SUPER T SERIES OM-06610
PARTS LIST
Pump Model T6A60S-5.7 NG-ESP
(From S/N 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 BASE WELDMENT 41565-603 24150 1
2 COMPRESSION MOUNT 24631-104 --- 6
3 SUB BASE ASSY 41531-571 24150 1
4 PUMP END ASSY 46186-187 --- 1
5 GM 5.7L NG ENGINE 29161-018 --- 1
6 ' ENCLOSURE ASSY 42164-036 --- 1
7 GRADE SILENCER 29334-105 --- 1
8 MOUNTING BRKT 29334-288 --- 2
9 WEATHER CAP S1706 --- 1
10 HOIST BAIL ASSY 44715-045 24150 1
11 GASKET 33311-060 19460 1
12 PIPE NIPPLE T9636 15079 1
13 PIPE NIPPLE T9654 15070 1
14 REDUCING ELBOW 29284-041 --- 1
15 AIR INTAKE PIPE 31417-069 15210 1
16 CONTROL PANEL 29284-067 --- 1
17 GASKET 38687-560 19460 1
18 COVER PLATE 34851-317 13000 1
19 BATTERY BOX ASSY 42432-005 --- 1
20 RADIATOR FRAME ASSY 41437-086 24130 1
21 BULKHEAD CVR PLATE 34851-614 13000 1
22 CVR PLT INSULATION 33188-138 19460 2
23 MOUNTING ASSY 41881-788 --- 1
24 INSERT 29334-042 --- 1
25 PUMP SPACER 33246-058 15120 2
26 HEX HEAD CAP SCREW B0806 15991 4
27 FLAT WASHER K08 15991 4
28 LOCK WASHER J08 15991 22
29 HEX NUT D08 15991 4
30 HEX HEAD CAP SCREW B0805 15991 18
31 HEX HEAD CAP SCREW B1006-1/2 15991 6
32 LOCK WASHER J10 15991 10
33 HEX NUT D10 15991 10
34 HEX HEAD CAP SCREW B1010 15991 4
35 THREADED INSERT 21769-160 --- 8
36 LOCK WASHER J06 15991 22
37 HEX HEAD CAP SCREW B0605 15991 18
38 HEX HEAD CAP SCREW B0604 15991 4
39 FLAT WASHER K05 15991 21
40 LOCK WASHER J05 15991 21
41 HEX HEAD CAP SCREW B0504 15991 11
42 HEX HEAD CAP SCREW B0505 15991 10
43 24” LG HOSE 18533-173 --- 1
44 BAND CLAMP 29334-287 --- 1
45 EXHAUST BLANKET 29334-285 --- 1
46 MALE HOSE END 26525-020 --- 1
47 HOSE FITTING 26523-335 1
48 CONT PANEL MTG BRKT 34512-055 13000 1
49 FLAT WASHER K06 15991 4
50 HEX NUT D06 15991 4
51 RED PIPE BUSHING AP2016 17040 1
52 PIPE NIPPLE T1608 15079 1
53 PIPE ELBOW R16 15079 1
54 RED PIPE BUSHING AP2016 11999 2
55 HOSE FITTING 26523-394 --- 3
56 FLEX CONNECTOR 31782-004 --- 1
57 BALL VALVE 26631-025 --- 1
58 1” ID X 14" LG HOSE 18513-045 --- 1
59 HOSE CLAMP 26518-666 --- 4
60 3/8” I.D. X 87" LG HOSE 18513-054 --- 1
61 BATTERY 29331-527 --- 1
62 1/2” I.D. X 32" LG HOSE 18513-056 --- 1
63 HEAT SHIELD ASSY 42381-145 --- 1
' CONSULT FACTORY FOR ADDITIONAL ENCLOSURE PARTS
64 BELT GUARD 34851-615 15120 1
65 STREET ELBOW RS16 11999 1
66 OPW ADAPTER 1 1/4 26531-404 --- 1
67 1” ID X 40" LG HOSE 18513-045 --- 1
68 NATURAL GAS HOSE 29332-306 --- 1
69 T‐BOLT CLAMP 26518-164 --- 5
70 T‐BOLT CLAMP 26518-166 --- 1
71 POS. CABLE ASSY 47311-112 --- 1
72 NEG. CABLE ASSY 47311-142 --- 1
73 46" LG STARTER CABLE 18124-004 --- 1
74 29 1/2" LG POS BATT CBL 18124-009 --- 1
75 CLOSE PIPE NIPPLE T16 15070 3
76 PIPE ELBOW R16 15070 1
76 PIPE ELBOW R16 15070 1
77 PIPE TEE U16 11999 1
78 RED PIPE BUSHING AP1604 15070 1
79 PIPE PLUG P04 15070 1
80 PRESSURE GAUGE 26853-721 --- 1
81 PRESSURE GAUGE 26851-363 --- 1
82 PIPE TEE U04 11999 2
83 STREET ELBOW RS04 11999 4
84 BALL VALVE 26631-053 --- 2
85 CONNECTOR S1447 --- 2
86 HOSE BARB FTG 26523-015 2
87 PIPE PLUG P04 15079 2
88 MALE NPT HOSE BARB 26523-388 --- 2
89 3/8” I.D. X 48" LG HOSE 18513-054 --- 1
90 3/8” I.D. X 43" LG HOSE 18513-054 --- 1
91 ELBOW 29284-039 --- 1
92 EXHAUST TUBING 31417-076 15210 2
93 SPACER 31141-037 13000 2
94 HEX HEAD CAP SCREW BD0507 15991 2
95 WASHER J05 15991 2
NOT SHOWN:
PIPE PLUG P08 15079 2
BATT MAINTENANCE KIT 48313-814 --- 1
PIPE PLUG P20 10009 1
PIPE PLUG P32 14990 3
PUMP DRAIN LABEL 38816-320 --- 1
RADIATOR DRAIN LABEL 38816-322 --- 1
OIL DRAIN LABEL 38816-323 --- 1
LEVEL CONTROL LABEL 38816-332 --- 1
WARNING DECAL 2613FE --- 1
SUCTION STICKER 6588AG --- 1
DISCHARGE STICKER 6588BJ --- 1
CAUTION DECAL 2613FJ --- 1
DECAL KIT RELIAPRIME 48154-820 --- 1
SUPER "T" DECAL 38812-089 --- 1
INSTRUCTION TAG 38817-085 --- 1
WARNING DECAL 38816-203 --- 1
ENGINE START‐UP TAG 38816-269 --- 1
WARNING DECAL 38816-345 --- 1
INSTRUCTION DECAL 38818-144 --- 1
168" LG FOAM TAPE 18668-003 --- 1
FLOAT SWITCH 48312-980 --- 1
NAT GAS ONLY DECAL 38816-258 --- 1
AIR RELEASE DRAIN 38816-333 --- 1
COVER PLATE 33273-262 13000 1
SLOTTED MACH SCREW X#08-04 15991 4
LOCK WASHER J#08 15991 4
NUT D#08 15991 4
PRESS REGULATOR 29332-329 --- 1
MAINTENANCE & REPAIR PAGE E - 7
Page 35
ILLUSTRATION
SUPER T SERIESOM-06610
Figure 4. T6A60S-(5.7 NG-ESP) Pump End Assembly
MAINTENANCE & REPAIRPAGE E - 8
Page 36
SUPER T SERIES OM-06610
PARTS LIST
T6A60S-(5.7 NG-ESP) Pump End Assembly
ITEM
PART NAME PART
NO.
NUMBER
MAT'L
CODE
QTY ITEM
NO.
PART NAME PART
NUMBER
MAT'L
CODE
QTY
1 . PUMP CASING SEE NOTE BELOW 1
2 SHIM 13131-3 17040 8
3 REPAIR ROTATING ASSY 44163-547 --- 1
WEAR PLATE 46451-723 24150 1
4
5 BACK CVR PLATE ASSY 42111-803 --- 1
-WARNING PLATE 2613EV 13990 1
-DRIVE SCREW BM#04-03 17000 4
-PRESS RELIEF VALVE 26662-005 --- 1
6 . PIPE PLUG P04 15079 2
6A PIPE PLUG P04 15079 1
7 LOCK WASHER J08 15991 8
8 HEX HEAD CAP SCREW B0806 15991 4
9 GASKET 25113-036 --- 1
10 O‐RING 25152-453 --- 1
11 LOCK WASHER J06 15991 6
12 HEX NUT D06 15991 4
13 O‐RING S1676 --- 1
13A O‐RING S1676 --- 1
14 . CASING DRAIN PLUG P20 10009 1
15 HANDLE 12354 13010 1
16 HEX HEAD CAP SCREW B0604 15991 2
17 LOCK COLLAR 38115-551 15001 4
18 HEX HEAD CAP SCREW B0804-1/2 15991 4
19 ADJUSTING SCREW 31871-070 1500G 4
20 . STUD C1213 15991 4
21 BACK COVER NUT 31871-073 15000 4
22 SUCT FLANGE GASKET 11402G 19370 1
23 SUCTION FLANGE 11402 10010 1
24 CHECK VALVE PIN 11645 17010 1
25 LOCK WASHER J12 15991 8
26 HEX HEAD CAP SCREW B1211 15991 6
INDICATES PARTS RECOMMENDED FOR STOCK
27 . PIPE PLUG P08 15079 1
28 FILL COVER ASSY 42111-344 --- 1
-DRIVE SCREW BM#04-03 17000 2
-WARNING PLATE 38816-097 13990 1
-COVER GASKET 50G 19210 1
29 CLAMP BAR 38111-004 11010 1
30 . MACHINE BOLT A1014 15991 2
31 CLAMP BAR SCREW 31912-009 15000 1
32 FLAP VALVE ASSY 46411-064 --- 1
33 CHK VLV/AIR REL ASSY 46421-100 --- 1
34 MOUNTING BRKT ASSY 41888-286 --- 1
35 HEX HEAD CAP SCREW B1212 15991 2
NOT SHOWN:
G‐R DECAL GR-06 --- 1
INSTR TAG 38817-023 --- 1
LUBRICATION DECAL 38817-084 --- 1
WARNING DECAL 2613FE --- 1
SUCTION STICKER 6588AG --- 1
PRIMING STICKER 6588AH --- 1
DISCHARGE STICKER 6588BJ --- 1
SUPER "T" DECAL 38812-089 --- 1
NAME PLATE 38818-040 13990 1
DRIVE SCREW BM#04-03 17000 4
COUPLING KIT 48112-001 --- 1
STRAINER ASSY 7823A 24000 1
OPTIONAL:
ALLOY STEEL WEAR
PLATE ASSY 46451-729 24160 1
DISASSEMBLY TOOL 12859 24000 1
SEWAGE SLUDGE
PRESS RELIEF VALVE 46431-628 --- 1
. INCLUDED W/REPAIR PUMP CASING ASSY 46472-722 --- 1
MAINTENANCE & REPAIR PAGE E - 9
Page 37
ILLUSTRATION
SUPER T SERIESOM-06610
Figure 5. 44163-547 Repair Rotating Assembly
MAINTENANCE & REPAIRPAGE E - 10
Page 38
SUPER T SERIES OM-06610
PARTS LIST
44163-547 Repair Rotating Assembly
ITEM
NO.
1 IMPELLER 38615-087 11010 1
2 SEAL ASSEMBLY 46513-154 --- 1
3 SEAL PLATE 38272-254 10010 1
4 OIL SEAL S1917 --- 1
4A OIL SEAL S1917 --- 1
4B OIL SEAL S1917 --- 1
5 SEAL PLATE GSKT 10959G 20000 1
6 HEX HD CAPSCREW B0805 1/2 15991 4
7 LOCKWASHER J08 15991 4
8 BEARING HOUSING 38251-517 10000 1
9 VENTED PLUG 4823A 15079 1
10 REDUCER BUSHING AP0802 15079 1
11 AIR VENT S1530 --- 1
12 PIPE PLUG P12 15079 1
13 BALL BEARING S616 --- 1
14 SHAFT SLEEVE O‐RING 25154-026 --- REF
15 IMPELLER SHAFT 38514-823 1706H 1
16 INTERMEDIATE GUARD 42381-509 24152 2
17 SHAFT KEY N0607 15990 1
18 DRIVE FLANGE GASKET 38683-478 18000 1
19 BALL BEARING S1030 --- 1
20 SNAP RING 24124-425 --- 1
21 DRIVE FLANGE 38545-023 10000 1
22 HEX HD CAPSCREW 21632-938 15991 8
23 LOCKWASHER J06 15991 8
24 SIGHT GAUGE S1471 --- 1
24A SIGHT GAUGE S1471 --- 1
25 BEARING HOUSING DRAIN PLUG P04 15079 1
25A SEAL CAVITY DRAIN PLUG P04 15079 1
26 IMPELLER ADJUSTING SHIM SET 5091 17090 REF
27 BEARING HOUSING O‐RING S1676 --- 1
28 SHIPPING PLUG 11495B 15079 2
29 SERIAL NUMBER PLATE 2613GG 13990 1
30 DRIVE SCREW BM#04-03 17000 2
31 ROTATING ASSY ADJ SHIMS 13131-3 17040 8
NOT SHOWN:
PART NAME
SOC HD PIPE PLUG PC20 10009 1
ROTATION DECAL 2613M --- 1
INSTRUCTION TAG 6588U --- 1
PART
NUMBER
MAT'L
CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 11
Page 39
ILLUSTRATION
SUPER T SERIESOM-06610
Figure 6. Check Valve/Air Release Assembly
MAINTENANCE & REPAIRPAGE E - 12
Page 40
SUPER T SERIES OM-06610
PARTS LIST
Check Valve/Air Release Assembly
ITEM
NO.
1 ELBOW 38647-905 10010 1
2 GASKET 25113-036 --- 2
3 6" NPT FLANGE 1758 10010 1
4 LOCK WASHER J12 15991 24
5 HEX HEAD CAP SCREW B1214 15991 14
6 HEX NUT D12 15991 14
7 CHECK VALVE 46421-416 --- 1
8 WASHER 21161-446 --- 14
9 HEX HEAD CAP SCREW B1208 15991 10
10 PIPE TEE U16 11999 1
11 UNION AH16 11999 1
12 PIPE PLUG P16 10009 1
13 HOSE FITTING 26523-394 --- 1
14 1" BALL VALVE 26631-024 --- 1
15 CLOSE PIPE NIPPLE T16 15079 4
16 STREET ELBOW RS16 11999 1
17 AIR RELEASE VALVE GRP33-07 --- 1
INDICATES PARTS RECOMMENDED FOR STOCK
PART NAME
PART
NUMBER
MAT'L
CODE
QTY
MAINTENANCE & REPAIR PAGE E - 13
Page 41
ILLUSTRATION
SUPER T SERIESOM-06610
Figure 7. 6 Inch Check Valve Assembly
PARTS LIST
ITEM
NO.
10 -CHECK VALVE ARM 38122-002 17070 1
11 -CHECK VLV HANDLE 38582-018 11060 1
12 -BUSHING 23161-106 --- 2
PART
NAME
6 IN CHK VLV ASSY 46421-416 --- 1
1 -MOLDED CHK VLV 46411-136 24010 1
2 -VALVE WEIGHT 11588 10010 1
3 -BUSHING 31143-148 17000 1
4 -FLAT WASHER KE08 17000 1
5 -NYLOCK CAPSCRW BT0806 15991 1
6 -O‐RING 25152-166 --- 2
7 -SHAFT NUT 31871-072 14100 1
8 -O‐RING 25152-114 --- 2
9 -PIPE PLUG P04 15079 1
PART
NUMBER
MAT'L
CODE
QTY ITEM
NO.
13 -ROLL PIN S984 --- 1
14 -SOC HD CAPSCREW BD0404 17000 2
15 -CHECK VLV GASKET 25113-097 --- 1
16 -CHECK VALVE SEAT 31265-042 17050 1
17 -SHAFT 31671-006 17010 1
18 -SHIM 513A-3 17090 1
19 -VALVE ACCESS CVR 38346-013 10000 1
20 -HEX HD CAPSCREW B0606 15991 6
21 -LOCK WASHER J06 15991 6
22 -O‐RING 25152-318 --- 1
23 -VALVE BODY 38341-414 10000 1
24 -SPRING 38572-004 17110 1
PART
NAME
PART
NUMBER
MAT'L
CODE
MAINTENANCE & REPAIRPAGE E - 14
QTY
Page 42
SUPER T SERIES OM-06610
ILLUSTRATION
MODEL T6A60S
LOCATE COUPLING
AS DIMENSIONED
Figure 8. 48112-001 Coupling Assembly
PARTS LIST
ITEM
NO.
1 BUSHING 24131-345 --- 1
2 COUPLING ASSEMBLY 44165-011 --- 1
3 . LOCKWASHER J06 15991 8
4 . SOCKET HD CAPSCREW BD0606-1/2 15991 8
3 ' LOCKWASHER 21171-536 --- 8
4 ' SOCKET HD CAPSCREW 22644-220 --- 8
MAINTENANCE & REPAIR PAGE E - 15
PART NAME
. USE FOR SAE APPLICATIONS
' USE FOR METRIC APPLICATIONS
PART
NUMBER
MAT'L
CODE
QTY
Page 43
OM-06610 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 illustrations (see Figures 1 through 8) 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 back cover
assembly. If major repair is required, the piping
and/or engine must be disconnected. The follow
ing instructions assume complete disassembly is
required.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Switch off the engine ignition and
disconnect the positive battery
cable to ensure that the pump will
remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau
tiously.
7. Drain the pump.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment.
Back Cover And Wear Plate Removal
(Figure 4)
Before attempting to service the pump, disconnect
or lock out the power source and take precautions
to ensure that it will remain inoperative. Close all
valves in the suction and discharge lines.
No instructions for removal and/or disassembly of
the enclosure or its components are provided in
this manual. If removal of the enclosure is required
for pump service, be sure to use safe shop practic
es so as not to endanger personnel, and use cau
tion to prevent damage to the enclosure.
For engine disassembly and repair, consult the lit
erature supplied with the engine, or contact your
local engine representative.
The wear plate (4) is easily accessible and may be
serviced by removing the back cover assembly (5).
Before attempting to service the pump, open the
ball valve (57, Figure 3) and drain the pump. Close
the valve after draining is complete.
Remove the back cover nuts (21) and pry the back
cover and assembled wear plate from the pump
casing (1).
NOTE
An alternate method of removing the back cover
from the pump casing is to remove the back cover
nuts (21) and two diagonally opposing locking col
lars (17). Install two 1/2-16 UNC x 2 inch long
screws in the tapped holes in the back cover and
MAINTENANCE & REPAIRPAGE E - 16
Page 44
SUPER T SERIES
OM-06610
use them to press the back cover out of the pump
casing.
Inspect the wear plate and replace it if badly scored
or worn. To remove the wear plate, disengage the
hardware (11 and 12).
Inspect the back cover and wear plate O‐rings (10
and 13) and replace them if damaged or worn.
Suction Check Valve Removal
(Figure 4)
If the check valve assembly (32) is to be serviced,
remove the check valve pin (24), reach through the
back cover opening and pull the complete assem
bly from the suction flange (23).
NOTE
Further disassembly of the check valve is not re
quired since it must be replaced as a complete unit.
Individual parts are not sold separately.
Separating Intermediate and Coupling
Assembly From Engine
(Figure 8)
Further disassembly requires separating the pump
end and drive assembly from the engine. Remove
the hardware securing the check valve/air release
valve assembly (33, Figure 4) to the pump casing.
Disengage and remove any additional compo
nents necessary for the removal of the pump end.
Install a standard 5/8‐11 UNC lifting eye in the
tapped hole in the top of the pump casing. Be sure
to screw the eye into the casing until fully engaged.
Support the pump using a suitable hoist and the
lifting eye.
weight may result in damage to the
pump or failure of the eye bolt.
Remove the hardware securing the pump casing
to the base.
Disengage the hardware (36 and 38, Figure 1) se
curing the drive flange to the engine bellhousing,
and remove the guards (16, Figure 5). Separate
the pump end and drive assembly from the engine
by pulling the pump end straight away from the en
gine.
As the assemblies separate, the flexible portion of
the coupling assembly (2) will remain on the shaft.
To remove the coupling from the shaft, unscrew the
two allen head setscrews from the bushing (1).
Screw one of the setscrews into the puller hole on
the circumference of the bushing. As the coupling
and bushing separate, remove the bushing, and
slide the coupling off the shaft. Remove the shaft
key (17, Figure 5).
It is not necessary to remove the outer ring of the
coupling from the engine flywheel unless the cou
pling must be replaced. To remove the ring, disen
gage the hardware (3 and 4) securing it to the fly
wheel.
Remove any leveling shims used under the casing
mounting feet. Tie and tag the shims for ease of
reassembly.
Move the pump end to a clean, well equipped shop
area for further disassembly.
Loosening Impeller
(Figure 5)
Before attempting to loosen the impeller, remove
the seal cavity drain plug (25A) and drain the lubri
cant. This will prevent the oil from escaping as the
impeller is removed. Clean and reinstall the drain
plug.
With the pump end separated from the engine and
the back cover (5, Figure 4) removed, wedge a
Do not attempt to lift the complete pump
block of wood between the vanes of the impeller
and the pump casing to prevent rotation.
unit using the lifting eye. It is designed
to facilitate removal or installation of in
dividual components only. Additional
MAINTENANCE & REPAIR PAGE E - 17
If removed, install the shaft key (17) in the shaft
keyway. Install a lathe dog on the drive end of the
Page 45
OM-06610 SUPER T SERIES
shaft (15) with the “V” notch positioned over the
shaft key.
With the impeller rotation still blocked, see Figure 9
and use a long piece of heavy bar stock to pry
against the arm of the lathe dog in a counterclock
wise direction (when facing the drive end of the
shaft). Use caution not to damage the shaft or key
way. When the impeller breaks loose, remove the
lathe dog, key and wood block.
TEE
APPROX. 6 IN.
(152 MM) LONG
NOTE
Do not remove the impeller until the rotating assem
bly has been removed from the pump casing.
Turn
Counterclockwise
Lathe Dog Arm
“V” Notch
Heavy
Bar Stock
Figure 9. Loosening Impeller
Shaft Key
Impeller
Shaft
Lathe Dog
Setscrew
APPROX. 14 IN.
(356 MM) LONG
Figure 10. Rotating Assembly Tool
To install the tool, remove the vented plug (9, Figure
5) from the bearing housing, and screw the longest
length of pipe into the vent hole until fully engaged.
Install the tee, and screw the handles into the tee.
Use caution when lifting the rotating assembly to
avoid injury to personnel or damage to the assem
bly.
Remove the bearing housing O‐ring (13A).
Impeller Removal
(Figure 5)
With the rotating assembly removed from the
pump casing, unscrew the impeller from the shaft.
Use caution when unscrewing the impeller; ten
sion on the shaft seal spring will be released as the
impeller is removed. Inspect the impeller and re
place if cracked or badly worn.
Rotating Assembly Removal
(Figure 4)
Remove the hardware (7 and 8) securing the rotat
ing assembly to the pump casing. Separate the ro
tating assembly by pulling straight away from the
pump casing. Tie and tag the rotating assembly
shims (2) for ease of reassembly.
NOTE
An optional disassembly tool is available from the
factory. If the tool is used, follow the instructions
packed with it. A similar tool may be assembled us
ing 1/2‐inch pipe (schedule 80 steel or malleable
iron) and a standard tee (see Figure 10). All threads
are 1/2‐inch NPT. Do not pre‐assemble the tool.
Remove the impeller adjusting shims (26); tie and
tag the shims, or measure and record their thick
ness for ease of reassembly.
Seal Removal
(Figure 5)
Slide the integral shaft sleeve and rotating portion
of the seal off the shaft as a unit.
Use a pair of stiff wires with hooked ends to remove
the stationary element and seat.
An alternate method of removing the stationary
seal components is to remove the hardware (6 and
7) and separate the seal plate (3) and gasket (5)
MAINTENANCE & REPAIRPAGE E - 18
Page 46
SUPER T SERIES
from the bearing housing (8). Position the seal
plate on a flat surface with the impeller side down.
Use a wooden dowel or other suitable tool to press
on the back side of the stationary seat until the
seat, O‐rings, and stationary element can be re
moved.
Remove the shaft sleeve O‐ring (14).
If no further disassembly is required, refer to Seal
Installation.
Shaft and Bearing Removal and Disassembly
(Figure 5)
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.
OM-06610
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.
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 (25) and
drain the lubricant. Clean and reinstall the drain
plug.
Disengage the hardware (22 and 23) and slide the
drive flange (21) and oil seal (4B) off the shaft. Re
move the flange gasket (18) and press the oil seal
from the drive flange.
Place a block of wood against the impeller end of
the shaft and tap the shaft and assembled bear
ings (13 and 19) from the bearing housing.
Pry or press the oil seals (4 and 4A) from the bear
ing housing.
After removing the shaft and bearings, clean and
inspect the bearings in place as follows.
Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.
Bearings must be kept free of all dirt and
foreign material. Failure to do so will great
ly shorten bearing life. Do not spin dry
bearings. This may scratch the balls or
races and cause premature bearing fail
ure.
Rotate the bearings by hand to check for rough
ness or binding and inspect the bearing balls. If ro
tation is rough or the bearing balls are discolored,
replace the bearings.
The bearing tolerances provide a tight press fit
onto the shaft and a snug slip fit into the bearing
housing. Replace the bearings, shaft, or bearing
housing if the proper bearing fit is not achieved.
MAINTENANCE & REPAIR PAGE E - 19
Page 47
OM-06610 SUPER T SERIES
If bearing replacement is required, remove the out
board bearing snap ring (20) and use a bearing
puller to remove the bearings from the shaft.
Shaft and Bearing Reassembly and Installation
(Figure 5)
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 (4A) in the bearing
housing bore with the lip positioned as shown in
Figure 5. Press the oil seal into the housing until the
face is just flush with the machined surface on the
inside of the housing.
The bearings may be heated to ease installation.
An induction heater, hot oil bath, electric oven, or
hot plate may be used to heat the bearings. Bear
ings should never be heated with a direct flame or
directly on a hot plate.
NOTE
If a hot oil bath is used to heat the bearings, both the
oil and the container must be absolutely clean. If
the oil has been previously used, it must be thor
oughly filtered.
Heat the bearings to a uniform temperature no
higher than 250_F (120_C) and slide the bearings
onto the shaft, one at a time, until they are fully
seated. This should be done quickly, in one con
tinuous motion, to prevent the bearings from cool
ing and sticking on the shaft.
After the bearings have been installed and allowed
to cool, check to ensure that they have not moved
away from the shaft shoulders in shrinking. If
movement has occurred, use a suitably sized
sleeve and a press to reposition the bearings
against the shaft shoulders.
If heating the bearings is not practical, use a suit
ably sized sleeve, and an arbor (or hydraulic) press
to install the bearings on the shaft.
When installing the bearings onto the
shaft, never press or hit against the outer
race, balls, or ball cage. Press only on the
inner race.
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.
NOTE
Position the inboard bearing (13) on the shaft with
the shielded side toward the impeller end of the
shaft. Position the outboard bearing (19) on the
shaft with the integral retaining ring on the bearing
O.D. toward the drive end of the shaft.
Secure the outboard bearing on the shaft with the
bearing snap ring (20).
It is recommended that a sleeve be positioned
against the inboard oil seal (4A) 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
MAINTENANCE & REPAIRPAGE E - 20
Page 48
SUPER T SERIES
OM-06610
the retaining ring on the outboard bearing seats
against the bearing housing. Remove the lip seal
sleeve.
When installing the shaft and bearings into
the bearing bore, push against the outer
race. Never hit the balls or ball cage.
Position the outboard oil seal (4) on the lubricated
shaft with the lip positioned as shown in Figure 4.
Press the oil seal into the bearing housing until the
face of the seal is just flush with the machined sur
face on the bearing housing.
Press the oil seal (4B) into the drive flange (21) with
the lip positioned as shown in Figure 5. Replace
the flange gasket (18) and secure the flange to the
bearing housing with the hardware (22 and 23). Be
careful not to damage the oil seal lip on the shaft
keyway.
Lubricate the bearing housing as indicated in LU
BRICATION.
Seal Installation
(Figures 5, 11, 12 and 13)
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 seal cavity and shaft with a cloth soaked
in fresh cleaning solvent. Inspect the stationary
seat bore in the seal plate for dirt, nicks and burrs,
and remove any that exist. The stationary seat bore
must be completely clean before installing the
seal.
A new seal assembly should be installed
any time the old seal is removed from the
pump. Wear patterns on the finished faces
cannot be realigned during reassembly.
Reusing an old seal could result in prema
ture failure.
To ease installation of the seal, lubricate the shaft
sleeve O‐ring (14) and the external stationary seat
O‐ring with a very small amount of light lubricating
oil. See Figure 11 for seal part identification.
MAINTENANCE & REPAIR PAGE E - 21
Page 49
OM-06610 SUPER T SERIES
SPRING
IMPELLER
IMPELLER
SHIMS
IMPELLER
SHAFT
BELLOWS
SPRING
CENTERING
WASHER
RETAINER
DRIVE BAND
ROTATING
ELEMENT
STATIONARY
ELEMENT
SEAL PLATE
O‐RINGS
SLEEVE
O‐RING
INTEGRAL
SHAFT
SLEEVE
SHEAR
RING
(SHEARED)
STATIONARY
SEAT
Figure 11. Cartridge Seal Assembly
This seal is not designed for operation at
temperatures above 160_F (71_C). Do not
use at higher operating temperatures.
If the seal plate (3) was removed, install the seal
plate gasket (5), position the seal plate over the
shaft and secure it to the bearing housing with the
hardware (6 and 7). Install the bearing housing O‐
ring (27) and lubricate it with light grease.
To prevent damaging the shaft sleeve O‐ring (14)
on the shaft threads, stretch the O‐ring over a piece
of tubing just large enough to slide over the shaft.
Slide the tube over the shaft threads, then slide the
O‐ring off the tube and onto the shaft. Remove the
tube, and continue to slide the O‐ring down the
shaft until it seats against the shaft shoulder.
When installing a new cartridge seal assembly,
remove the seal from the container, and remove
the mylar storage tabs, if so equipped, from be
tween the seal faces.
New cartridge seal assemblies may be
equipped with mylar storage tabs between
the seal faces. If so equipped, these stor
age tabs must be removed before install
ing the seal.
Lubricate the external stationary seat O‐ring with
light oil. Slide the seal assembly onto the shaft until
the external stationary seat O‐ring engages the
bore in the seal plate.
Clean and inspect the impeller as described in Im
peller Installation and Adjustment. Install the full
set of impeller shims (26) provided with the seal,
and screw the impeller onto the shaft until it is
seated against the seal (see Figure 12).
MAINTENANCE & REPAIRPAGE E - 22
Page 50
SUPER T SERIES
OM-06610
Continue to screw the impeller onto the shaft. This
will press the stationary seat into the seal plate
bore.
O‐RING ENGAGED
WITH SEAL PLATE
BORE
SHEAR RING
(UNSHEARED)
Figure 12. Seal Partially Installed
NOTE
A firm resistance will be felt as the impeller presses
the stationary seat into the seal plate bore.
As the stationary seat becomes fully seated, the
seal spring compresses, and the shaft sleeve will
break the nylon shear ring. This allows the sleeve
to slide down the shaft until seated against the
shaft shoulder. Continue to screw the impeller onto
the shaft until the impeller, shims, and sleeve are
fully seated against the shaft shoulder (see Figure
13).
STATIONARY SEAT
FULLY SEATED IN
SEAL PLATE BORE
proper clearance as described in Impeller Instal
lation and Adjustment.
If necessary to reuse an old seal in an emer
gency, carefully separate the rotating and station
ary seal faces from the bellows retainer and sta
tionary seat.
A new seal assembly should be installed
any time the old seal is removed from the
pump. Wear patterns on the finished faces
cannot be realigned during reassembly.
Reusing an old seal could result in prema
ture failure.
Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate precision
finished faces; even fingerprints on the faces can
shorten seal life. If necessary, clean the faces with a
non‐oil based solvent and a clean, lint‐free tissue.
Wipe lightly in a concentric pattern to avoid
scratching the faces.
Carefully wash all metallic parts in fresh cleaning
solvent and allow to dry thoroughly.
Do not attempt to separate the rotating
portion of the seal from the shaft sleeve
when reusing an old seal. The rubber bel
lows will adhere to the sleeve during use,
and attempting to separate them could
damage the bellows.
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.
SHEAR RING
(SHEARED)
Figure 13. Seal Fully Installed
Measure the impeller‐to‐seal plate clearance, and
remove impeller adjusting shims to obtain the
MAINTENANCE & REPAIR PAGE E - 23
Install the stationary seal element in the stationary
seat. Press this stationary subassembly into the
seal plate bore until it seats squarely against the
bore shoulder. A push tube made from a piece of
plastic pipe would aid this installation. The I.D. of
the pipe should be slightly larger than the O.D. of
the shaft sleeve.
Page 51
OM-06610 SUPER T SERIES
Slide the rotating portion of the seal (consisting of
the integral shaft sleeve, spring centering washer,
spring, bellows and retainer, and rotating element)
onto the shaft until the seal faces contact.
Proceed with Impeller Installation and Adjust
ment.
Impeller Installation
(Figure 5)
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 (26) as previously removed. Apply `Never‐
Seez' or equivalent to the shaft threads and screw
the impeller onto the shaft until tight. Be sure the
seal spring seats squarely on the back side of the
impeller.
Rotating Assembly Installation
(Figure 4)
NOTE
If the pump has been completely disassembled, it
is recommended that the suction check valve and
back cover assembly be reinstalled at this point.
The back cover assembly must be in place to adjust
the impeller face clearance.
NOTE
There is a 1‐1/2 inch diameter socket head pipe
plug located in the side of the bearing housing. This
hole is required for manufacturing purposes only;
therefore the pipe plug should never require remov
al.
Install the bearing housing O‐ring (13A) and lubri
cate it with light grease. Ease the rotating assem
bly into the pump casing using the installation tool.
Be careful not to damage the O‐ring.
Install the rotating assembly adjusting shims (2)
using the same thickness as previously removed.
Secure the rotating assembly to the pump casing
with the hardware (7 and 8).
To set the impeller and wear plate clearance refer
to the Back Cover Installation And Adjustment.
Suction Check Valve Installation
(Figure 4)
NOTE
At the slightest sign of binding, immediately back
the impeller off, and check the threads for dirt. Do
not try to force the impeller onto the shaft.
A clearance of .025 to .040 inch (0,64 to 1,02 mm)
between the impeller and the seal plate is recom
mended for maximum pump efficiency. Measure
this clearance, and add or remove impeller adjust
ing shims as required.
NOTE
If the rotating assembly has been installed in the
pump casing, this clearance may be measured by
reaching through the priming port with a feeler
gauge.
Inspect the check valve assembly (32) and replace
it if badly worn.
NOTE
The check valve assembly must be replaced as a
complete unit. Individual parts are not sold sepa
rately.
Reach through the back cover opening with the
check valve and position the check valve adaptor
in the mounting slot in the suction flange (23). Align
the adaptor with the flange hole and secure the as
sembly with the check valve pin (24).
NOTE
If the suction or discharge flanges were removed,
replace the respective gaskets, apply `Permatex
MAINTENANCE & REPAIRPAGE E - 24
Page 52
SUPER T SERIES
OM-06610
Aviation No. 3 Form‐A‐Gasket' or equivalent com
pound to the mating surfaces, and secure them to
the pump casing with the attaching hardware.
Back Cover Installation And Adjustment
(Figures 4 and 14)
If the wear plate (4) was removed for replacement,
carefully center it on the back cover and secure it
with the hardware (11 and 12). The wear plate
must be concentric to prevent binding when the
back cover is installed.
The clearance between the impeller and wear plate
is adjusted using four adjusting screws (19) and
locking collars (17). There are 18 detents on the
I.D. of each locking collar. Indexing the collars one
detent on the adjusting screws represents approxi
mately .005 inch (0,13 mm) of wear plate clear
ance. The recommended clearance between the
wear plate and the impeller is .010 to .020 inch
(0,25 to 0,50 mm).
Replace the back cover and wear plate O‐rings (10
and 13) and lubricate them with a generous
amount of No. 2 grease. Clean any scale or debris
from the contacting surfaces in the pump casing
that might interfere or prevent a good seal with the
back cover.
USE TWO REMAINING
ADJUSTING SCREWS AND
LOCKING COLLARS TO
SET FACE CLEARANCE
USE TWO
OPPOSING
BACK COVER NUTS
TO PRESS
BACK COVER
INTO PUMP
CASING
INDEX COLLARS 3
DETENTS COUNTER‐
CLOCKWISE, THEN
TURN CLOCKWISE
UNTIL SCREW
HOLES ALIGN
just flush with the machined surface on the back
side of the cover plate.
Align the back cover plate over the studs (20) and
slide it into the pump casing. Use two back cover
nuts (21) on diagonally opposing studs to press
the back cover into the pump casing until the wear
plate just touches the impeller when the shaft is
turned by hand. Tighten the back cover nuts
evenly to avoid binding.
With the wear plate just touching the impeller, turn
the two free adjusting screws until they engage the
pump casing. Position the locking collars over the
adjusting screws so the holes in the collars for the
locking screws align approximately with the holes
in the cover plate.
Loosen the back cover nuts used to press the back
cover into the pump casing one full turn.
Pull the collars off the adjusting screws, index them
three detents counterclockwise, and reinstall the
collars on the adjusting screws. Use the collars to
turn the adjusting screws clockwise until the holes
in the locking collars realign with the tapped screw
holes in the back cover plate. Secure the locking
collars to the back cover plate with the hardware (7
and 18). Install the two remaining back cover nuts
snugly against the adjusting screws.
Remove the first two back cover nuts from their
studs. Turn the adjusting screws clockwise until
they engage the pump casing. Install the locking
collars and hardware (7 and 18). Reinstall the back
cover nuts.
Be sure the wear plate does not scrape against the
impeller.
Over time it may be necessary to repeat the adjust
ment process to compensate for normal wear be
tween the impeller and wear plate. When all of the
adjustment has been used on the back cover side
of the pump, an additional 0.125 inch (3,2 mm) of
adjustment may be obtained by removing the ro
tating assembly adjusting shims (2).
Allow an installed pump to completely cool before
draining liquid from the pump casing. Remove the
back cover. Remove the rotating assembly adjust
Figure 14. Installing and Adjusting Back Cover
ing shims, then reinstall the hardware securing the
rotating assembly to the pump casing. Perform the
Screw the four adjusting screws (19) into the
tapped holes in the back cover plate until they are
back cover adjustment procedure described
above to obtain the proper face clearance.
MAINTENANCE & REPAIR PAGE E - 25
Page 53
OM-06610 SUPER T SERIES
Securing Pump and Coupling Assembly to
Engine
(Figure 8)
Install the shaft key (17, Figure 5) in the shaft key
way. Position the flexible portion of the coupling as
sembly (2) on the shaft as shown in Figure 8.
Align the keyway in the bushing (1) with the shaft
key, and slide it onto the shaft to the dimension
shown in Figure 8. Rotate the flexible portion of the
coupling until the tapped holes for the two set
screws align with those in the bushing, and install
the setscrews.
Make certain that the flexible portion of the
coupling is mounted as shown in Figure 8.
This is critical. If the coupling is not prop
erly positioned on the shaft, the coupling
parts may not fully engage, or a pre‐load
condition can cause premature bearing
failure.
NOTE
To ease installation, lightly lubricate the rubber por
tion of the coupling with a non‐petroleum based
lubricant such as vegetable oil or glycerin, or a sili
con‐based lubricant such as “WD40” or equivalent.
Do not use petroleum‐based lubricants, or any oth
er substance which may soften or otherwise dam
age the rubber.
Install the intermediate guards (16, Figure 5), and
secure the drive flange to the engine bellhousing
with the hardware (36 and 38, Figure 1).
Secure the check valve/air release valve assembly
(33, Figure 4) to the pump casing using the pre
viously removed hardware. Reinstall any additional
components removed at disassembly.
Install any leveling shims used under the casing
mounting feet, and secure the casing to the base
with the previously removed hardware.
If a lifting eye was used to move the pump casing,
be sure to remove the lifting eye from the pump
casing.
The end of the shaft must protrude 1.25
inch (32 mm) from the face of the bush
ing. This will allow the two portions of the
coupling to fully engage when the drive
flange is secured to the engine bellhous
ing, without pre‐loading the bearings.
With the flexible portion of the coupling and the
bushing properly positioned on the shaft, tighten
the two setscrews in an alternating sequence until
the bushing and coupling are fully secured. Torque
the setscrews to 14.6 ft. lbs. (175 in. lbs. or 2 m.
kg.).
If the complete coupling assembly is being re
placed, apply `Loctite Retaining Compound No.
242' or equivalent to the threads of the hardware (3
and 4) and secure the outer ring of the coupling to
the engine flywheel by torquing the hardware to 45
ft. lbs. (540 in. lbs. or 6,2 m. kg.).
Using a suitable lifting device, position the pump
end so the flexible portion of the coupling seats in
side the outer ring attached to the engine flywheel.
Do not attempt to lift the complete pump
unit using the lifting eye. It is designed
to facilitate removal or installation of in
dividual components only. Additional
weight may result in damage to the
pump or failure of the eye bolt.
PRESSURE RELIEF VALVE
MAINTENANCE
(Figure 4)
The back cover is equipped with a pressure relief
valve (not shown) to provide additional safety for
the pump and operator (refer to Liquid Tempera
ture And Overheating in OPERATION).
It is recommended that the pressure relief valve as
sembly be replaced at each overhaul, or any time
the pump overheats and activates the valve. Never
replace this valve with a substitute which has not
MAINTENANCE & REPAIRPAGE E - 26
Page 54
SUPER T SERIES
OM-06610
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 4
with the discharge port pointing down.
Final Pump Assembly
Be sure the pump is secured to the base and en
gine. Be sure to install any guards used over the ro
tating members.
Do not operate the pump without the
guards in place over the rotating parts.
Exposed rotating parts can catch cloth
ing, fingers, or tools, causing severe in
jury to personnel.
Install the suction and discharge lines and open all
valves. Make certain that all piping connections are
tight, properly supported and secure.
ounces (2,6 liter) of SAE No. 30 non‐detergent oil to
the middle of the sight gauge (24) and maintain it at
the middle of the gauge. Clean and reinstall the
vented plug. Maintain the oil at this level.
Bearings
(Figure 5)
The bearing housing was fully lubricated when
shipped from the factory. Check the oil level regu
larly through the sight gauge (24A) and maintain it
at the middle of the gauge. When lubrication is re
quired, add SAE No. 30 non‐detergent oil through
the hole for the air vent (11). Do not over‐lubricate.
Over‐lubrication can cause the bearings to over‐
heat, resulting in premature bearing failure.
Under normal conditions, drain the bearing hous
ing once each year and refill with approximately 24
ounces (0,7 liter) clean oil. Change the oil more fre
quently if the pump is operated continuously or in
stalled in an environment with rapid temperature
change.
Be sure the pump and engine have been properly
lubricated, see LUBRICATION.
Remove the fill cover assembly (28, Figure 4) and
fill the pump casing with clean liquid. Reinstall the
fill cover and tighten it. Refer to OPERATION, Sec
tion C, before putting the pump back into service.
LUBRICATION
Seal Assembly
(Figure 5)
Before starting the pump, remove the vented plug
(9) and fill the seal cavity with approximately 88
Monitor the condition of the bearing lubri
cant regularly for evidence of rust or mois
ture condensation. This is especially im
portant in areas where variable hot and
cold temperatures are common.
For cold weather operation, consult the factory or a
lubricant supplier for the recommended grade of
oil.
Engine
Consult the literature supplied with the engine, or
contact your local engine representative.
MAINTENANCE & REPAIR PAGE E - 27
Page 55
For U.S. and International Warranty Information,
Please Visit www.grpumps.com/warranty
or call:
U.S.: 419-755-1280
International: +1-419-755-1352
For Canadian Warranty Information,
Please Visit www.grcanada.com/warranty
or call:
519-631-2870
THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA
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