Gorman-Rupp Pumps T6A60S-F4L User Manual

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Page 1

ACDEU

OM-05514-02

June 9, 2005

Rev. D 10‐24‐12

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

SUPER T SERIES PUMP

MODEL

T6A60S-F4L

THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO

www.grpumps.com

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

e2005 The Gorman‐Rupp Company

Page 2

Gorman‐Rupp pump online at

www.grpumps.com

Valid serial number and e‐mail address required.

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

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

Please record your pump model and serial number in the spaces provided below. Your Gorman‐Rupp distributor needs this information when you require parts or service.

Pump Model:

Serial Number:

Page 3

TABLE OF CONTENTS

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

SAFETY ‐ SECTION A PAGE A - 1............................................

INSTALLATION - SECTION B PAGE B - 1....................................

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

PREINSTALLATION INSPECTION PAGE B - 2............................................

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

POSITIONING PUMP PAGE B - 2.......................................................

Lifting PAGE B - 2.................................................................

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

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

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

Materials PAGE B - 3..............................................................

Line Configuration PAGE B - 3......................................................

Connections to Pump PAGE B - 3..................................................

Gauges PAGE B - 3...............................................................

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

Fittings PAGE B - 3...............................................................

Strainers PAGE B - 4..............................................................

Sealing PAGE B - 4...............................................................

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

Suction Line Positioning PAGE B - 4................................................

FLOAT SWITCHES PAGE B - 5.........................................................

Installation PAGE B - 5............................................................

OPTIONAL SUBMERSIBLE TRANSDUCER PAGE B - 6...................................

DISCHARGE LINES PAGE B - 7........................................................

Siphoning PAGE B - 7.............................................................

Valves PAGE B - 7................................................................

Bypass Lines PAGE B - 7..........................................................

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

Theory of Operation PAGE B - 8....................................................

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

ALIGNMENT PAGE B - 10..............................................................

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

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

STARTING PAGE C - 2................................................................

Manual Starting PAGE C - 2........................................................

Automatic Starting PAGE C - 2.....................................................

OPTIONAL EPS CONTROL PAGE C - 3.................................................

Features PAGE C - 3..............................................................

Functional Description PAGE C - 3..................................................

EPS Functions PAGE C - 4.........................................................

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

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

Span Adjustment PAGE C - 5......................................................

Level Adjustment PAGE C - 5......................................................

Page 4

TABLE OF CONTENTS

(continued)

Horn Delay PAGE C - 5............................................................

OPERATION PAGE C - 5..............................................................

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

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

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

Liquid Temperature And Overheating PAGE C - 6.....................................

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 - 7...............................................

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

Cold Weather Preservation PAGE C - 7..............................................

BEARING TEMPERATURE CHECK PAGE C - 8..........................................

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

Power Unit Kit PAGE E - 5.........................................................

Pump End Assy PAGE E - 7........................................................

Repair Rotating Assy PAGE E - 9...................................................

Drive Assy PAGE E - 10............................................................

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

Back Cover And Wear Plate Removal PAGE E - 11.....................................

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

Separating Intermediate And Drive Assembly From Engine PAGE E - 12..................

Loosening Impeller PAGE E - 12.....................................................

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

Impeller Removal PAGE E - 13......................................................

Seal Removal PAGE E - 13..........................................................

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

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

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

Impeller Installation PAGE E - 19.....................................................

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

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

Back Cover Installation And Adjustment PAGE E - 19..................................

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

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

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

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

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

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

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

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SUPER T SERIES

OM-05514

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 also is designed with external shimless adjusters for setting the wear plate to im peller clearance. The pump is close coupled to a Deutz F4L diesel engine, and is designed for han dling dirty water containing specified entrained sol ids and slurries. The basic material of construction is gray iron, with ductile iron impeller and steel wearing parts.

Because pump installations are seldom identical, this manual cannot possibly provide detailed in structions and precautions for every aspect of each specific application. Therefore, it is the re sponsibility of the owner/installer of the pump to ensure that applications not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity are com promised by the installation. Pumps and related equipment must be installed and operated ac cording to all national, local and industry stan dards.

For information or technical assistance on the en gine, contact the engine manufacturer's local dealer or representative.

The following are used to alert maintenance per sonnel to procedures which require special atten tion, to those which could damage equipment, and to those which could be dangerous to personnel:

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

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

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

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

NOTE

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

PAGE I - 1INTRODUCTION

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OM-05514

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.

Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and pre cautions for each specific application. Therefore, it is the owner/installer's re sponsibility to ensure that applications not addressed in this manual are per formed only

after establishing that nei ther operator safety nor pump integrity are compromised by the installation.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Set the HAND‐OFF‐AUTO switch to `OFF', 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.

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.

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.

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

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

PAGE A - 1SAFETY

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SUPER T SERIESOM-05514

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.

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 refuel a hot or run ning engine. Avoid overfilling the fuel tank. Always use the correct type of fuel.

Never tamper with the governor to gain more power. The governor establishes safe operating limits that should not be exceeded. The maximum continuous operating speed for this pump is 1700 RPM.

PAGE A - 2 SAFETY

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SUPER T SERIES OM-05514

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-F4L

PAGE B - 1INSTALLATION

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OM-05514 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.

Table 1. Battery Specifications

Reserve

Capacity

@ 80

_ F

(Minutes)

120

Amp/

Hr.

Rating

Approx.

Overall

Dims.

(Inches)

10.25L x

6.75W x

8.88H

Voltage

12 Volts

Cold Crank Amps

@ 0_ F

850

Refer to the information accompanying the battery and/or electrolyte solution for activation and charg ing instructions.

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.

POSITIONING PUMP

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

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

Lifting

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

The pump assembly can be seriously

PAGE B - 2 INSTALLATION

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SUPER T SERIES OM-05514

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

ing piping couplings in suction lines is not 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.

Gauges

Clearance

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

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by 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

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

SUCTION LINES

To avoid air pockets which could affect pump 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

PAGE B - 3INSTALLATION

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OM-05514 SUPER T SERIES

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.

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.

Sealing

Since even a slight leak will affect priming, head, and capacity, especially when operating with a high suction lift, all connections in the suction line should be sealed with pipe dope to ensure an air tight seal. Follow the sealant manufacturer's rec ommendations when selecting and applying the pipe dope. The pipe dope should be compatible with the liquid being pumped.

Suction Lines In Sumps

If a single suction line is installed in a sump, it should be positioned away from the wall of the

Suction Line Positioning

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

ity.

Figure 2 shows

NOTE

The pipe submergence required may be reduced by installing a standard pipe increaser fitting at the end of the suction line. The larger opening size will reduce the inlet velocity. Calculate the required submergence using the following formula based on the increased opening size (area or diameter).

PAGE B - 4 INSTALLATION

Page 12

SUPER T SERIES OM-05514

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 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.

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.

PAGE B - 5INSTALLATION

Page 13

OM-05514 SUPER T SERIES

ENGINE

CONTROL

BOX

(Emptying)

OFF

(Filling)

OPERATING

CABLE

TETHER

RANGE

(See Table Below)

POINT

OFF

(Emptying)

1.25” Pipe (Not Furnished)

(Filling)

Figure 3. Float Switch Data

OPTIONAL SUBMERSIBLE TRANSDUCER

This unit may be equipped with an optional Elec tronic Pressure Switch (EPS) that works in con 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”.

3.0

(0.9)

2.5

(.76)

2.0

(0.6)

1.5

(.46)

1.0

(0.3)

0.5

(.15)

1.0

(0.3)

APPROXIMATE FREE CORD LENGTH IN FT. (M)

2.0

(0.6)

3.0

(0.9)

above the point where it bends along the 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.

4.0

(1.2)

When installing the submersible transducer, note the following:

a. Handle the signal cable and transducer with

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

b. Be sure to provide sufficient room in the wet

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

e. Thoroughly clean the transducer after each

use to prevent clogging.

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

warranty.

PAGE B - 6 INSTALLATION

Page 14

SUPER T SERIES OM-05514

SUCTION

DISCHARGE

LINE

SIGNAL CABLE

(ATTACH TO

SUCTION LINE)

SUBMERSIBLE

TRANSDUCER

(DOWNSTREAM

FROM SUCTION)

SUCTION

STRAINER

Figure 4. Typical Submersible Transducer Installation

DISCHARGE LINES

Siphoning

Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a si phon breaker is used in the line. Otherwise, a si phoning action causing damage to the pump could result.

Valves

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

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

FLOW

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

Bypass Lines

Self‐priming pumps are not air compressors. 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

PAGE B - 7INSTALLATION

Page 15

OM-05514 SUPER T SERIES

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.

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

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

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

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

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

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.

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 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 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

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.

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

Except in certain specific applications (to prevent flooding during service of an auto matic air release valve in a below‐ground

PAGE B - 8 INSTALLATION

valve is fully closed. Be sure the bypass line is directed back to the wet well or tank to prevent hazardous spills.

Page 16

SUPER T SERIES OM-05514

Consult the manual accompanying the Air Release Valve for additional information on valve installation and performance.

Air Release Valve Installation

The Automatic Air Release Valve must be inde

CLEAN‐OUT COVER

INSTALL AIR RELEASE VALVE IN HORIZONTAL POSITION

90_ LONG

RADIUS ELBOW

SUPPORT BRACKET

BLEED LINE 1” (25,4 MM) DIA. MIN. (CUSTOMER FUR NISHED) EXTEND 6” (152 MM) BELOW PUMP OFF LIQUID LEVEL

SUCTION LINE

pendently mounted in a horizontal position be tween the pump discharge port and the inlet side of the discharge check valve (see Figure 5). The inlet opening in the Air Release Valve is equipped with standard 1‐inch NPT pipe threads.

DISCHARGE PIPE

DISCHARGE CHECK VALVE

PUMP DISCHARGE

SELF‐PRIMING CENTRIFUGAL

PUMP

WET WELL OR SUMP

Figure 5. Typical Automatic Air Release Valve Installation

Connect the valve outlet to a bleed line which slopes back to the wet well or sump. The bleed line must be the same size as the outlet opening or larger, depending on which Air Release Valve is be ing used. If piping is used for the bleed line, avoid the use of elbows whenever possible.

NOTE

For multiple pump installations, it is recommended that each Air Release Valve be fitted with an inde pendent bleeder line directed back to the wet well. If multiple Air Release Valves are installed in a sys tem, do not direct bleeder lines to a common mani

fold pipe. Contact your Gorman‐Rupp distributor or the Gorman‐Rupp Company for information about installation of an Automatic Air Release Valve for your specific application.

ALIGNMENT

The alignment of the pump and the engine is criti cal for trouble‐free mechanical operation. See Sec tion E, Securing Intermediate And Drive Assem

bly To Engine for detailed information.

PAGE B - 9INSTALLATION

Page 17

SUPER T SERIES

OM-05514

OPERATION - SECTION C

Review all SAFETY information in Section A.

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

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

cated (see LUBRICATION in MAINTENANCE AND REPAIR).

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

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

Add liquid to the pump casing when:

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

2. The pump has not been used for a 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. The maximum continuous operating speed for this pump is 1700 RPM.

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 18

OM-05514 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 and hold the white “AUTO” button on the control panel until the red “AUTO” light illuminates. The auto‐start system is now armed.

NOTE

The unit can continue to be started manually with the keyswitch in the “AUTO START” position by pressing the white “MAN” button on the control. The “Single Lightning Bolt” light on the control will illu minate in conjunction with an audible alarm before the unit starts. The unit can then be stopped manu ally by pressing the “OFF/SET” button.

In the auto‐start mode, the “Single Lightning Bolt” light will illuminate in conjunction with an audible alarm when the liquid level in the sump or wet well rises and activates the float(s). The light will blink and the alarm will sound for approximately 8 sec onds before the unit starts.

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 “AUTO START” position. To cancel the auto‐start process, press the “OFF/SET” button.

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 “AUTO START” position.

NOTE

For security purposes, the key can be removed with the switch in the “AUTO START” position.

The control panel is equipped with high oil temper ature, low oil pressure, V‐belt and start failure (3 at tempts) safety shutdowns. If any of these problems occur, the red “Double Lightning Bolt” light will illu minate to indicate a system fault. When the prob lem is corrected, press the “OFF/SET” button to re set the control.

NOTE

The “OFF/SET” button has dual functionality when in program mode. If necessary, consult the factory for details on programming functions.

The unit can be started manually with the key switch in the “AUTO START” position by pressing the white “MAN” button. The “Single Lightning Bolt” light will illuminate in conjunction with an au dible alarm before the unit starts.

OPERATIONPAGE C - 2

Page 19

SUPER T SERIES

OM-05514

Stop the unit manually by pressing the “OFF/SET” button.

OPTIONAL EPS CONTROL

Features

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

S 3 Output Relays: 1. A output, delayed

2. B output, no delay

3. Horn output, no delay

S 3 Inputs: 1. Horn silence

2, Pressure transducer

3. Low Temp Thermostat

S LCD screen with backlight for function moni

toring

S Bright LEDs to indicate output status and dis

play modes

S Three switches on front panel for all adjust

ments

S Battery level indicator on LCD screen to alert

operator of low battery condition

S Microprocessor Control

S Error display to alert user of errors in calibra

tion

Functional Description

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

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

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

h) LO BAT... Indicator, shows battery

voltage level is below 12VDC.

i) Lo tpt... Shows status of Low Tem

perature Thermostat con tacts.

2. LEDs:

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

showing level on the LCD display.

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

output relay is closed.

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

output relay is closed

NOTE

LED's and all segments of the display are lighted upon connection of power as a lamp test feature. However, no relay outputs are closed during test.

3. Switches:

a) The switch functions as a “round rob

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

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.

OPERATION PAGE C - 3

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.

Page 20

OM-05514 SUPER T SERIES

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.

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 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.

ter false signals that could cause “nuisance” trip ping of the contacts.

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 level adjustments will be used whenever “ON” and “OFF” liquid levels must be reset.

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

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.

OPERATIONPAGE C - 4

Page 21

SUPER T SERIES

Press 3 times and the LCD screen will display

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

Press to accept the entry and advance to “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

“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.

OM-05514

Lines With a Bypass

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

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

Lines Without a Bypass

Open all valves in the discharge line and start the 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.

OPERATION

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

OPERATION PAGE C - 5

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.

Page 22

OM-05514 SUPER T SERIES

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 completely cool before servic

ing it. Refill the pump casing

with cool 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

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

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 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 switching the HAND‐OFF‐AUTO switch 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.

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

Automatic Stopping

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

OPERATIONPAGE C - 6

Page 23

SUPER T SERIES

OM-05514

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:

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 within a pre‐set peri od of time.

4. If the engine speed exceeds the safe operat ing range.

shutdown before putting the unit back into service. Consult the factory for ad ditional information.

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.

5. If the engine V‐belt breaks.

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

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

All safety shutdown features are pre‐set at the 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

Cold Weather Preservation

In below freezing conditions, drain the pump to prevent damage from freezing. Also, clean out any solids by flushing with a hose. Operate the pump for approximately one minute; this will remove any remaining liquid that could freeze the pump rotat ing parts. If the pump will be idle for more than a few hours, or if it has been pumping liquids con taining a large amount of solids, drain the pump, and flush it thoroughly with clean water. To prevent large solids from clogging the drain port and pre venting the pump from completely draining, insert a rod or stiff wire in the drain port, and agitate the liquid during the draining process. Clean out any remaining solids by flushing with a hose.

OPERATION PAGE C - 7

Page 24

OM-05514 SUPER T SERIES

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.

OPERATIONPAGE C - 8

Page 25

TROUBLESHOOTING - SECTION D

Review all SAFETY information in Section A.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Set the HAND‐OFF‐AUTO switch to `OFF', 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.

OM-05514SUPER T SERIES

5. Close the suction and discharge valves.

6. Vent the pump slowly and cau tiously.

7. Drain the pump.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO PRIME Not enough liquid in casing.

Suction check valve contaminated or damaged.

Air leak in suction line.

Lining of suction hose collapsed.

Leaking or worn seal or pump gas ket.

Suction lift or discharge head too high.

Strainer clogged.

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE

Air leak in suction line.

Lining of suction hose collapsed.

Leaking or worn seal or pump gas ket.

Add liquid to casing. See PRIMING.

Clean or replace check valve.

Correct leak.

Replace suction hose.

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

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

Check strainer and clean if neces sary.

Correct leak.

Replace suction hose.

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

Strainer clogged.

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

TROUBLESHOOTING PAGE D - 1

Check strainer and clean if neces sary.

Check installation and correct sub mergence as needed.

Page 26

OM-05514 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-05514SUPER T SERIES

PREVENTIVE MAINTENANCE

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

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

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

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

Preventive Maintenance Schedule

Service Interval*

Item

General Condition (Temperature, Unusual

Noises or Vibrations, Cracks, Leaks,

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

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

Daily Weekly Monthly Semi‐

Annually

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

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

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

TROUBLESHOOTING PAGE D - 3

Page 28

SUPER T SERIES OM-05514

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-F4L

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-05514

SECTION DRAWING

Figure 1. Pump Model T6A60S-F4L

PARTS LIST

Pump Model T6A60S-F4L

(From S/N 1313299 Up)

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

ITEM NO.

1 PUMP END ASSY T6A60S-(SAE 4/10) --- 1 2 POWER UNIT KIT 46143-035 --- 1 3 G‐R DECAL GR-06 --- 5 4 PUMP MOUNTING KIT 48157-003 --- 1

NOT SHOWN:

OPTIONAL:

PART NAME

WARNING DECAL 2613FE --- 1

12V BATTERY 29331-515 --- 1 WHEEL KIT GRP30-262 --- 1

PART NUMBER

MAT'L CODE

QTY

MAINTENANCE & REPAIRPAGE E - 2

Page 30

SUPER T SERIES OM-05514

SECTION DRAWING

Figure 2. 46143-035 Deutz F4L Power Unit Kit

MAINTENANCE & REPAIR PAGE E - 3

Page 31

PARTS LIST

46143-035 Deutz F4L Power Unit Kit

SUPER T SERIESOM-05514

ITEM NO.

1 DEUTZ F4L ENGINE 29217-421 --- 1 2 BASE/FUEL TANK 41553-006 24150 1 3 MUFFLER GUARD ASSY 42331-031 --- 1 4 NEG BATTERY CABLE 47311-134 --- 1 5 POS BATTERY CABLE 47311-113 --- 1 6 BATTERY BOX ASSY 42432-005 --- 1 7 OIL DRAIN ASSY 46342-036 --- 1 8 HEX HD CAPSCREW B1017 15991 2

9 LOCKWASHER J10 15991 2 10 HEX NUT D10 15991 2 11 4' HOSE 18513-302 --- 1 12 HOSE CLAMP 26518-642 --- 2 13 HOSE BARB FITTING 26523-333 --- 2 14 HEX HD CAPSCREW B1007 15991 4 15 HEX NUT D10 15991 4 16 LOCKWASHER J10 15991 4 17 FLAT WASHER K10 15991 8 18 FUEL GAUGE 29332-135 --- 1 19 FUEL PICKUP 29332-145 --- 2 20 HOSE ASSY 46341-796 --- 1 21 MALE CONNECTOR S1447 --- 1 22 R.H. ENGINE SIDE RAIL 34451-085 15080 1 23 L.H. ENGINE SIDE RAIL 34451-086 15080 1 24 HEX HD CAPSCREW B1007 15991 4 25 HEX NUT D10 15991 4 26 LOCKWASHER J10 15991 4 27 CONTROL PANEL KIT 48313-794 --- 1 28 EXHAUST ELBOW 31912-023 15990 1 29 WEATHER CAP S1331 --- 1 30 WARNING DECAL 38816-169 --- 1 31 LIFTING BAIL KIT 48274-801 --- 1

NOT SHOWN:

PART NAME

FLOAT SWITCH 48312-980 --- 1 ENGINE STARTUP TAG 38816-269 --- 1 INSTRUCTION DECAL 38818-144 --- 1 WARNING DECAL 38816-203 --- 4 LOW SULFER FUEL DECAL 38816-196 --- 1

PART NUMBER

MAT'L CODE

QTY

MAINTENANCE & REPAIRPAGE E - 4

Page 32

SUPER T SERIES OM-05514

SECTION DRAWING

TOP VIEW

DRIVE END VIEW

Figure 3. T6A60S-(SAE 4/10) Pump End Assembly

MAINTENANCE & REPAIR PAGE E - 5

Page 33

ITEM

PART NAME PART

NO.

PARTS LIST

T6A60S-(SAE 4/10) Pump End Assembly

NUMBER

MAT'L CODE

QTY ITEM

NO.

PART NAME PART

SUPER T SERIESOM-05514

NUMBER

MAT'L CODE

QTY

1 PUMP CASING 10957E 10000 1 2 REPAIR ROTATING ASSY 44163-349 --- 1

3 PIPE PLUG P04 15079 1 4 HEX HD CAPSCREW B1208 15991 8 5 LOCKWASHER J12 15991 8 6 PIPE NIPPLE T96 15070 1 7 PIPE ELBOW R96 11990 1 8 DISCHARGE FLANGE 1758 10010 1

9 DISCH FLANGE GSKT 25113-036 --- 1 10 BEARING HSG O‐RING S1676 --- 1 11 HEX HD CAPSCREW B0806 15991 4

12 LOCKWASHER J08 15991 4 13 ROT ASSY ADJ SHIMS 13131-3 17040 8 14 WEAR PLATE ASSY 46451-723 24150 1 15 BACK COVER O‐RING 25152-453 --- 1

16 LOCKWASHER J06 15991 4 17 HEX NUT D06 15991 4 18 BACK COVER O‐RING S1676 --- 1 19 CASING DRAIN PLUG P20 10009 1 20 BACK CVR PLATE ASSY 42111-803 --- 1 21 -DRIVE SCREW BM#04-03 17000 4 22 -WARNING PLATE 2613EV 13990 1 23 -PRESS RELIEF VALVE 26662-005 --- 1 24 -BACK COVER PLATE NOT AVAILABLE 1 25 -WARNING DECAL 38816-302 --- 1 26 CVR PLATE HANDLE 12354 13010 1 27 HEX HD CAPSCREW B0604 15991 2 28 LOCKWASHER J06 15991 2 29 HEX HD CAPSCREW B0804-1/2 15991 4 30 LOCKWASHER J08 15991 4 31 LOCK COLLAR 38115-551 15001 4 32 ADJUSTING SCREW 31871-070 1500G 4 33 BACK COVER NUT 31871-073 15000 4 34 STUD C1213 15991 4

35 SUCTION FLANGE GSKT 11402G 19370 1 36 HEX HD CAPSCREW B1211 15991 8 37 LOCKWASHER J12 15991 8 38 PIPE PLUG P04 15079 1

INDICATES PARTS RECOMMENDED FOR STOCK

39 SUCT CHK VALVE ASSY 46411-064 --- 1 40 SUCTION FLANGE 11402 10010 1 41 CHECK VALVE PIN 11645 17010 1 42 CLAMP BAR SCREW 31912-009 15000 1 43 PIPE PLUG P04 15079 1 44 CLAMP BAR 38111-004 11010 1 45 MACHINE BOLT A1014 15991 2 46 FILL COVER ASSY 42111-344 --- 1 47 -DRIVE SCREW BM#04-03 17000 2 48 -FILL COVER PLATE NOT AVAILABLE 1 49 -WARNING PLATE 38816-097 13990 1 50 -COVER GASKET 50G 19210 1 51 PIPE PLUG P08 15079 1

NOT SHOWN:

DRIVE SCREW BM#04-03 17000 4 LUBE DECAL 38817-084 --- 1 WARNING DECAL 2613FE --- 1 NAME PLATE 38818-040 13990 1 SUCTION STICKER 6588AG --- 1 PRIMING STICKER 6588AH --- 1 DISCHARGE STICKER 6588BJ --- 1 SUPER “T” DECAL 38812-089 --- 1 STRAINER ASSEMBLY 7823A 24000 1 G‐R DECAL GR-06 --- 1 INSTRUCTION TAG 38817-023 --- 1 DRIVE ASSEMBLY 44162-119 --- 1

OPTIONAL:

.SELF CLEANING

WEAR PLATE 46451-766 24150 1 ALLOY STEEL WEAR PLATE ASSY 46451-729 24160 1 DISASSEMBLY TOOL 48711-020 --- 1 SEWAGE SLUDGE PRESS RELIEF VALVE 46431-628 --- 1 CLEANOUT KIT 48783-010 AIR RELEASE VALVES:

-10# COMP SPRING GRP33-07A --- 1

-25# COMP SPRING GRP33-07 --- 1

-80# COMP SPRING GRP33-07B --- 1

. FOR PUMP RETRO‐FITTING, BACK COVER OPENING MUST BE 6.19 INCH DIAMETER ‐ CONSULT FACTORY FOR DETAILS.

MAINTENANCE & REPAIRPAGE E - 6

Page 34

SUPER T SERIES OM-05514

SECTION DRAWING

DRIVE END VIEW

Figure 4. 44163-349 Repair Rotating Assembly

MAINTENANCE & REPAIR PAGE E - 7

Page 35

PARTS LIST

44163-349 Repair Rotating Assembly

SUPER T SERIESOM-05514

ITEM NO.

1 IMPELLER 38615-087 11010 1 2 SEAL ASSEMBLY 46513-154 --- 1 3 SEAL PLATE GSKT 10959G 20000 1 4 BALL BEARING S616 --- 1 5 BEARING HOUSING 38251-517 10000 1 6 VENTED PLUG 4823A 15079 1 7 AIR VENT S1530 --- 1 8 REDUCING BUSHING AP0802 15079 1

9 BALL BEARING S1030 --- 1 10 DRIVE FLANGE 38545-006 10000 1 11 SHAFT KEY N0611 15990 1 12 IMPELLER SHAFT 38514-823 1706H 1 13 OIL SEAL S1917 --- 1 14 SNAP RING 24124-425 --- 1 15 HEX HD CAPSCREW 21632-938 15991 8 16 LOCKWASHER J06 15991 8 17 BEARING CAP GASKET 38683-478 18000 1 18 OIL SEAL S1917 --- 1 19 OIL SEAL S1917 --- 1 20 HEX HD CAPSCREW B0805 1/2 15991 4 21 LOCKWASHER J08 15991 4 22 SEAL PLATE 38272-254 10010 1 23 SEAL CAVITY DRAIN PLUG P04 15079 1 24 BEARING HOUSING DRAIN PLUG P04 15079 1 25 SIGHT GAUGE S1471 --- 1 26 SIGHT GAUGE S1471 --- 1 27 PIPE PLUG P12 15079 1 28 INTERMEDIATE GUARD ASSY 42381-509 24152 2 29 IMPELLER ADJUSTING SHIM SET 5091 17090 1 30 SHAFT SLEEVE O‐RING 25154-026 --- 1 31 SHIPPING PLUG 11495B 15079 2 32 ROTATING ASSY ADJ SHIMS 13131-3 17040 8 33 BEARING HOUSING O‐RING S1676 --- 1 34 DRIVE SCREW BM#04-03 17000 2 35 SERIAL NUMBER PLATE 2613GG 13990 1

PART NAME

PART NUMBER

MAT'L CODE

QTY

NOT SHOWN:

ROTATION DECAL 2613M --- 1 INSTRUCTION TAG 6588U --- 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIRPAGE E - 8

Page 36

SUPER T SERIES OM-05514

SECTION DRAWING

Figure 5. 44162-119 Drive Assembly

PARTS LIST

ITEM NO.

1 COUPLING KIT 48112-001 --- 1

2 -BUSHING 24131-345 --- 1

3 -COUPLING ASSEMBLY 44165-011 --- 1

4 -LOCKWASHER J06 15991 8

5 -SAE SOCKET HD CAPSCREW BD0606-1/2 15991 8

5 -METRIC SOCKET HD CAPSCREW 22644-220 --- 8

SAE APPLICATION

6 HEX HD CAPSCREW B0605 15991 12

7 LOCKWASHER JO6 15991 12

METRIC APPLICATION

6 HEX HD CAPSCREW 22645-164 --- 12

7 LOCKWASHER 21171-511 --- 12

MAINTENANCE & REPAIR PAGE E - 9

PART NAME

PART NUMBER

MAT'L CODE

QTY

Page 37

OM-05514 SUPER T SERIES

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Before attempting to open or service the

Review all SAFETY information in Section A.

pump:

1. Familiarize yourself with this man ual.

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

2. Switch off the engine ignition and disconnect the positive battery cable to ensure that the pump will

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

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.

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.

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 3)

Many service functions may be performed by draining the pump and removing the back cover assembly. If major repair is required, the piping and/or power source must be disconnected. The following instructions assume complete disassem bly is required.

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

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

The wear plate (14) is easily accessible and may be serviced by removing the back cover assembly (20). Before attempting to service the pump, re move the pump casing drain plug (19) and drain the pump. Clean and reinstall the drain plug.

Remove the back cover nuts (33) 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 (33) and two diagonally opposing locking col lars (31). Install two 1/2-13 UNC x 2 inch long screws in the tapped holes in the back cover and use them to press the back cover out of the pump

MAINTENANCE & REPAIRPAGE E - 10

Page 38

SUPER T SERIES

OM-05514

casing.

Inspect the wear plate, and replace it if badly scored or worn. To remove the wear plate, disen gage the hardware (16 and 17).

Inspect the back cover and wear plate O‐rings (15 and 18) and replace it if damaged or worn.

Suction Check Valve Removal

(Figure 3)

If the check valve assembly (39) is to be serviced, remove the check valve pin (41), reach through the back cover opening and pull the complete assem bly from the suction flange (40).

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.

Remove the hardware securing the pump casing to the base.

Disengage the hardware (6 and 7) securing the drive flange to the engine bellhousing, and remove the guards (24, Figure 4). Separate the pump end and drive assembly from the engine by pulling the pump end straight away from the engine.

As the assemblies separate, the flexible portion of the coupling assembly (3) will remain on the shaft. To remove the coupling from the shaft, unscrew the two allen head setscrews from the bushing (2). Screw one of the setscrews into the puller hole on the circumference of the bushing. As the coupling and bushing separate, remove the bushing, and slide the coupling off the shaft. Remove the shaft key (11, Figure 4).

It is not necessary to remove the outer ring of the coupling from the engine flywheel unless the cou pling must be replaced. To remove the ring, disen gage the hardware (4 and 5) securing it to the fly wheel.

Separating Intermediate And Drive Assembly From Engine

(Figure 5)

Further disassembly requires separating the pump end and drive assembly from the engine. Install a standard 5/8‐11 UNC lifting eye in the tapped hole in the top of the pump casing. Be sure to screw the eye into the casing until fully engaged. Support the pump using a suitable hoist and the lifting eye.

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

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

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

Loosening Impeller

(Figure 4)

Before attempting to loosen the impeller, remove the seal cavity drain plug (23) 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 (20, Figure 3) removed, wedge a block of wood between the vanes of the impeller and the pump casing to prevent rotation.

If removed, install the shaft key (11) in the shaft keyway. Install a lathe dog on the drive end of the

MAINTENANCE & REPAIR PAGE E - 11

Page 39

OM-05514 SUPER T SERIES

shaft (12) with the “V” notch positioned over the shaft key.

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

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 6. Loosening Impeller

Shaft Key

Impeller Shaft

Lathe Dog

Setscrew

APPROX. 14 IN.

(356 MM) LONG

Figure 7. Rotating Assembly Tool

To install the tool, remove the vented plug (6, Figure

4) from the bearing housing, and screw the longest length of pipe into the vent hole until fully engaged. Install the tee, and screw the handles into the tee. Use caution when lifting the rotating assembly to avoid injury to personnel or damage to the assem bly.

Remove the bearing housing O‐ring (10).

Impeller Removal

(Figure 4)

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

Rotating Assembly Removal (Figure 4)

Remove the hardware (11 and 12, Figure 3) secur ing the rotating assembly to the pump casing. Sep arate the rotating assembly by pulling straight away from the pump casing. Tie and tag the rotat ing assembly shims (32) 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 7). All threads are 1/2‐inch NPT. Do not pre‐assemble the tool.

Remove the impeller adjusting shims (29); tie and tag the shims, or measure and record their thick ness for ease of reassembly.

Seal Removal

(Figure 4)

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

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

An alternate method of removing the stationary seal components is to remove the hardware (20 and 21) and separate the seal plate (22) and gas

MAINTENANCE & REPAIRPAGE E - 12

Page 40

SUPER T SERIES

ket (3) from the bearing housing (5). Position the seal plate on a flat surface with the impeller side down. Use a wooden dowel or other suitable tool to press on the back side of the stationary seat until the seat, O‐rings, and stationary element can be removed.

Remove the shaft sleeve O‐ring (30).

If no further disassembly is required, refer to Seal

Installation.

Shaft and Bearing Removal and Disassembly

(Figure 4)

When the pump is properly operated and main tained, the bearing housing should not require dis assembly. Disassemble the shaft and bearings

only when there is evidence of wear or damage.

OM-05514

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 (24) and drain the lubricant. Clean and reinstall the drain plug.

Disengage the hardware (15 and 16) and slide the drive flange (10) and oil seal (13) off the shaft. Re move the flange gasket (17), 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 (4 and 9) from the bearing housing.

Pry or press the oil seals (18 and 19) 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 - 13

Page 41

OM-05514 SUPER T SERIES

If bearing replacement is required, remove the out board bearing snap ring (14), and use a bearing puller to remove the bearings from the shaft.

Shaft and Bearing Reassembly and Installation

(Figure 4)

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

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

Position the inboard oil seal (18) in the bearing housing bore with the lip positioned as shown in Figure 4. Press the oil seal into the housing until the face is just flush with the machined surface 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.

NOTE

Position the inboard bearing (4) on the shaft with the shielded side toward the impeller end of the shaft. Position the outboard bearing (9) 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 (14).

It is recommended that a sleeve be positioned against the inboard oil seal (18) 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 - 14

Page 42

SUPER T SERIES

OM-05514

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 (19) 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.

Seal Installation

(Figures 4, 8, 9 and 10)

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

Press the oil seal (13) into the drive flange (10) with

the lip positioned as shown in Figure 4. Replace

the flange gasket (17), and secure the flange to the

bearing housing with the hardware (15 and 16). Be careful not to damage the oil seal lip on the shaft

keyway.

Lubricate the bearing housing as indicated in LU

BRICATION.

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 (30) and the external stationary seat O‐ring with a very small amount of light lubricating oil. See Figure 8 for seal part identification.

MAINTENANCE & REPAIR PAGE E - 15

Page 43

OM-05514 SUPER T SERIES

RETAINER

SPRING

SEAL PLATE

O‐RINGS

IMPELLER

SLEEVE

O‐RING

BELLOWS

IMPELLER

SHAFT

ROTATING

ELEMENT

IMPELLER

SHIMS

DRIVE BAND

Figure 8. 46513-154 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 (22) was removed, install the seal plate gasket (3). Position the seal plate over the shaft and secure it to the bearing housing with the hardware (20 and 21). Install the bearing housing O‐ring (33) and lubricate it with light grease.

To prevent damaging the shaft sleeve O‐ring (30) on the shaft threads, stretch the O‐ring over a piece of tubing 1‐1/2 I.D. x 1‐3/4 O.D. x 2‐inches long (38 mm x 43 mm x 51 mm). Slide the tube over the shaft threads, then slide the O‐ring off the tube and onto the shaft. Remove the tube, and continue to slide the O‐ring down the shaft until it seats against the shaft shoulder.

SHAFT

SLEEVE

STATIONARY

ELEMENT

STATIONARY

SEAT

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 (29) provided with the seal, and screw the impeller onto the shaft until it is seated against the seal (see Figure 9).

When installing a new cartridge seal assembly, remove the seal from the container, and remove

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

MAINTENANCE & REPAIRPAGE E - 16

Page 44

SUPER T SERIES

OM-05514

O‐RING ENGAGED WITH SEAL PLATE

BORE

SHEAR RING

(UNSHEARED)

Figure 9. Seal Partially Installed

NOTE

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

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

10).

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.

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.

STATIONARY SEAT

FULLY SEATED IN

SEAL PLATE BORE

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

SHEAR RING

(SHEARED)

Figure 10. Seal Fully Installed

Measure the impeller‐to‐seal plate clearance, and remove impeller adjusting shims to obtain the proper clearance as described in Impeller Instal

lation and Adjustment.

MAINTENANCE & REPAIR PAGE E - 17

the sleeve is damaged, replace the complete seal; never mix old and new seal parts.

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

Page 45

OM-05514 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 4)

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

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

Install the same thickness of impeller adjusting shims (29) as previously removed. Apply `Never‐ Seez' or equivalent to the shaft threads and screw the impeller onto the shaft until tight. Be sure the seal spring seats squarely on the back side of the impeller.

Rotating Assembly Installation

(Figure 3)

NOTE

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

Install the bearing housing O‐ring (33) 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 (13) using the same thickness as previously removed. Secure the rotating assembly to the pump casing with the hardware (11 and 12).

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

Suction Check Valve Installation

(Figure 3)

Inspect the check valve assembly (39) 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.

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.

Reach through the back cover opening with the check valve and position the check valve adaptor in the mounting slot in the suction flange (40). Align the adaptor with the flange hole, and secure the as sembly with the check valve pin (41).

NOTE

If the suction or discharge flanges were removed, replace the respective gaskets, apply `Permatex Aviation No. 3 Form‐A‐Gasket' or equivalent com pound to the mating surfaces, and secure them to the pump casing with the attaching hardware.

Back Cover Installation And Adjustment

(Figures 3 and 11)

If the wear plate (14) was removed for replace ment, carefully center it on the back cover and se

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SUPER T SERIES

OM-05514

cure it with the hardware (16 and 17). 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 (32) and locking collars (31). 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 (15 and 18) 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

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 (29 and 30). 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 (29 and 30). 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 (13).

Allow an installed pump to completely cool before draining liquid from the pump casing. Remove the back cover. Remove the rotating assembly adjust

Figure 11. 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 (32) into the tapped holes in the back cover plate until they are

back cover adjustment procedure described above to obtain the proper face clearance.

just flush with the machined surface on the back side of the cover plate.

Align the back cover plate over the studs (34) and slide it into the pump casing. Use two back cover nuts (33) on diagonally opposing studs to press the back cover into the pump casing until the wear

Securing Pump End To Engine

(Figure 5)

Install the shaft key (11, Figure 4) in the shaft key way. Position the flexible portion of the coupling as sembly (3) on the shaft as shown in Figure 5.

plate just touches the impeller when the shaft is turned by hand. Tighten the back cover nuts

evenly to avoid binding.

Align the keyway in the bushing (2) with the shaft key, and slide it onto the shaft to the dimension

MAINTENANCE & REPAIR PAGE E - 19

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OM-05514 SUPER T SERIES

shown in Figure 5. Rotate the flexible portion of the coupling until the tapped holes for the two set screws align with those in the bushing, and install the setscrews.

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

The end of the shaft must protrude 1.25 inch (32 mm) from the face of the bushing. This will allow the two portions of the cou pling to fully engage when the drive flange is secured to the engine bellhousing, with out 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.).

Install the intermediate guards (28, Figure 4), and secure the drive flange to the engine bellhousing with the hardware (6 and 7).

(Figure 1)

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.

PRESSURE RELIEF VALVE MAINTENANCE

If the complete coupling assembly is being re placed, apply `Loctite Retaining Compound No. 242' or equivalent to the threads of the hardware (4 and 5), and secure the outer ring of the coupling to the engine flywheel by torquing the hardware to 45 ft. lbs. (540 in. lbs. or 6,2 m. kg.).

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

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.

(Figure 3)

The back cover is equipped with a pressure relief valve (23) to provide additional safety for the pump and operator (refer to Liquid Temperature And Overheating in OPERATION).

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

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

MAINTENANCE & REPAIRPAGE E - 20

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SUPER T SERIES

OM-05514

Final Pump Assembly

(Figure 1)

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.

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

Remove the fill cover assembly (46, Figure 3) and fill the pump casing with clean liquid. Reinstall the fill cover and tighten it. Refer to OPERATION, Sec tion C, before putting the pump back into service.

tioned horizontally to provide proper drainage.

Bearings

(Figure 4)

The bearing housing was fully lubricated when shipped from the factory. Check the oil level regu larly through the sight gauge (26) the middle of the gauge. When lubrication is re quired, add SAE No. 30 non‐detergent oil through the hole for the air vent (7). Do not over‐lubricate. Over‐lubrication can cause the bearings to over‐ heat, resulting in premature bearing failure.

and maintain it at

NOTE

The white reflector in the sight gauge must be posi tioned horizontally to provide proper drainage.

Under normal conditions, drain the bearing hous ing once each year and refill with 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.

LUBRICATION

Seal Assembly

(Figure 4)

Before starting the pump, remove the vented plug (6) and fill the seal cavity with approximately 88 ounces (2,6 liter) of SAE No. 30 non‐detergent oil to the middle of the sight gauge (25) and maintain it at the middle of the gauge. Clean and reinstall the vented plug. Maintain the oil at this level.

NOTE

The white reflector in the sight gauge must be posi

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 - 21

Page 49

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