ACDEU OM‐05512-OE01 June 11, 2003 Rev. A 08‐05‐03 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST SUPER T SERIES PUMP MODEL T4A60S-F3L THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA www.gormanrupp.com Copyright by the Gorman‐Rupp Company Printed in U.S.A.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE I - 1 SAFETY ‐ SECTION A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE A - 1 INSTALLATION - SECTION B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 1 Pump Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (continued) Horn Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lines With a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lines Without a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPER T SERIES OM-05512 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. 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.
SUPER T SERIES OM-05512 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.
OM-05512 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.
SUPER T SERIES OM-05512 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.
OM-05512 SUPER T SERIES 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.
SUPER T SERIES 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.
OM-05512 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.
SUPER T SERIES OM-05512 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.
OM-05512 SUPER T SERIES 3.0 (0.9) ENGINE CONTROL BOX ON (Emptying) OFF (Filling) OPERATING RANGE CABLE (See Table Below) TETHER POINT OFF (Emptying) 1.25” Pipe (Not Furnished) ON (Filling) 2.5 (.76) 2.0 (0.6) 1.5 (.46) 1.0 (0.3) 0.5 (.15) 1.0 2.0 3.0 4.0 (0.3) (0.6) (0.9) (1.2) APPROXIMATE FREE CORD LENGTH IN FT. (M) Figure 3.
SUPER T SERIES OM-05512 SUCTION LINE DISCHARGE LINE SIGNAL CABLE (ATTACH TO SUCTION LINE) SUCTION STRAINER SUBMERSIBLE TRANSDUCER (DOWNSTREAM FROM SUCTION) FLOW 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.
OM-05512 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.
SUPER T SERIES É É É Figure 5. Valve in Open Position During the priming cycle, air from the pump casing flows through the bypass line, and passes through the Air Release Valve to the wet well (Figure 5). É É É É OM-05512 Liters) per minute) will occur when the valve is fully closed. Be sure the bypass line is directed back to the wet well or tank to prevent hazardous spills. When the pump shuts down, the spring returns the diaphragm to its original position.
OM-05512 SUPER T SERIES DISCHARGE PIPE CLEAN‐OUT COVER INSTALL AIR RELEASE VALVE IN HORIZONTAL POSITION DISCHARGE CHECK VALVE 90 LONG RADIUS ELBOW SUPPORT BRACKET BLEED LINE 1” (25,4 MM) DIA. MIN. (CUSTOMER FUR‐ NISHED) EXTEND 6” (152,4 MM) BELOW PUMP OFF LIQUID LEVEL PUMP DISCHARGE SELF‐PRIMING CENTRIFUGAL PUMP SUCTION LINE WET WELL OR SUMP Figure 7.
OM-05512 SUPER T SERIES OPERATION - SECTION C Review all SAFETY information in Section A. Follow the instructions on all tags, labels and decals attached to the pump. Do not operate an internal combustion engine in an explosive atmosphere. When operating internal combustion engines in an enclosed area, make cer tain that exhaust fumes are piped to the outside. These fumes contain carbon monoxide, a deadly gas that is color less, tasteless, and odorless.
OM-05512 SUPER T SERIES Press and hold the white “AUTO” button on the control panel until the red “AUTO” light illuminates. The auto‐start system is now armed. STARTING NOTE 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.
OM-05512 SUPER T SERIES Stop the unit manually by pressing the “OFF/SET” button. 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.
OM-05512 SUPER T SERIES ter false signals that could cause “nuisance” trip ping of the contacts. 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.
OM-05512 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.
OM-05512 Liquid Temperature And Overheating The maximum liquid temperature for this pump is 160 F (71 C). Do not apply it at a higher operat ing temperature. Overheating can occur if operated with the valves in the suction or discharge lines closed. Operating against closed valves could bring the liquid to a boil, build pressure, and cause the pump to rup ture or explode. If overheating occurs, stop the pump and allow it to cool before servicing it. Refill the pump casing with cool liquid.
OM-05512 SUPER T SERIES Automatic Stopping In the automatic mode, the pump will stop when the liquid in the wet well or sump lowers and acti vates the “Off” float switch(s) or “Off” setpoint stored in the optional EPS. The pump will restart automatically when the liquid rises and activates the “On” float switch(s) or “On” setpoint stored in the optional EPS. Safety Shutdown System The unit is equipped with a safety system to auto matically shut down the engine under certain con ditions.
OM-05512 liquid during the draining process. Clean out any remaining solids by flushing with a hose. BEARING TEMPERATURE CHECK Bearings normally run at higher than ambient tem peratures because of heat generated by friction. Temperatures up to 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.
SUPER T SERIES OM-05512 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. Turn the keyswitch 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.
OM-05512 SUPER T SERIES Table 1. Trouble Shooting Chart (cont.) TROUBLE PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE (cont.) POSSIBLE CAUSE PROBABLE REMEDY Leaking or worn seal or pump gas ket. Check pump vacuum. Replace leaking or worn seal or gasket. Strainer clogged. Check strainer and clean if neces sary. Suction intake not submerged at proper level or sump too small. Check installation and correct sub mergence as needed. Impeller or other wearing parts worn or damaged.
SUPER T SERIES OM-05512 Table 1. Trouble Shooting Chart (cont.) TROUBLE BEARINGS RUN TOO HOT POSSIBLE CAUSE Bearing temperature is high, but within limits. Check bearing temperature regular ly to monitor any increase. Low or incorrect lubricant. Check for proper type and level of lubricant. Suction and discharge lines not properly supported. Check piping installation for proper support. Drive misaligned. Align drive properly.
OM-05512 SUPER T SERIES Preventive Maintenance Schedule Service Interval* Item General Condition (Temperature, Unusual Noises or Vibrations, Cracks, Leaks, Loose Hardware, Etc.
SUPER T SERIES OM-05512 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.
OM-05512 SUPER T SERIES SECTION DRAWING Figure 1.
SUPER T SERIES OM-05512 PARTS LIST Pump Model T4A60S-F3L (From S/N 1264856 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.
OM-05512 SUPER T SERIES SECTION DRAWING Figure 2.
SUPER T SERIES OM-05512 PARTS LIST 46143-002 Deutz F3L Power Unit Kit ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 PART NAME PART NUMBER MAT'L CODE QTY DEUTZ F3L ENGINE BASE/FUEL TANK MUFFLER GUARD ASSY WARNING DECAL HEX HD CAPSCREW LOCKWASHER HEX NUT BATTERY BOX KIT OIL DRAIN ASSY POS BATTERY CABLE HEX HD CAPSCREW HEX NUT LOCKWASHER FLAT WASHER FUEL GAUGE FUEL PICKUP HOSE ASSY MALE CONNECTOR R.H. ENGINE SIDE RAIL L.H.
OM-05512 SUPER T SERIES SECTION DRAWING TOP VIEW Figure 3.
SUPER T SERIES OM-05512 PARTS LIST T4A60S-(SAE 4/10) Pump End Assembly ITEM PART NAME NO.
OM-05512 SUPER T SERIES SECTION DRAWING DRIVE END VIEW Figure 4.
SUPER T SERIES OM-05512 PARTS LIST 44163-347 Repair Rotating Assembly ITEM NO.
OM-05512 SUPER T SERIES SECTION DRAWING Figure E-5. 44162-161 Drive Assembly PARTS LIST ITEM NO.
SUPER T SERIES OM-05512 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Review all SAFETY information in Section A. Follow the instructions on all tags, label and de cals attached to the pump. This pump requires little service due to its rugged, minimum‐maintenance design. However, if it be comes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the sectional views (see Figures 1, 2, 3, 4 and 5) and the accompanying parts lists.
OM-05512 SUPER T SERIES Inspect the wear plate, and replace it if badly scored or worn. To remove the wear plate, disen gage the hardware (17 and 18). Inspect the back cover O‐rings (16 and 20) and re place it if damaged or worn. Suction Check Valve Removal (Figure 3) If the check valve assembly (41) is to be serviced, remove the check valve pin (42), reach through the back cover opening and pull the complete assem bly from the suction flange (37).
SUPER T SERIES OM-05512 Turn Counterclockwise TEE APPROX. 6 IN. (152 MM) LONG Lathe Dog Arm “V” Notch Heavy Bar Stock APPROX. 14 IN. (356 MM) LONG Shaft Key Impeller Shaft Lathe Dog Setscrew Figure 6. Loosening Impeller Figure 7. Rotating Assembly Tool To install the tool, remove the vented plug (8, 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.
OM-05512 An alternate method of removing the stationary seal components is to remove the hardware (20 and 21) and separate the seal plate (3) and gasket (4) from the bearing housing (7). Position the seal plate on a flat surface with the impeller side down. Use a wooden dowel or other suitable tool to press on the back side of the stationary seat until the seat, O‐rings, and stationary element can be re moved. Remove the shaft sleeve O‐ring (28).
SUPER T SERIES OM-05512 Shaft and Bearing Reassembly and Installation ings should never be heated with a direct flame or directly on a hot plate. (Figure 4) NOTE Clean the bearing housing, shaft and all compo nent parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage as necessary. Most cleaning solvents are toxic and flammable. Use them only in a well ven tilated area free from excessive heat, sparks, and flame.
OM-05512 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 (5) on the lubricated shaft with the lip positioned as shown in Figure 4. Press the oil seal into the bearing housing until the face of the seal is just flush with the machined sur face on the bearing housing. Press the oil seal (15) into the drive flange (12) with the lip positioned as shown in Figure 4.
SUPER T SERIES OM-05512 RETAINER SEAL PLATE SPRING O‐RINGS IMPELLER SLEEVE O‐RING IMPELLER SHIMS IMPELLER SHAFT ROTATING ELEMENT BELLOWS STATIONARY ELEMENT INTEGRAL SHAFT SLEEVE SHEAR RING (SHEARED) SPRING CENTERING WASHER STATIONARY SEAT DRIVE BAND Figure 8. 46513-151 Cartridge Seal Assembly When installing a new cartridge seal assembly, remove the seal from the container, and remove the mylar storage tabs, if so equipped, from be tween the seal faces.
OM-05512 SUPER T SERIES Continue to screw the impeller onto the shaft. This will press the stationary seat into the seal plate bore. O‐RING ENGAGED WITH SEAL PLATE BORE SHEAR RING (UNSHEARED) Figure 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.
SUPER T SERIES OM-05512 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 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.
OM-05512 SUPER T SERIES cure it with the hardware (17 and 18). 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 (34) and locking collars (33). 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.
SUPER T SERIES OM-05512 with the end of the shaft. Rotate the flexible portion of the coupling until the tapped holes for the two setscrews align with those in the bushing, and in stall the setscrews. Install the intermediate guards (24, 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.
OM-05512 SUPER T SERIES Final Pump Assembly tioned horizontally to provide proper drainage. (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. Bearings (Figure 3) The bearing housing was fully lubricated when shipped from the factory.
AV-05355 (Rev 3-13-02) SUPER T SERIESR PUMP 60 MONTH LIMITED WARRANTY EXTENT AND DURATION OF WARRANTY Coverage: The Gorman‐Rupp Company/Gorman‐Rupp of Canada Limited (herein “GR”) warrants that its Super T Series pumps shall be free from defects in material and workmanship for a period of sixty (60) months from the date of purchase by the original end user when installation is made and use and mainte nance is performed in accordance with GR's recommendations.
