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GORMAN-RUPP PUMPS T SERIES, Installation, Operation, And Maintenance Manual With Parts List

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GORMAN-RUPP PUMPS T SERIES Installation, Operation, And Maintenance Manual With Parts List Download Page 29

SUPER T SERIES

OM-05512

MAINTENANCE & REPAIR

PAGE E - 2

ILLUSTRATION

PARTS PAGE

4

2

3

1

Figure 1.  Pump Model T4A60S-F3L

PARTS LIST

Pump Model T4A60S-F3L

(From S/N 1721674 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.

PART NAME

PART 
NUMBER

QTY

1

PUMP END ASSY

46186-469

1

2

POWER UNIT KIT

46143-032

1

3

BATTERY

SEE OPTIONS

REF

4

PUMP MOUNTING KIT

48157-002

1

NOT SHOWN:

WARNING DECAL

2613FE

1

G-R DECAL

GR-06

4

OPTIONAL:

12V BATTERY

29331-527

1

WHEEL KIT

GRP30-261

1

Summary of Contents for T SERIES

Page 1: ...OM 05512 03 February 5 2020 GORMAN RUPP PUMPS www grpumps com e2020 Gorman Rupp Pumps Printed in U S A INSTALLATION OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST SUPER T SERIESr PUMP MODEL T4A60S F3L ...

Page 2: ...L 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 The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 3: ...ling 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 Air Release Valve Installation PAGE B 9 ALIGNMENT PAGE B 9 OPERATION SECTION C PAGE C 1 PRIMING PAGE C 1 STARTING ...

Page 4: ...sembly PAGE E 6 Repair Rotating Assembly PAGE E 8 Drive Assembly PAGE E 9 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E 10 Back Cover And Wear Plate Removal PAGE E 11 Suction Check Valve Removal PAGE E 11 Separating Intermediate And Drive Assembly From Engine PAGE E 11 Loosening Impeller PAGE E 12 Rotating Assembly Removal PAGE E 12 Impeller Removal PAGE E 13 Seal Removal PAGE E 13 Shaft and Bea...

Page 5: ...ny P O Box 1217 Mansfield Ohio 44901 1217 Phone 419 755 1011 or Gorman Rupp of Canada Limited 70 Burwell Road St Thomas Ontario N5P 3R7 Phone 519 631 2870 For information or technical assistance on the power source contact the power source manufac turer s local dealer or representative HAZARD AND INSTRUCTION DEFINITIONS The following are used to alert maintenance per sonnel to procedures which req...

Page 6: ...s subject to au tomatic restart Keep hands and cloth ing away from the unit to prevent injury during automatic operation Disconnect the positive battery cable before per forming any maintenance Failure to do so may result in serious personal injury This pump is designed to handle dirty water containing specified entrained solids Do not attempt to pump volatile corrosive or flammable liquids which ...

Page 7: ...ss 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 shou...

Page 8: ...ecific 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 OUT...

Page 9: ...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 Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed Make certain that hoists chains slings or cables are in good working condi...

Page 10: ...t 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 ...

Page 11: ...w 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 ...

Page 12: ...ion 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 s...

Page 13: ...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...

Page 14: ...nded that a throttling valve and a system check valve be in stalled in the discharge line to protect the pump from excessive shock pressure and reverse rota tion when it is stopped If the application involves a high discharge head gradually close the discharge throttling valve before stopping the pump Bypass Lines Self priming pumps are not air compressors Dur ing the priming cycle air from the su...

Page 15: ...on 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 Except in certain specific applications to prevent flooding during service of an auto matic air release valve in a below ground lift station if a manual shut off valve is in stalled anywhere in a bypass line it must b...

Page 16: ...LEVEL 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 recommende...

Page 17: ...ns are tight and that the pump is securely mounted Check that the pump is properly lubri cated see LUBRICATION in MAINTENANCE AND REPAIR This pump is self priming but the pump should never be operated unless there is liquid in the pump casing Never operate this pump unless there is liquid in the pump casing The pump will not prime when dry Extended operation of a dry pump will destroy the seal ass...

Page 18: ... 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 ...

Page 19: ...n 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 NO...

Page 20: ... 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 NOTE One second delays in contact opening closing is a result of time sampling of the pressure signal to fil ter false signals that could cause nuisance trip ping of the contacts NOTE If the Hrn dLy is changed during the actual A out put delay cycle the...

Page 21: ...be left closed during operation A pump which has lost prime may continue to operate without reaching prime causing dan gerous overheating and possible explo sive rupture of the pump casing Per sonnel could be severely injured Lines With a Bypass If a Gorman Rupp Automatic Air Release Valve has been installed the valve will automatically open to allow the pump to prime and automatically close after...

Page 22: ...stitute which has not been specified or provided by the Gorman Rupp Company Strainer Check If a suction strainer has been shipped with the pump or installed by the user check the strainer regularly and clean it as necessary The strainer should also be checked if pump flow rate begins to drop If a vacuum suction gauge has been in stalled monitor and record the readings regularly to detect strainer ...

Page 23: ...ional 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...

Page 24: ...urs or if it has been pumping liquids con taining a large amount of solids drain the pump and flush it thoroughly with clean water To prevent large solids from clogging the drain port and pre venting the pump from completely draining insert a rod or stiff wire in the drain port and agitate the liquid during the draining process Clean out any remaining solids by flushing with a hose BEARING TEMPERA...

Page 25: ...so may result in serious personal injury 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 Add liquid to casing See PRIMING Clean or replace check valve Correct leak R...

Page 26: ...ischarge valve Dilute if possible Disassemble pump and check bearing s PUMP CLOGS FREQUENTLY Discharge flow too slow Suction check valve or foot valve clogged or binding Liquid solution too thick Open discharge valve fully to in crease flow rate and run engine at maximum governed speed Clean valve Dilute if possible EXCESSIVE NOISE Cavitation in pump Pumping entrained air Pump or drive not securel...

Page 27: ...ately 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 G...

Page 28: ...evel 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 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 per formance or part numbers Pump speed and operating condition ...

Page 29: ...ial 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 PART NAME PART NUMBER QTY 1 PUMP END ASSY 46186 469 1 2 POWER UNIT KIT 46143 032 1 3 BATTERY SEE OPTIONS REF 4 PUMP MOUNTING KIT 48157 002 1 NOT SHOWN WARNING DECAL 2613FE 1 G R DECAL GR 06 4 OPTIONAL 12V BATTERY 29331 527 1 WHEEL KIT GRP30 261 1 ...

Page 30: ...UPER T SERIES OM 05512 MAINTENANCE REPAIR PAGE E 3 ILLUSTRATION 32 6 7 10 1 3 2 15 14 9 11 8 16 27 12 13 25 30 24 29 26 4 5 28 23 31 4 5 6 5 6 25 22 21 19 18 17 20 FUEL TANK VENT Figure 2 Power Unit Kit ...

Page 31: ... 1 15 1 0 POS CABLE ASSEMBLY 47311 113 1 16 BATTERY BOX ASSY 42432 005 1 17 AIR VENT S1703 1 18 HOSE BARB FITTING 26523 447 1 19 CABLE TIE 27111 218 1 20 37 ID X 36 LG HOSE 18513 302 1 21 OIL DRAIN ASSEMBLY 46342 033 1 22 CONNECTOR S1447 1 23 FUEL TANK CAP 29332 111 1 24 HOSE BARB FITTING 26523 389 1 25 FUEL PICKUP 29332 145 2 26 HOSE ASSY 46341 796 1 27 SOCKET HEAD CAP SCREW BD 10 03S 15991 5 28 ...

Page 32: ...5512 MAINTENANCE REPAIR PAGE E 5 ILLUSTRATION 17 13 18 16 19 15 14 35 34 32 3 9 11 36 29 23 18 4 19 27 1 12 39 41 38 40 28 26 21 10 25 6 5 2 2 2 22 20 31 33 8 37 42 24 30 14 7 7 Figure 3 T4A60S SAE 4 10 Pump End Assembly ...

Page 33: ...ELIEF VLV 26662 005 1 DRIVE SCREW BM 0403 17000 4 WARNING PLATE 2613EV 13990 1 29 HANDLE 12354 13010 1 30 LOCK WASHER J06 15991 2 31 HEX HEAD CAP SCREW B0604 15991 2 32 BACK COVER NUT 31871 075 15000 2 33 HEX HEAD CAP SCREW B0804 1 2 15991 4 34 BACK COVER NUT 31871 073 15000 4 35 ADJUSTING SCREW 31871 070 1500G 4 36 LOCK COLLAR 38115 551 15001 4 37 HEX HEAD CAP SCREW B1008 15991 8 38 SUCTION FLANG...

Page 34: ...31 30 32 32 26 9 SEALAREA DETAIL Ç Ç Ç ÎÎÎÎÎÎ ÎÎÎÎÎÎ ÎÎÎÎÎÎ Î ÏÏÏÏ ÏÏÏÏ ÏÏÏÏ ÏÏÏÏ ÏÏÏÏ ÏÏÏÏ ÏÏ ÏÏ ÏÏ ÏÏ Î Î Î Î Ì Ì Ì ÇÇ ÇÇ ÇÇ ÇÇ Ç Ç ÇÇÇÇÇÇ ÇÇÇÇÇÇ ÇÇ ÇÇ Ç ÇÇ ÇÇ ÇÇ ÇÇ Ç Ç Ç Ç ÇÇ Ç ÇÇ Ç Ç Ç Î Î Î Î Ç Ç Ï Ï ÏÏ ÏÏ Ï Ï ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÌÌ ÌÌ ÌÌ ÌÌ ÌÌ ÌÌÌ ÌÌÌ ÌÌÌ Ç Î Ì ÌÌÌÌÌ ÌÌÌÌÌ ÌÌÌÌÌ ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ ÏÏÏ ÏÏÏ ÏÏÏ Ç Ç Figure 4 Repair Rotating Assembly ...

Page 35: ... 15079 1 13 PIPE PLUG P12 15079 1 14 SIGHT GAUGE S1471 2 15 PIPE PLUG P04 15079 2 16 CAPSCREW 375 x 1 375 21632 936 8 17 LOCK WASHER J06 15991 8 18 DRIVE FLANGE 38545 005 10000 1 19 INTERMEDIATE GUARD 42381 509 24152 2 20 GASKET 38683 275 18000 1 21 RETAINING RING S442 1 22 BALL BEARING S375 1 23 KEY N0608 15990 1 24 v IMPELLER SHAFT 38514 822 1706H 1 25 BALL BEARING S1088 1 26 PIPE PLUG PC20 1000...

Page 36: ...COUPLING KIT 48112 005 1 2 BUSHING 24131 496 1 3 COUPLING ASSEMBLY 24391 105 1 4 LOCKWASHER 21171 536 8 ALTERNATE PARTS 5 SOCKET HD CAPSCREW BD0606 1 2 15991 8 5 J SOCKET HD CAPSCREW 22644 220 8 6 HEX HD CAPSCREW B0605 15991 12 6 J HEX HD CAPSCREW 22645 164 12 7 LOCKWASHER J06 15991 12 7 J LOCKWASHER 21171 511 12 J METRIC APPLICATIONS SAE APPLICATIONS ...

Page 37: ...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 shut down the engine and take precautions to ensure that it will remain inoperative Close all valves in the suc tion and discharge lines For engine disassembly and repair c...

Page 38: ...s 34 and two diagonally opposing locking col lars 36 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 casing Inspect the wear plate and replace it if badly scored or worn To remove the wear plate disengage the hardware 24 and 25 Inspect the back cover O rings 18 and 19 and re place them if damaged or worn Suction...

Page 39: ...ll the drain plug With the pump end separated from the engine and the back cover 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 23 in the shaft keyway Install a lathe dog on the drive end of the shaft 24 with the V notch positioned over the shaft key With the impeller rotation still blocked see Figure 6 and u...

Page 40: ...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 7 and 8 and separate the seal plate 4 and gasket 5 from the bearing housing 9 Position the seal plate on a flat surface with the impeller side down Use a wooden dowel or other suitable tool to press on ...

Page 41: ...aring housing if the proper bearing fit is not achieved If bearing replacement is required remove the out board bearing retaining ring 21 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 ...

Page 42: ... than the bearing housing bore while the I D of the sleeve should be just larger than the O D of the lip seal area of the shaft With the lip seal sleeve in place lubricate the lip seal area of the shaft and slide the shaft and as sembled bearings into the bearing housing until the retaining ring on the outboard bearing seats against the bearing housing Remove the lip seal sleeve When installing th...

Page 43: ...it to the bearing housing with the hardware 7 and 8 Install the bearing housing O ring 29 and lubricate it with light grease To prevent damaging the shaft sleeve O ring not shown on the shaft threads cover the threads with electrical or duct tape Slide the O ring over the shaft until it seats against the shaft shoulder Re move the tape covering the threads Check to en sure that the shaft threads a...

Page 44: ... parts with extreme care to prevent damage Be careful not to contaminate precision finished faces even fingerprints on the faces can shorten seal life If necessary clean the faces with a non oil based solvent and a clean lint free tissue Wipe lightly in a concentric pattern to avoid scratching the faces Carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly Do not ...

Page 45: ...ecommended that the suction check valve and back cover assembly be reinstalled at this point The back cover assembly must be in place to adjust the impeller face clearance NOTE There is a 1 1 2 inch diameter socket head pipe plug not shown located in the side of the bearing housing This hole is required for manufacturing purposes only therefore the pipe plug should nev er require removal Install t...

Page 46: ...impeller when the shaft is turned by hand Tighten the back cover nuts evenly to avoid binding With the wear plate just touching the impeller turn the two free adjusting screws until they engage the pump casing Position the locking collars over the adjusting screws so the holes in the collars for the locking screws align approximately with the holes in the cover plate Loosen the back cover nuts use...

Page 47: ...e 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...

Page 48: ... approximately 58 ounces 1 7 liter of SAE No 30 non detergent oil to the middle of the sight gauge 14 and maintain it at the middle of the gauge Clean and reinstall the vented plug Maintain the oil at this level Bearings Figure 4 The bearing housing was fully lubricated when shipped from the factory Check the oil level regu larly through the sight gauge 14 and maintain it at the middle of the gaug...

Page 49: ...For Warranty Information Please Visit www grpumps com warranty or call U S 419 755 1280 Canada 519 631 2870 International 1 419 755 1352 GORMAN RUPP PUMPS ...

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