GORMAN-RUPP PUMPS SUPER T T6A60S-4LE2X FT4 Series Installation, Operation, And Maintenance Manual With Parts List Download

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OM-07207-01

September 6, 2018

GORMAN‐RUPP PUMPS

www.grpumps.com

2018 Gorman‐Rupp Pumps

Printed in U.S.A.

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

SUPER T SERIES

PUMP

MODEL

T6A60S‐4LE2X FT4

Summary of Contents for SUPER T T6A60S-4LE2X FT4 Series

Page 1: ...7207 01 September 6 2018 GORMAN RUPP PUMPS www grpumps com e2018 Gorman Rupp Pumps Printed in U S A INSTALLATION OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST SUPER T SERIESr PUMP MODEL T6A60S 4LE2X FT4 ...

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: ...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 OPERATION PAGE C 1 STARTING PAGE C 1 P...

Page 4: ...AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E 11 Back Cover And Wear Plate Removal PAGE E 12 Suction Check Valve Removal PAGE E 12 Separating Intermediate And Drive Assembly From Engine PAGE E 12 Loosening Impeller PAGE E 13 Rotating Assembly Removal PAGE E 13 Impeller Removal PAGE E 14 Seal Removal PAGE E 14 Shaft and Bearing Removal and Disassembly PAGE E 14 Shaft and Bearing Reassembly and Install...

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

Page 7: ...l 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 over...

Page 8: ...s 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 OUTLINE DRAWING 69 17 5 DIA 7 HOLES EACH SIDE 69 17 5 DIA 4 HOLES SUCTION 6 00 8 NPT DISCHARGE 6 00 8 NPT POWERED BY ISUZU 4LE2X DIESEL ENGINE 95 50 2425 7 104 00 2641 6 12 00 304 8 2 75 69 8 ...

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 Lifting 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 worki...

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: ...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 suction line must be vented to ...

Page 15: ...he 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 be a full opening ball type valve to pre vent plugging by solids A manual shut off valve ...

Page 16: ...lve 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...

Page 17: ...evel Lower the jack stands and chock the wheels if so equipped Make sure the pump is level Lower jack stands and chock the wheels if so equipped Use caution when positioning the skid mounted unit to prevent damage to the fuel tank 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 automa...

Page 18: ...ypass line or the bypass line may be left open A manual shut off valve should not be installed in any bypass line A manual shut off valve may inadvertently be left closed during operation A pump which has lost prime may continue to operate without reaching prime causing dan gerous overheating and possible explo sive rupture of the pump casing Per sonnel could be severely injured Lines With a Bypas...

Page 19: ...ff rapidly after stabilization an air leak exists Before checking for the source of the leak check the point of installa tion of the vacuum gauge 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 c...

Page 20: ...ODIC CHECKS Seal Cavity and Bearing Lubrication Both the seal and bearing cavities were fully lubri cated at the factory Check the lubrication levels before startup and regularly thereafter as indi cated in Section E Maintenance and Repair When lubrication is required use only SAE No 30 non detergent oil Bearing Temperature Check Bearings normally run at higher than ambient tem peratures because o...

Page 21: ... 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 comple...

Page 22: ...y during automatic operation Disconnect the positive battery cable before per forming any maintenance Failure to do so may result in serious personal injury Table 1 Trouble Shooting Chart TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP FAILS TO PRIME Not enough liquid in casing Suction check valve contaminated or damaged Air leak in suction line Lining of suction hose collapsed Leaking or worn seal or...

Page 23: ...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 PUMP REQUIRES TOO MUCH POWER Pump speed too high Discharge head too low Liquid solution too thick Bearing s frozen Check engine output Adjust discharge valve Dilute if possible Disassemble pump and check bearing s PUMP CLOGS ...

Page 24: ...l 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 probl...

Page 25: ...ar 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 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 sche...

Page 26: ...a 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 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 conditi...

Page 27: ...SUPER T SERIES OM 07207 MAINTENANCE REPAIR PAGE E 2 ILLUSTRATION PARTSPAGE 3 1 4 2 Figure 1 Pump Model T6A60S 4LE2X FT4 ...

Page 28: ...owed 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 ASSEMBLY 46186 050 1 2 POWER UNIT ISUZU 4LE2X FT4 46143 217 1 3 BATTERY 12V SEE OPTIONS REF 4 PUMP MOUNTING KIT 48157 003 1 NOT SHOWN G R DECAL 6 IN GR 06 4 OPTIONAL BATTERY 12V 29331 527 1 ...

Page 29: ...PER T SERIES OM 07207 MAINTENANCE REPAIR PAGE E 4 ILLUSTRATION PARTSPAGE 27 33 29 32 31 29 30 34 28 26 25 DETAIL A 1 2 6 7 8 9 11 10 5 4 3 21 22 24 23 16 17 18 20 19 12 13 15 14 A Figure 2 Power Unit Kit ...

Page 30: ...15 PIPE CAP V08 15079 1 16 BATTERY BOX ENCLOSURE 42432 013 1 17 1 0 POS CABLE ASSEMBLY 47311 113 1 18 1 0 NEG CABLE ASSEMBLY 47311 178 1 19 62 ID X 42 LG HOSE 18513 304 1 20 CABLE TIE 27111 227 2 21 37 ID X 30 LG HOSE 18513 302 1 22 CABLE TIE 27111 218 1 23 HOSE BARB FITTING 26523 447 1 24 AIR VENT S1703 1 25 37 ID X 28 LG HOSE 18513 302 1 26 HOSE BARB FITTING 26523 015 1 27 LOCKING FUEL CAP 29332...

Page 31: ...PER T SERIES OM 07207 MAINTENANCE REPAIR PAGE E 6 ILLUSTRATION 13 28 32 31 36 20 25 6 26 9 15 18 18 33 34 24 21 8 14 35 17 7 3 3 3 10 19 22 23 11 4 27 16 16 12 12 5 1 29 5 2 30 Figure 3 Pump End Assembly ...

Page 32: ... 12354 13010 1 22 HEX HEAD CAP SCREW B0804 1 2 15991 4 23 HEX HEAD CAP SCREW B0604 15991 2 24 LOCK COLLAR 38115 551 15001 4 25 ADJUSTING SCREW 31871 070 1500G 4 26 BACK COVER NUT 31871 073 15000 4 27 STUD C1213 15991 4 28 GASKET SUCT FLANGE 11402G 19370 1 29 HEX HEAD CAP SCREW B1211 15991 8 30 6 FLAP VALVE ASSY 46411 064 1 31 SUCTION FLANGE 11402 10010 1 32 CHECK VALVE PIN 11645 17010 1 33 SCREW C...

Page 33: ...07 MAINTENANCE REPAIR PAGE E 8 ILLUSTRATION 13 15 4 18 21 17 20 19 23 16 22 16 1 2 5 4 26 3 24 4 25 25 12 11 10 9 7 6 8 14 27 28 29 29 30 31 32 REPAIR ROTATING ASSEMBLY REF SEAL AREA DETAIL Figure 4 Repair Rotating Assembly ...

Page 34: ...3 BALL BEARING S616 1 14 O RING 25154 026 REF 15 IMPELLER SHAFT 38514 823 1706H 1 16 INTERMEDIATE GUARD 42381 509 24152 2 17 SHAFT KEY N0607 15990 1 18 BEARING CAP GASKET 38683 478 18000 1 19 BALL BEARING S1030 1 20 SNAP RING 24124 425 1 21 DRIVE FLANGE 38545 006 10000 1 22 HEX HEAD CAP SCREW GRADE 8 21632 938 8 23 LOCK WASHER J06 15991 8 24 SIGHT GAUGE S1471 2 25 PIPE PLUG P04 15079 2 26 ADJ SHIM...

Page 35: ...QTY 1 COUPLING KIT 48112 001 1 2 BUSHING 24131 345 1 3 COUPLING ASSEMBLY 44165 011 1 4 LOCKWASHER J06 15991 8 4 LOCKWASHER 21171 536 8 5 SOCKET HD CAPSCREW BD0606 1 2 15991 8 5 SOCKET HD CAPSCREW 22644 220 8 6 HEX HD CAPSCREW B0605 15991 12 6 HEX HD CAPSCREW 22645 164 12 7 LOCKWASHER J06 15991 12 7 LOCKWASHER 21171 511 12 USE FOR SAE APPLICATIONS USE FOR METRIC APPLICATIONS ...

Page 36: ... this manual cannot possibly antici pate and provide detailed instructions and precautions for every situation that might occur during maintenance of the unit Therefore it is the responsibility of the owner maintenance personnel to ensure that only safe established main tenance procedures are used and that any procedures not addressed in this manual are performed only after estab lishing that neit...

Page 37: ...or worn Suction Check Valve Removal Figure 3 If the check valve assembly 30 is to be serviced remove the check valve pin 32 reach through the back cover opening and pull the complete assem bly from the suction flange 31 NOTE Further disassembly of the check valve is not re quired since it must be replaced as a complete unit Individual parts are not sold separately Separating Intermediate And Drive...

Page 38: ... 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 NOTE Do not remove the impeller until the rotating assem bly has been removed from the pump casing Turn Counterclockwise Lathe ...

Page 39: ... 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 Shaft and bearing disassembly in the field is not recommended These operations should be performed only in a properly equipped s...

Page 40: ...e or emery cloth Replace the shaft if defective Position the inboard oil seal 4 in the bearing hous ing 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 To prevent damage during removal from the shaft it is recommended that bearings be cleaned and inspected in place It is strong...

Page 41: ... 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 4 into the drive flange 21 with the lip positioned as shown in Figure 4 Replace the flange gasket 18 and secure the flange to the bearing housing with the hardware 22 and 23 Be careful not to damage the oi...

Page 42: ...e enough to slide over the shaft Slide the tube over the shaft threads then slide the O ring off the tube and onto the shaft Remove the tube and continue to slide the O ring down the shaft until it seats against the shaft shoulder When installing a new cartridge seal assembly remove the seal from the container and remove the mylar storage tabs if so equipped from be tween the seal faces New cartri...

Page 43: ... seal is removed from the pump Wear patterns on the finished faces cannot be realigned during reassembly Reusing an old seal could result in prema ture failure Handle the seal parts with extreme care to prevent damage Be careful not to contaminate precision finished faces even fingerprints on the faces can shorten seal life If necessary clean the faces with a non oil based solvent and a clean lint...

Page 44: ...s been installed in the pump casing this clearance may be measured by reaching through the priming port with a feeler gauge 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 NOTE Th...

Page 45: ...ess the back cover into the pump casing until the wear plate just touches the impeller when the shaft is turned by hand Tighten the back cover nuts evenly to avoid binding With the wear plate just touching the impeller turn the two free adjusting screws until they engage the pump casing Position the locking collars over the adjusting screws so the holes in the collars for the locking screws align ...

Page 46: ... 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 47: ...ith approximately 64 ounces 1 9 liter of SAE No 30 non detergent oil to the middle of the sight gauge 24 and maintain it at the middle of the gauge Clean and reinstall the vented plug Maintain the oil at this level Bearings Figure 4 The bearing housing was fully lubricated when shipped from the factory Check the oil level regu larly through the sight gauge 24 and maintain it at the middle of the g...

Page 48: ...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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GORMAN-RUPP PUMPS SUPER T T6A60S-4LE2X FT4 Series, Installation, Operation, And Maintenance Manual With Parts List

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Summary of Contents for SUPER T T6A60S-4LE2X FT4 Series

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