GORMAN-RUPP PUMPS T SERIES Application guide

OM-07174-01

June 15, 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

ENVIRONMENTAL SILENT PUMP

MODEL

T6A60S-ZPP857-ESP

Gorman‐Rupp pump online at

www.grpumps.com

Valid serial number and e‐mail address required.

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

Please record your pump model and serial number in the

spaces provided below. Your Gorman‐Rupp distributor

needs this information when you require parts or service.

Pump Model:

Serial Number:

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 - 1............................................

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

SAFETY AND CONFORMANCE PAGE B - 2.............................................

POSITIONING PUMP PAGE B - 3.......................................................

Lifting PAGE B - 3.................................................................

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

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

NATURAL GAS FUEL PAGE B - 3......................................................

LPG FUEL PAGE B - 3................................................................

FUEL TANK (LPG ONLY) PAGE B - 4....................................................

REGULATORS (NATURAL GAS) PAGE B - 4.............................................

REGULATORS (LP GAS) PAGE B - 4...................................................

CONNECTING FUEL SUPPLY LINE TO THE UNIT PAGE B - 5.............................

CHANGING FUEL TYPE PAGE B - 5....................................................

SUCTION AND DISCHARGE PIPING PAGE B - 5.........................................

Materials PAGE B - 5..............................................................

Line Configuration PAGE B - 5......................................................

Connections to Pump PAGE B - 5..................................................

Gauges PAGE B - 5...............................................................

SUCTION LINES PAGE B - 6...........................................................

Fittings PAGE B - 6...............................................................

Strainers PAGE B - 6..............................................................

Sealing PAGE B - 6...............................................................

Suction Lines In Sumps PAGE B - 6.................................................

Suction Line Positioning PAGE B - 6................................................

SUBMERSIBLE TRANSDUCER PAGE B - 7..............................................

DISCHARGE LINES PAGE B - 8........................................................

Siphoning PAGE B - 8.............................................................

Valves PAGE B - 8................................................................

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

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

STARTING PAGE C - 1................................................................

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

OPTIONAL EPS CONTROL PAGE C - 2.................................................

Features PAGE C - 2..............................................................

Functional Description PAGE C - 2..................................................

EPS Functions PAGE C - 3.........................................................

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

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

Span Adjustment PAGE C - 4......................................................

Level Adjustment PAGE C - 4......................................................

TABLE OF CONTENTS

(continued)

Horn Delay PAGE C - 4............................................................

ROUTINE OPERATION PAGE C - 4.....................................................

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

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

OPERATION IN EXTREME HEAT PAGE C - 5............................................

OPERATIONAL CHECKS PAGE C - 5...................................................

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

Pump Vacuum Check PAGE C - 5..................................................

Liquid Temperature And Overheating PAGE C - 5.....................................

Strainer Check PAGE C - 6.........................................................

STOPPING PAGE C - 6................................................................

Manual Stopping PAGE C - 6.......................................................

Automatic Stopping PAGE C - 6....................................................

Safety Shutdown System PAGE C - 6...............................................

PERIODIC CHECKS PAGE C - 6.......................................................

Seal Cavity and Bearing Lubrication PAGE C - 6......................................

Bearing Temperature Check PAGE C - 6.............................................

Engine Fuel Filter PAGE C - 7......................................................

Engine Oil PAGE C - 7.............................................................

COLD WEATHER PRESERVATION PAGE C - 7...........................................

TROUBLESHOOTING - SECTION D PAGE D - 1..............................

PREVENTIVE MAINTENANCE PAGE D - 3...............................................

PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................

STANDARD PERFORMANCE CURVE PAGE E - 1........................................

PARTS LISTS:

Pump Model PAGE E - 3..........................................................

Pump Model (Cont'd) PAGE E - 5...................................................

Pump End Assembly PAGE E - 7...................................................

Repair Rotating Assembly PAGE E - 9...............................................

Coupling Kit PAGE E - 10...........................................................

PUMP 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 Coupling Kit 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 Installation PAGE E - 15............................

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

Impeller Installation and Adjustment PAGE E - 19......................................

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

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

Back Cover Installation And Adjustment PAGE E - 20..................................

Securing Pump and Coupling Kit to Engine PAGE E - 21...............................

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

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

TABLE OF CONTENTS

(continued)

iii

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

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

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

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

SUPER T SERIES OM-07174

PAGE I - 1INTRODUCTION

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.

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.

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

The Gorman‐Rupp Company:

The Gorman‐Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901-1217

Phone: (419) 755-1011

or:

Gorman‐Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631-2870

For information or technical assistance on the

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 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.

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.

SUPER T SERIES OM-07174

PAGE A - 1SAFETY

SAFETY ‐ SECTION A

This information applies to Super T Se

riesrengine 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. Shut down the engine, remove the

key and disconnect the positive

battery cable to ensure that the

pump will remain inoperative.

3. Allow the pump to completely cool

if overheated.

4. Check the temperature before

opening any covers, plates, or

plugs.

5. Close the suction and discharge

valves.

6. Vent the pump slowly and cau

tiously.

7. Drain the pump.

This pump is equipped with an automat

ic starting system, and is subject to au

tomatic restart. Keep hands and cloth

ing away from the unit to prevent injury

during automatic operation. Disconnect

the positive battery cable before per

forming any maintenance. Failure to do

so may result in serious personal injury.

This pump is designed to handle dirty

water containing specified entrained

solids. Do not attempt to pump volatile,

corrosive, or flammable liquids which

may damage the pump or endanger per

sonnel as a result of pump failure.

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 condition and of suffi

cient capacity and that they are posi

tioned so that loads will be balanced

and the pump or components will not be

damaged when lifting. Suction and dis

charge hoses and piping must be re

moved from the pump before lifting. Lift

the pump or component only as high as

necessary and keep personnel away

from suspended objects.

After the unit has been installed, make

certain that the pump and all piping or

hose connections are tight, properly

supported and secure before operation.

Do not operate the pump against a

closed discharge valve for long periods

SUPER T SERIESOM-07174

PAGE A - 2 SAFETY

of time. If operated against a closed dis

charge valve, pump components will

deteriorate, and the liquid could come

to a boil, build pressure, and cause the

pump casing to rupture or explode.

Do not remove plates, covers, gauges,

pipe plugs, or fittings from an over

heated pump. Vapor pressure within the

pump can cause parts being disen

gaged to be ejected with great force. Al

low the pump to cool before servicing.

Do not operate an internal combustion

engine in an explosive atmosphere.

When operating internal combustion

engines in an enclosed area, make cer

tain that exhaust fumes are piped to the

outside. These fumes contain carbon

monoxide, a deadly gas that is color

less, tasteless, and odorless.

Natural gas presents an extreme explo

sion and fire hazard. Follow all safety

precautions outlined by the National

Fire Protection Association when de

signing and installing the system. Make

certain that the regulators and fuel lines

are of the proper size and capacity for

the system, and that all fuel lines are se

curely connected and free of leaks.

Fuel used by internal combustion en

gines presents an extreme explosion

and fire hazard. Make certain that all

fuel lines are securely connected and

free of leaks.

Never tamper with the governor to gain

more power. The governor establishes

safe operating limits that should not be

exceeded. Refer to the performance

curve in Section E for the maximum con

tinuous operating speed for this pump.

Pumps and related equipment must be in

stalled and operated according to all na

tional, local and industry standards.

SUPER T SERIES OM-07174

PAGE B - 1INSTALLATION

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

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.

OUTLINE DRAWING

4.00/[101,6] X 10.00/[254,0]

FORK LIFT POCKET

2 PLACES

DISCHARGE:

6.00−8 NPT

.75/[19,0] DIA

6 HOLES

SUCTION:

6.00−8

NPT

50.26

[ 1276,5]

65.69

[ 1668,5]

1.00

[ 25,4 ]

46.00

[ 1168,4 ]

30.02

[ 762,4]

APPROX

48.00

[ 1219,2]

55.12

[ 1400,2] APPROX

112.58

[ 2859,7] APPROX

82.77

[ 2102,5]

APPROX

22.78

[ 578,7]

16.05

[ 407,7]

24.00

[ 609,6]

48.00

[ 1219,2]

37.42

[ 950,5]

74.84

[ 1900,9]

96.00

[ 2438,4]

36.35

[ 923,4]

10.59

[ 268,9] 24.00

[ 609,6]

DIMENSIONS:

INCHES

[MILLIMETERS]

Figure 1. Pump Model T6A60S-ZPP857-ESP

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

OM-07174 SUPER T SERIES

PAGE B - 2 INSTALLATION

ing, check for loose hardware at mating sur

faces.

c. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties

indicated.

d. Check levels and lubricate as necessary. Re

fer to LUBRICATION in the MAINTENANCE

AND REPAIR section of this manual and per

form duties as instructed.

e. If the pump and engine have been stored for

more than 12 months, some of the compo

nents or lubricants may have exceeded their

maximum shelf life. These must be inspected

or replaced to ensure maximum pump serv

ice.

If the maximum shelf life has been exceeded, or if

anything appears to be abnormal, contact your

Gorman‐Rupp distributor or the factory to deter

mine the repair or updating policy. Do not put the

pump into service until appropriate action has

been taken.

Battery Specifications And Installation

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.

Table 1. Battery Specifications

Crank

@ 0_F

Reserve

Capacity

(Minutes)

@ 80_F

Overall

Dims.

(Inches)

950 175

13L

Cold

Amps

Approx.

Amp/

Hr.

Rating

95 7W

9.5H

Voltage

12 Volts

Before installing the battery, clean the positive and

negative cable connectors, and the battery termi

nals. Secure the battery by tightening the

holddown brackets. The terminals and clamps

may be coated with petroleum jelly to retard corro

sion. Connect and tighten the positive cable first,

then the negative cable.

SAFETY AND CONFORMANCE

All aspects of the design and installation of the fuel

supply system must be evaluated in terms of safety

to personnel and equipment, and conformance to

all applicable codes.

Natural Gas and Liquefied Petroleum

Gas (LPG) presents an extreme explo

sion and fire hazard. Follow all safety

precautions outlined by the National

Fire Protection Association when de

signing and installing the system. Make

certain that the regulators and fuel lines

are of the proper size and capacity for

the system, and that all fuel lines are se

curely connected and free of leaks.

Before installing the system:

1. Check all state and local codes pertaining to

installations of stationary combustion engines

and fuel systems.

2. Consult the following National Fire Protection

Association pamphlet:

NFPA No. 37 - Stationary Combustion

Engines/Gas Turbines

NFPA No. 54 - National Fuel Gas Code Hand

book.

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