GORMAN-RUPP PUMPS T SERIES User manual

OM---03724---OE06
September 19, 2003
D
THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
www.gormanrupp.com
ECopyright by the Gorman-Rupp Company
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
T SERIES SILENT PUMP
MODEL
T6A3 --- F4L --- SPA

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

TABLE OF CONTENTS
i
INTRODUCTION PAGE I --- 1.................................................
RECORDING PUMP SERIAL NUMBER PAGE I --- 1.......................................
WARRANTY INFORMATION PAGE I --- 1.................................................
SAFETY SYMBOLS PAGE I --- 1........................................................
PUMP 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....................................
POSITIONING PUMP PAGE B --- 2.......................................................
Lifting PAGE B --- 2.................................................................
Positioning PAGE B --- 2............................................................
SUCTION AND DISCHARGE PIPING PAGE B --- 3.........................................
Materials PAGE B --- 3..............................................................
Line Configuration PAGE B --- 3......................................................
Connections to Pump PAGE B --- 3..................................................
SUCTION LINES PAGE B --- 3...........................................................
Fittings PAGE B --- 3...............................................................
Strainers PAGE B --- 3..............................................................
Sealing PAGE B --- 3...............................................................
Suction Lines In Sumps PAGE B --- 4.................................................
Suction Line Positioning PAGE B --- 4................................................
SUBMERSIBLE TRANSDUCER PAGE B --- 5..............................................
Installation PAGE B --- 5............................................................
Transducer Connections 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............................................
OPER ATION --- SECTION C PAGE C --- 1......................................
PRIMING PAGE C --- 1.................................................................
EPS CONTROL PAGE C --- 2............................................................
Features PAGE C --- 2..............................................................
Functional Description PAGE C --- 2..................................................
EPS Functions PAGE C --- 3.........................................................
EPS Calibration PAGE C --- 3........................................................
Zero Adjustment PAGE C --- 4.......................................................
Span Adjustment PAGE C --- 4......................................................
Level Adjustment PAGE C --- 4......................................................
STARTING PAGE C --- 4................................................................
Manual Starting PAGE C --- 4........................................................
Automatic Starting PAGE C --- 4.....................................................
OPERATION PAGE C --- 5..............................................................

TABLE OF CONTENTS
(continued)
ii
Lines With a Bypass PAGE C --- 5....................................................
Lines Without a Bypass PAGE C --- 5.................................................
Leakage PAGE C --- 5..............................................................
Liquid Temperature And Overheating PAGE C --- 5.....................................
Strainer Check PAGE C --- 5.........................................................
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 --- 6...............................................
OPERATIONINEXTREMEHEAT PAGEC---7............................................
BEARING TEMPERATURE CHECK PAGE C --- 7..........................................
Cold Weather Preservation PAGE C --- 7..............................................
TROUBLESHOOTING --- SECTION D PAGE D --- 1..............................
TROUBLESHOOTING CHART PAGE D --- 1...............................................
ELECTRICAL SYSTEM PAGE D --- 3.....................................................
Wiring Schematic PAGE D --- 3......................................................
PREVENTIVE MAINTENANCE PAGE D --- 3...............................................
PUMP MAINTENANCE AND REPAIR --- SECTION E PAGE E --- 1................
PERFORMANCE CURVE PAGE E --- 1...................................................
PARTS LISTS:
Pump Assembly PAGE E --- 3.......................................................
Pump Assembly PAGE E --- 4.......................................................
Pump Assembly PAGE E --- 5.......................................................
Pump Assembly PAGE E --- 6.......................................................
Pump Assembly PAGE E --- 7.......................................................
Muffler Enclosure Assembly PAGE E --- 8.............................................
Canopy Assembly PAGE E --- 10......................................................
Canopy Assembly PAGE E --- 11......................................................
Pump Subassembly PAGE E --- 13....................................................
Engine Modification Assembly PAGE E --- 15...........................................
Gauge Assembly PAGE E --- 17.......................................................
Gauge Assembly PAGE E --- 19.......................................................
Gauge Assembly PAGE E --- 21.......................................................
Control Panel Sub-Assembly PAGE E --- 23............................................
Pump End Assembly PAGE E --- 25...................................................
Repair Rotating Assembly PAGE E --- 27...............................................
Drive Assembly PAGE E --- 28........................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E --- 29.........................
Accessing Pump PAGE E --- 30.......................................................
Back Cover and Wear Plate Removal PAGE E --- 30.....................................
Suction Check Valve Removal PAGE E --- 30...........................................
Canopy Removal PAGE E --- 30.......................................................
Separating Pump End From Engine PAGE E --- 31......................................
Loosening Impeller PAGE E --- 31.....................................................
Rotating Assembly Removal PAGE E --- 32.............................................
Impeller Removal PAGE E --- 32......................................................
Seal Removal PAGE E --- 32..........................................................

TABLE OF CONTENTS
(continued)
iii
Shaft and Bearing Removal and Disassembly PAGE E --- 33.............................
Shaft and Bearing Reassembly and Installation PAGE E --- 33............................
Seal Installation PAGE E --- 34........................................................
Impeller Installation And Adjustment PAGE E --- 37......................................
Rotating Assembly Installation PAGE E --- 37...........................................
Securing Pump End to Engine PAGE E --- 38...........................................
Suction Check Valve Installation PAGE E --- 38.........................................
Back Cover Installation PAGE E --- 39.................................................
Canopy Installation PAGE E --- 39.....................................................
Final Pump Assembly PAGE E --- 39..................................................
PRESSURE RELIEF VALVE MAINTENANCE PAGE E --- 40..................................
LUBRICATION PAGE E --- 40.............................................................
Seal Assembly PAGE E --- 40.........................................................
Bearings PAGE E --- 40..............................................................
Engine PAGE E --- 40................................................................
TRAILER OPERATION, MAINTENANCE AND REPAIR --- SECTION F PAGE F --- 1.
TRAILER SPECIFICATIONS PAGE F --- 2.................................................
Trailer Dimensions PAGE F --- 2.....................................................
PRE-OPERATION INSPECTION PAGE F --- 3.............................................
OPERATION PAGE F --- 3..............................................................
Brake System PAGE F --- 3.........................................................
Hitching Trailer To Vehicle PAGE F --- 3...............................................
Towing PAGE F --- 4................................................................
Backing PAGE F --- 4...............................................................
Parking PAGE F --- 5...............................................................
PERIODIC SERVICE PAGE F --- 6.......................................................
Wheel Bolt Adjustment PAGE F --- 7.................................................
Tires PAGE F --- 7..................................................................
Brake Actuator Master Cylinder PAGE F --- 7..........................................
BRAKE SERVICE PAGE F --- 7..........................................................
Bleeding Brakes PAGE F --- 7.......................................................
Brake Adjustment PAGE F --- 7......................................................
WHEEL BEARING SERVICE PAGE F --- 8................................................
Inspection PAGE F --- 8.............................................................
Disassembly PAGE F --- 8..........................................................
Cleaning And Inspection PAGE F --- 8................................................
Repacking PAGE F --- 9............................................................
Reassembly PAGE F --- 9...........................................................
Adjustment PAGE F --- 9............................................................
ELECTRICAL SYSTEM PAGE F --- 9.....................................................
TRAILER COMPONENT PARTS LISTS PAGE F --- 10........................................
Original Equipment Manufacturers PAGE F --- 10.......................................

TSERIES OM--03724
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.
This manual is designed to help you achieve the
best performance and longest life from your Gor-
man-Rupp pump.
This pump is a T Series, semi-open impeller, self-
priming centrifugal model with a suction check
valve. It is designed for handling sewage contain-
ing large entrained solids andmild corrosives.The
basic material of construction for wetted parts is
gray iron, with ductile iron impeller and steel wear-
ing parts.
The pump is close-coupled to a Deutz F4L diesel
engine, and mounted on a 2-wheel trailer meeting
D.O.T. specifications. It is housed in a sound-resis-
tant enclosure that reduces the operating noise
levelbelow EPA 74DBA standard at 23feet (7 me-
ters).
Standard equipment includes HAND-OFF-AUTO
switch, suction vacuum and discharge pressure
gauges, tachometer, oil pressure and engine tem-
perature gauges, ammeter, elapsed running time
meter, fuel level indicator, and Electronic Pressure
Switch liquid level control with submersible trans-
ducer (see the separate literaturefor start/stopset
point adjustments, troubleshooting and repair of
the EPS switch). The unit is protected by an auto-
matic safety system that will shut down the engine
in the event of high temperature, low oil pressure,
engine overcrank or engine over-speed.
If there are any questions regarding the pump
applicationwhicharenotcoveredinthismanualor
other accompanying literature, contact your Gor-
man-Rupp distributor, or write:
The Gorman-Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901--1217
Phone: [phone]
or:
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: [phone]
RECORDING PUMP SERIAL NUMBER
Record the pump serial number in the following
spaces. Your Gorman-Rupp distributor needs
both the model and serial number of the unit
when you require parts or service.
Serial Number:
WARRANTY INFORMATION
The warranty provided with your pump is part of
Gorman-Rupp’s support program for customers
who operate and maintain their equipment as
describedinthisand theotheraccompanyingliter-
ature. Please note that should the equipment be
abused or modified to change its performance
beyond the original factory specifications, the
warranty will become void and any claim will be
denied.
SAFETY SYMBOLS
The following are used throughout this manual to
alert personnel to procedures which require spe-
cial attention, which could damage equipment, or
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.
HazardsorunsafepracticeswhichCOULD

TSERIES
OM--03724
PAGE I -- 2 INTRODUCTION
resultinminorpersonalinjuryorproductor
property damage. These instructions de-
scribe the requirements and the possible
damage which could result from failure to
follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.

TSERIES OM--03724
PAGE A -- 1SAFETY
PUMP SAFETY --- SECTION A
This information applies to T Series en-
gine driven pumps. Refer to the manual
accompanying the engine before at-
tempting 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.
Beforeattemptingtoopenorservicethe
pump:
1. Familiarize yourself with this man-
ual.
2. Set the HAND-OFF-AUTO switch to
‘OFF’, close and lock the control
panel cover, and disconnect the
positive battery cable to ensure
that the pump will remain inopera-
tive.
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 automatic
liquid level controls, and is subject to
automatic restart. Do not operate the
unit in the automatic mode with the side
doors open. Severe personal injury
could occur ifthe unit starts while main-
tenance orchecksarebeingperformed.
Before beginning any maintenance on
the unit, set the HAND-OFF-AUTO
switch to ‘OFF’, close and lock the con-
trol panel cover, and disconnect the
positive battery cable to ensure that the
pump will remain inoperative.
This pump is designed to handle sew-
age containing large entrained solids
andmildcorrosives.Donotattemptto
pump volatile, flammable, or highly cor-
rosive liquids which may damage the
pumporendangerpersonnelas aresult
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 lifting bail is in-
tended for use in lifting the pump and
trailer assembly only. Suction and dis-
charge hoses and piping must be re-
moved from the pump before lifting. Do
not suspend the pump by the lifting de-
vice for extended periods of time. Make
sure the area is clear of personnel when
lifting.
After the unit has been installed, make
certain that the pump and all piping or
hose connections are tight, properly
supportedandsecurebeforeoperation.
Do not operate the pump against a
closed discharge valve for long periods
oftime.Ifoperatedagainstacloseddis-

TSERIESOM--03724
PAGE A -- 2 SAFETY
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-
heatedpump. Vaporpressure within the
pump can cause parts being disen-
gaged to be ejected withgreat force. Al-
low the pump to cool before servicing.
Thispumpisdesignedtohandlemateri-
als which could cause illness through
direct exposure or emitted fumes. Wear
adequate protective clothing when
working on the pump or piping.
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, and clean up any fuel spills imme-
diately. 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 1800
RPM.
Read all instructions pertaining to the
function andoperationofthetrailer(see
Section F) before attempting to hitch or
move the unit. Failure to comply could
result in equipment damage or vehicle
accident.
The trailer is intended for hauling only
theGorman-Rupppumpforwhichitwas
designed. Do not haul additional equip-
ment which may damage the trailer or
overload the axle. Never haulpersonnel
on the trailer.
The maximum recommended towing
speedfortheunitis55mph(88kph)un-
der ideal conditions. Towing under un-
safe conditions or at higher speeds
couldcauselossofcontrolofthetowing
vehicle, resulting in injury or death to
personnel, and damage to the equip-
ment.
The approximate trailer tongue weight
is 280 lbs. (127 kg). Be sure the tow ve-
hicle hitch is rated for this capacity and
fitted with the proper sized ball.

TSERIES OM--03724
PAGE A -- 3SAFETY
Do not attempt to operate the pump un-
less the unit is level. Be sure the trailer
leveling stands are positioned on a sol-
id surface, and the wheels are chocked.
Pumps and related equipment must be in-
stalled and operated according to all na-
tional, local and industry standards.