Manual de V6A60-B

CDSOM-05817-01 September 30, 2005 Rev. J 08-18-10 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST ULTRA V PUMP MODEL V6A60-B INCLUDING: /WW THE GORMAN-RUPP COMPANY  MANSFIELD, OHIO www.grpumps.com GORMAN-RUPP OF CANADA LIMITED  ST. THOMAS, ONTARIO, CANADA 2005 The Gorman-Rupp Company Printed in U.S.A. Register your new 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 PREINSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POSITIONING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUCTION AND DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connections to Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUCTION LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction Lines In Sumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction Line Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCHARGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Siphoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUTOMATIC AIR RELEASE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Release Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupled Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE BELT TENSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Rules of Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION − SECTION C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lines With a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lines Without a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Temperature And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Strainer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Weather Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEARING TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i PAGE B − 1 PAGE B − 1 PAGE B − 1 PAGE B − 2 PAGE B − 2 PAGE B − 2 PAGE B − 2 PAGE B − 2 PAGE B − 2 PAGE B − 2 PAGE B − 2 PAGE B − 2 PAGE B − 2 PAGE B − 3 PAGE B − 3 PAGE B − 3 PAGE B − 4 PAGE B − 4 PAGE B − 4 PAGE B − 4 PAGE B − 5 PAGE B − 6 PAGE B − 6 PAGE B − 7 PAGE B − 7 PAGE B − 8 PAGE B − 8 PAGE C − 1 PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE C−1 C−1 C−1 C−2 C−2 C−2 C−2 C−2 C−3 C−3 C−3 C−3 C−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . Final Pump Assembly . . . . . . . . . . . . . . . . . . . . Seal Assembly . . . . . . . . . . . . . . . . . . . . . . LUBRICATION . . . . . . . . . . . . . . . . . . . Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TABLE OF CONTENTS (continued) TROUBLESHOOTING − SECTION D . . PUMP MAINTENANCE AND REPAIR − SECTION E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearings . Shaft and Bearing Removal and Disassembly . . . . . . . . . . . . . . . . . . . PARTS LISTS: Pump Model . . . . . . . . . . PRESSURE RELIEF VALVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP AND SEAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft and Bearing Reassembly and Installation . . . . . . . . . . . . . Back Cover And Wear Plate Removal . . . . . . . . . . . . . . . . Repair Rotating Assemblies . . . . . . . . . . . . . . . . ii PAGE D − 1 PAGE D − 3 PAGE E − 1 PAGE E − 1 PAGE E − 3 PAGE E − 5 PAGE E − 6 PAGE E − 6 PAGE E − 6 PAGE E − 7 PAGE E − 8 PAGE E − 8 PAGE E − 8 PAGE E − 9 PAGE E − 10 PAGE E − 13 PAGE E − 13 PAGE E − 13 PAGE E − 14 PAGE E − 14 PAGE E − 15 PAGE E − 15 PAGE E − 15 PAGE E − 15 PAGE E − 15 . Rotating Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotating Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction Check Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seal Installation . . . . . . . . . . . Impeller Installation And Adjustment . . . . . . . . . Back Cover Installation And Adjustment . . . . . . . . . . . . . . Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERFORMANCE CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and to those which could be dangerous to personnel: Immediate hazards which WILL result in severe personal injury or death. and that any procedures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such practices. Box 1217 Mansfield. These instructions describe the requirements and the possible damage which could result from failure to follow the procedure. self-priming centrifugal model with a suction check valve. and to those which could be dangerous to personnel. Read this manual carefully to learn how to safely install and operate your pump. this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit. For information or technical assistance on the power source. PAGE I − 1 . to those which could damage equipment. Hazards or unsafe practices which COULD result in severe personal injury or death. The pump is designed for handling liquids containing large entrained solids and slurries. This manual will alert personnel to known procedures which require special attention. Thomas.O. with ductile iron impeller and steel wearing parts. However. established maintenance procedures are used. The following are used to alert maintenance personnel to procedures which require special attention. If there are any questions regarding the pump or its application which are not covered in this manual or in other literature accompanying this unit. and maintenance or which clarify a procedure. Ontario N5P 3R7 Phone: (519) 631−2870 INTRODUCTION Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. Ohio 44901−1217 Phone: (419) 755−1011 or: Gorman-Rupp of Canada Limited 70 Burwell Road St. to those which could damage equipment. operation. or: The Gorman-Rupp Company P. contact the power source manufacturer’s local dealer or representative. it is the responsibility of the owner/maintenance personnel to ensure that only safe. These instructions describe the procedure required and the injury which could result from failure to follow the procedure. Failure to do so could result in personal injury or damage to the pump. NOTE Instructions to aid in installation. please contact your Gorman-Rupp distributor. These instructions describe the procedure required and the injury which will result from failure to follow the procedure. The basic material of construction is cast iron. Therefore. This pump is an Ultra V Series. semi-open impeller.ULTRA V SERIES OM−05817 INTRODUCTION Thank You for purchasing a Gorman-Rupp pump. 2. Allow the pump to completely cool if overheated. 4. plates. Close the suction and discharge valves. Because pump installations are seldom identical. build pressure. After the pump has been positioned. causing severe injury to personnel. or tools. or plugs. make certain that the pump and all piping connections are tight. pump components will deteriorate. this manual cannot possibly provide detailed instructions and precautions for each specific application. Drain the pump. and cause the pump casing to rupture or explode. and the liquid could come to a boil. Do not operate the pump without the guards in place over the rotating parts. Therefore. Do not attempt to pump volatile. 3. Do not operate the pump against a closed discharge valve for long periods of time. Check the temperature before opening any covers. it is the owner/installer’s responsibility to ensure that applications not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity are compromised by the installation. Disconnect or lock out the power source to ensure that the pump will remain inoperative. This pump is designed to handle liquids SAFETY containing large entrained solids or slurries. Refer to the manual accompanying the power source before attempting to begin operation. or flammable materials which may damage the pump or endanger personnel as a result of pump failure. 7. 6. Vapor pressure within the pump can cause parts being disengaged to be ejected with great force. Before attempting to open or service the pump: 1. Allow the pump to completely cool before servicing. gauges. pipe plugs. or fittings from an overheated pump. Vent the pump slowly and cautiously. PAGE A − 1 . corrosive. Gorman-Rupp has no control over or particular knowledge of the power source which will be used. Exposed rotating parts can catch clothing. properly supported and secure before operation. Familiarize yourself with this manual.ULTRA V SERIES OM−05817 SAFETY − SECTION A This information applies to Ultra V Series pumps. covers. fingers. 5. Do not remove plates. If operated against a closed discharge valve. OM−05817 Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or damage to equipment. Vapor pressure within the pump casing can eject these parts with great force when they are disengaged. PAGE A − 2 SAFETY . local and industry standards. Pumps and related equipment must be installed and operated according to all national. Suction and discharge hoses and piping must be removed from the pump before lifting. Allow the pump to completely cool before servicing it. ULTRA V SERIES Do not attempt to disengage any part of an overheated pump unit. Refer to ROTATION in OPERATION. INSTALLATION The pump assembly can be seriously damaged if the cables or chains used to lift and move the unit are improperly wrapped around the pump. d. Section C. Only operate this pump in the direction indicated by the arrow on the pump body and on the accompanying decal. be sure to limit the incoming pressure to 50% of the maximum permissible operating pressure as shown on the pump performance curve. dents. Check levels and lubricate as necessary. some of the components or lubricants may have exceeded their maximum shelf life. contact your Gorman-Rupp distributor or the Gorman-Rupp Company. Drain the pump and remove all customer-installed equipment such as suction and discharge hoses or piping before attempting to lift existing. some of the information such as mounting. check for loose hardware at mating surfaces. Note the direction of rotation indicated on the pump. or if anything appears to be abnormal. PREINSTALLATION INSPECTION The pump assembly was inspected and tested before shipment from the factory. PAGE B − 1 . c. POSITIONING PUMP Lifting Pump unit weights will vary depending on the mounting and drive provided. For further assistance. Check the shipping tag on the unit packaging for the actual weight. Check as follows: a. inspect the pump for damage which may have occurred during shipment. e. Since pump installations are seldom identical. and arrange the pump and piping. damaged threads. Since the pressure supplied to the pump is critical to performance and safety. Do not put the pump into service until appropriate action has been taken. contact your Gorman-Rupp distributor or the factory to determine the repair or updating policy. b. line configuration. position. 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. Before installation. and priming must be tailored to the specific application. Inspect the pump for cracks. installed units. Refer to LUBRICATION in the MAINTENANCE AND REPAIR section of this manual and perform duties as instructed. and perform all duties indicated. Carefully read all warnings and cautions contained in this manual or affixed to the pump.ULTRA V SERIES OM−05817 INSTALLATION − SECTION B Review all SAFETY information in Section A. These must be inspected or replaced to ensure maximum pump service. this section offers only general recommendations and practices required to inspect. Check for and tighten loose attaching hardware. If the maximum shelf life has been exceeded. Since gaskets tend to shrink after drying. If installed in a flooded suction application where the liquid is supplied to the pump under pressure. If the pump has been stored for more than 12 months. Check that the pump shaft rotates counterclockwise when facing the impeller. and other obvious damage. Pump Dimensions Consult the pump Specification Data Sheet or the factory for the approximate physical dimensions of your pump. and use lifting equipment with appropriate capacity. SUCTION LINES To avoid air pockets which could affect pump priming. the line must always slope upward to the pump from the source of the liquid being pumped. the suction line must be as short and direct as possible. reinforced type to prevent collapse under suction. however. Fittings Suction lines should be the same size as the pump inlet. and increased shaft and seal wear. if the line slopes down to the pump at any point along the suction run. any spherical solids which pass through a INSTALLATION . If hose-type lines are used. but if a valve is used. they should have adequate support to secure them when filled with liquid and under pressure. and should be installed with the flat part of the reducers uppermost to avoid creating air pockets. they should be the eccentric type. which substantially increase friction loss. Level mounting is essential for proper operation. A minimum clearance of 14 inches (355. If these gauges are desired for pumps that are not tapped. Before tightening a connecting flange. Installation closer to the pump may result in erratic readings. If reducers are used in suction lines. install it with the stem horizontal to avoid air pockets. SUCTION AND DISCHARGE PIPING Pump performance is adversely effected by increased suction lift. If hose is used in suction lines. align it exactly with the pump port. Make minimum use of elbows and fittings. Materials Either pipe or hose maybe used for suction and discharge lines. decreased bearing life. the materials must be compatible with the liquid being pumped. Clearance It is recommended that 24 inches (609. Never pull a pipe line into place by tightening the flange bolts and/or couplings. Strainers If a strainer is furnished with the pump. Line Configuration Keep suction and discharge lines as straight as possible to minimize friction losses.6 mm) of clearance be provided in front of the back cover to permit removal of the cover and easy access to the pump interior. discharge elevation. Gauges Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges. be certain to use it. drill and tap the suction and discharge lines not less than 18 inches (457. PAGE B − 2 Lines near the pump must be independently supported to avoid strain on the pump which could cause excessive vibration. use the long-radius type to minimize friction loss.2 mm) from the suction and discharge ports and install the lines. The pump may have to be supported or shimmed to provide for level operation or to eliminate vibration. If elbows are necessary. When operation involves a suction lift. See the performance curve and operating range shown on Page E-1 to be sure your overall application allows pump to operate within the safe operation range. Valves are not normally used in suction lines. air pockets will be created. it must be the rigid-wall.OM−05817 ULTRA V SERIES Mounting Connections to Pump Locate the pump in an accessible place as close as practical to the liquid being pumped. Using piping couplings in suction lines is not recommended.2 mm) must be maintained to permit removal of the cover. and friction losses. the flow should be kept away from the suc- INSTALLATION OM−05817 tion inlet because the inflow will carry air down into the sump. If two suction lines are installed in a single sump. Suction Lines In Sumps If a single suction line is installed in a sump. If it is necessary to position inflow close to the suction inlet. the flow paths may interact.ULTRA V SERIES strainer furnished with the pump will also pass through the pump itself. and capacity. If there is a liquid flow from an open pipe into the sump. all connections in the suction line should be sealed with pipe dope to ensure an airtight seal. Sealing Since even a slight leak will affect priming. The baffle will allow entrained air to escape from the liquid before it is drawn into the suction inlet. The larger opening size will reduce the inlet velocity. 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. To avoid this. The pipe dope should be compatible with the liquid being pumped. and air entering the suction line will reduce pump efficiency. Follow the sealant manufacturer’s recommendations when selecting and applying the pipe dope. reducing the efficiency of one or both pumps. it should be positioned away from the wall of the sump at a distance equal to 1 1/2 times the diameter of the suction line. and that the openings will not permit passage of solids larger than the solids handling capability of the pump. Suction Line Positioning The depth of submergence of the suction line is critical to efficient pump operation. If a strainer is not furnished with the pump. install a baffle between the inflow and the suction inlet at a distance 1 1/2 times the diameter of the suction pipe. Calculate the required submergence using the following formula based on the increased opening size (area or diameter).2 mm) diameter spherical solids. This pump is designed to handle up to 3 inch (76. PAGE B − 3 . Figure 1 shows recommended minimum submergence vs. but is installed by the pump user. velocity. especially when operating with a high suction lift. head. position the suction inlets so that they are separated by a distance equal to at least 3 times the diameter of the suction pipe. NOTE The pipe submergence required may be reduced by installing a standard pipe increaser fitting at the end of the suction line. If a throttling valve is desired in the discharge line. If the discharge line is open. this air will be vented through the discharge. INSTALLATION . a siphoning action causing damage to the pump could result. Velocity DISCHARGE LINES Siphoning Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a siphon breaker is used in the line. air from the suction line must be vented to atmosphere on the discharge side. however. the discharge side of the pump must be opened to atmospheric pressure through a bypass line installed between the pump discharge and the check valve. Bypass Lines Self-priming pumps are not air compressors.OM−05817 ULTRA V SERIES Figure 1. During the priming cycle. use a valve as large as the largest pipe to minimize friction losses. if a check valve has been installed in the discharge line. PAGE B − 4 With high discharge heads. Never install a throttling valve in a suction line. Otherwise. Valves If the application involves a high discharge head. However. NOTE The bypass line should be sized so that it does not affect pump discharge capacity. the bypass line should be at least 1 inch in diameter to minimize the chance of plugging. Recommended Minimum Suction Line Submergence vs. it is recommended that a throttling valve and a system check valve be installed in the discharge line to protect the pump from excessive shock pressure and reverse rotation when it is stopped. A self-priming centrifugal pump will not prime if there is sufficient static liquid head to hold the discharge check valve closed. the discharge throttling valve should close gradually before the pump is stopped. and located 6 inches below the water level or cut-off point of the low level pump. INSTALLATION OM−05817 If a manual shut-off valve is installed in a bypass line. A closed manual shutoff valve may cause a pump which has lost prime to continue to operate without reaching prime. If the installation involves a flooded suction such as a below-ground lift station. Gorman-Rupp Automatic Air Release Valves are reliable. See AUTOMATIC AIR RELEASE VALVE in this section for information about Gorman-Rupp Automatic Air Release Valves. smooth-bore hose. or fittings from an over-heated pump. A bypass line that is returned to a wet well must be secured against being drawn into the pump suction inlet. and to eliminate the possibility of flooding.8 to 19 liters] per minute) will occur when the valve is fully closed. Consult the manual accompanying the Air Release Valve for additional information on valve installation and performance. an excessive amount of liquid may be bypassed and forced back to the wet well under the full working pressure of the pump. It is also recommended that pipe unions be installed at each 90 elbow in a bypass line to ease disassembly and maintenance. Use caution when removing the plug to prevent injury to personnel from hot liquid. or other substances likely to cause clogging. air and liquid vented during the priming process will then agitate the hose and break up any solids. If a manual shut-off valve is installed anywhere in the air release piping. grease. and require minimum maintenance.D. gauges. Allow an over-heated pump to completely cool before servicing. Liquid within the pump can reach boiling temperatures. it is recommended that the bypass line be run back to the wet well. Be sure the bypass line is directed back to the wet well or tank to prevent hazardous spills. covers. AUTOMATIC AIR RELEASE VALVE When properly installed. it must not be left closed during operation. drain the liquid from the pump by removing the casing drain plug. Therefore. a Gorman-Rupp Automatic Air Release Valve will permit air to escape through the bypass line and then close automatically when the pump is fully primed and pumping at full capacity. it must be a full-opening ball type valve to prevent plugging by solids. this bypass line may be terminated with a six-to-eight foot length of 1−1/4 inch I. In some installations. this will reduce overall pumping efficiency. and vapor pressure within the pump can cause parts being disengaged to be ejected with great force. Some leakage (1 to 5 gallons [3. In high discharge head applications (more than 30 feet). causing dangerous overheating and possible explosive rupture of the pump casing. Do not remove plates. PAGE B − 5 .ULTRA V SERIES In low discharge head applications (less than 30 feet or 9 meters). or contact the Gorman-Rupp Company for selection of an Automatic Air Release Valve to fit your application. a pipe union and manual shut-off valve may be installed in the bleed line to allow service of the valve without shutting down the station. Personnel could be severely injured. Consult your Gorman-Rupp distributor. After the pump completely cools. it is recommended that a Gorman-Rupp Automatic Air Release Valve be installed in the bypass line. It is imperative that alignment be checked after the pump and piping are installed.4 MM) BELOW LIQUID LEVEL SURFACE PUMP DISCHARGE SELF-PRIMING CENTRIFUGAL PUMP SUCTION LINE WET WELL OR SUMP Figure 2. depending on which Air Release Valve is being used. Typical Automatic Air Release Valve Installation Connect the valve outlet to a bleed line which slopes back to the wet well or sump. Contact your Gorman-Rupp distributor or the Gorman-Rupp Company for information about installation of an Automatic Air Release Valve for your specific application. In either a flexible coupling or belt-driven system. the driver and pump must be mounted so that their shafts are aligned with and parallel to each other. NOTE Check Rotation.4 MM) DIA. Section C. INSTALLATION . If piping is used for the bleed line. MIN. (CUSTOMER FURNISHED) EXTEND 6" (152. it is recommended that each Air Release Valve be fitted with an independent bleeder line directed back to the wet well. and before operation. NOTE For multiple pump installations. before final alignment of the pump. 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. avoid the use of elbows whenever possible. PAGE B − 6 ALIGNMENT The alignment of the pump and its power source is critical for trouble-free mechanical operation. The bleed line must be the same size as the outlet opening or larger. do not direct bleeder lines to a common manifold pipe. The inlet opening in the Air Release Valve is equipped with standard 1-inch NPT pipe threads. If multiple Air Release Valves are installed in a system.OM−05817 ULTRA V SERIES Air Release Valve Installation The Automatic Air Release Valve must be independently mounted in a horizontal position be- tween the pump discharge port and the inlet side of the discharge check valve (see Figure 2). Before checking alignment. Aligning Non-Spider Type Couplings Align non-spider type couplings by using a feeler gauge or taper gauge between the coupling halves every 90. Adjusting the alignment in one direction may alter the alignment in another direction. Aligning Spider-Type Couplings INSTALLATION MISALIGNED: SHAFTS NOT IN LINE ALIGNED: SHAFTS PARALLEL AND SHEAVES IN LINE Figure 5. Drive Belts When using drive belts. driver and pump are aligned before shipment. Pumps must be checked and realigned before operation. The pump casing feet and/or pedestal feet. and side. Refer to the coupling manufacturer’s service literature. Use a straightedge along the sides of the pulleys to ensure that the pulleys are properly aligned (see Figure 5).ULTRA V SERIES OM−05817 When mounted at the Gorman-Rupp factory. In drive systems using two or more belts. When the straightedge rests evenly on both halves of the coupling. Align spider insert type couplings by using calipers to measure the dimensions on the circumference of the outer ends of the coupling hub every 90. Figure 4. unmatched sets will cause accelerated belt wear. check each procedure after altering alignment. the power source and the pump must be parallel. bottom. If the coupling is misaligned. use a feeler gauge between the coupling and the straightedge to measure the amount of misalignment. disconnect the power source to ensure that the pump will remain inoperative. and the driver mounting bolts should also be tightly secured. Alignment of V-Belt Driven Pumps PAGE B − 7 . MISALIGNED: SHAFTS NOT PARALLEL Figure 3. When checking alignment. tighten the foundation bolts. Check parallel adjustment by laying a straightedge across both coupling rims at the top. The coupling is in alignment when the hubs are the same distance apart at all points (see Figure 4). Most couplings require a specific gap or clearance between the driving and the driven shafts. Coupled Drives When using couplings. the coupling is in horizontal parallel alignment. the axis of the power source must be aligned to the axis of the pump shaft in both the horizontal and vertical planes. Misalignment will occur in transit and handling. make certain that the belts are a matched set. The coupling is in alignment when the hub ends are the same distance apart at all points (see Figure 3). oil and other foreign material which may cause slippage. grease. 20 and 50 hours of operation and re-tension as required. Always keep belts free from dirt. Over-tensioning will shorten both drive belt and bearing life. fingers. Under-tensioning will cause belt slippage. Thereafter.OM−05817 Tighten the belts in accordance with the belt manufacturer’s instructions. Ideal drive belt tension is the lowest tension at which the belt will not slip under peak load conditions. exposed rotating parts can catch clothing. overspeeding the pump may damage both pump and power source. check and re-tension if required monthly or at 500 hour intervals. If the belts are too loose. Do not over-tension drive belts. they will slip. if the belts are too tight. INSTALLATION . check the tension after 5. PAGE B − 8 ULTRA V SERIES DRIVE BELT TENSIONING General Rules of Tensioning For new drive belts. or tools. there will be excessive power loss and possible bearing failure. whichever comes first. causing severe injury to personnel. Select pulleys that will match the proper speed ratio. Do not operate the pump without the guard in place over the rotating parts. Pump speed and operating conditions must be within the performance range shown on page E-1. The pump could be damaged and performance adversely affected by incorrect rotation. Make sure that the piping connections are tight. Otherwise. This pump is self-priming. Replace the fill cover or fill plug before operating the pump. OPERATION Consult the operations manual furnished with the power source. The liquid in the pump casing has evaporated. Operate the motor independently while observing the direction of the motor shaft. remove the pump casing fill cover or fill plug in the top of the casing. check the direction of power source rotation before further troubleshooting. The pump is being put into service for the first time. To fill the pump. or cooling fan. remove drive belts. Do not attempt to pump volatile. Never operate this pump unless there is liquid in the pump casing. PAGE C − 1 . and add clean liquid until the casing is filled. 3. Follow the instructions on all tags. but the pump should never be operated unless there is liquid in the pump casing. If pump performance is not within the specified limits (see the curve on pages E-1). Check that the pump is properly lubricated (see LUBRICATION in MAINTENANCE AND REPAIR). reinstall and tighten the fill plug. The pump will not prime when dry. the pump will prime and reprime as necessary. Add liquid to the pump casing when: 1. If an electric motor is used to drive the pump. corrosive. This pump is designed to handle liquids containing large entrained solids and slurries.OM−05817 ULTRA V SERIES OPERATION − SECTION C Review all SAFETY information in Section A. After filling the pump casing. PRIMING STARTING Install the pump and piping as described in INSTALLATION. 2. and that the pump is securely mounted. extended operation of a dry pump will destroy the seal assembly. Do not attempt to operate the pump unless all connecting piping is securely installed. or otherwise disconnect the pump from the motor before checking motor rotation. Rotation The correct direction of pump rotation is counterclockwise when facing the impeller. The pump has not been used for a considerable length of time. labels and decals attached to the pump. or flammable liquids which may damage the pump or endanger personnel as a result of pump failure. Once the pump casing has been filled. couplings. liquid in the pump forced out under pressure could cause injury to personnel. If a Gorman-Rupp Automatic Air Release Valve has been installed. covers. Liquid Temperature And Overheating If the bypass line is open. Priming is indicated by a positive reading on the discharge pressure gauge or by a quieter operation. build pressure. gaskets. Approach any overOPERATION . partially close the discharge line throttling valve in order to fill the line slowly and guard against excessive shock pressure which could damage pipe ends. When the discharge line is completely filled. Do not operate the pump against a closed discharge throttling valve for long periods of time. or at pump connections or fittings. If overheating does occur. drain the liquid from the pump by removing the casing drain plug. Do not apply it at a higher operating temperature. Open all valves in the discharge line and start the power source. Lines Without a Bypass The maximum liquid temperature for this pump is 160F (71C). and automatically close after priming is complete (see INSTALLATION for Air Release Valve operation). gauges. The pump may not prime immediately because the suction line must first fill with liquid. stop the pump and allow it to cool before servicing it. If overheating occurs. After the pump completely cools. Liquid will then continue to circulate through the bypass line while the pump is in operation. After the pump has been primed. Operating against closed valves could bring the liquid to a boil. If operated against a closed discharge throttling valve. adjust the throttling valve to the required flow rate. sprinkler heads. If rotation is incorrect on a single-phase motor. Liquid within the pump can reach boiling temperatures. Do not remove plates. build pressure. As a safeguard against rupture or explosion due to heat. Refill the pump casing with cool liquid. If the pump fails to prime within five minutes. have a qualified electrician interchange any two of the three phase wires to change direction. and cause the pump casing to rupture or explode. and the liquid could come to a boil. ULTRA V SERIES pump components will deteriorate. PAGE C − 2 Allow an over-heated pump to completely cool before servicing. or fittings from an over-heated pump. and cause the pump to rupture or explode. Leakage OPERATION Lines With a Bypass No leakage should be visible at pump mating surfaces.OM−05817 If rotation is incorrect on a three-phase motor. and any other fixtures connected to the line. Use caution when removing the plug to prevent injury to personnel from hot liquid. Overheating can occur if operated with the valves in the suction or discharge lines closed. the valve will automatically open to allow the pump to prime. stop the pump immediately and allow it to cool before servicing it. Keep all line connections and fittings tight to maintain maximum pump efficiency. and vapor pressure within the pump can cause parts being disengaged to be ejected with great force. air from the suction line will be discharged through the bypass line back to the wet well during the priming cycle. consult the literature supplied with the motor for specific instructions. stop it and check the suction line for leaks. this pump is equipped with a pressure relief valve which will open if vapor pressure within the pump casing reaches a critical point. This could result in personal injury or damage to the equipment. Block the suction line and start the pump. Shut off the pump.OM−05817 ULTRA V SERIES heated pump cautiously. check the point of installation of the vacuum gauge. an air leak exists. and the liquid could come to a boil. Do not operate the pump against a closed discharge throttling valve for long periods of time. and agitate the liquid during the draining process. At operating speed the pump should pull a vacuum of 20 inches (508. Temperatures up to 160F (71C) are considered normal for bearings. Never replace this valve with a substitute 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 for air leaks in the seal. and clean it as necessary. Also. clean out any solids by flushing with a hose. BEARING TEMPERATURE CHECK Bearings normally run at higher than ambient temperatures because of heat generated by friction. check the strainer regularly. If the pump will be idle for more than a few hours. liquid pressure must be limited to 50% of the maximum permissible operating pressure shown on the pump performance curve. The strainer should also be checked if pump flow rate begins to drop. and flush it thoroughly with clean water. and should then stabilize. drain the pump. and cause the pump casing to rupture or explode. and they can operate safely to at least 180F (82C). Close all connecting valves slowly. pump components will deteriorate. PAGE C − 3 . Before checking for the source of the leak. gasket. or if it has been pumping liquids containing a large amount of solids. gradually close the discharge throttling valve before stopping the pump. If the application involves a high discharge head. using pipe dope on the threads. Open the suction line. If operated against a closed discharge throttling valve. Clean out any remaining solids by flushing with a hose. After stopping the pump. drain the pump to prevent damage from freezing. and read the vacuum gauge with the pump primed and at operation speed. STOPPING Never halt the flow of liquid suddenly. If the vacuum reading falls off rapidly after stabilization. Cold Weather Preservation Pump Vacuum Check With the pump inoperative. or discharge valve. or any time the pump casing overheats and activates the valve. monitor and record the readings regularly to detect strainer blockage. lock out or disconnect the power source to ensure that the pump will remain inoperative. install a vacuum gauge in the system. build pressure. insert a rod or stiff wire in the drain port. To prevent large solids from clogging the drain port and preventing the pump from completely draining. It is recommended that the pressure relief valve assembly be replaced at each overhaul.0 mm) or more of mercury. If the liquid being pumped is stopped abruptly. If it does not. If a vacuum suction gauge has been installed. damaging OPERATION In below freezing conditions. If backflushing is absolutely necessary. this will remove any remaining liquid that could freeze the pump rotating parts. shock waves can be transmitted to the pump and piping system. Never introduce air or steam pressure into the pump casing or piping to remove a blockage. The vacuum gauge reading will immediately drop proportionate to static suction lift. Operate the pump for approximately one minute. Continued operation should bring the temperatures down to normal levels. rect level (see LUBRICATION in MAINTENANCE AND REPAIR). Make certain that the bearing lubricant is of the proper viscosity and at the cor- When pumps are first started. Bearing overheating can also be caused by shaft misalignment and/or excessive vibration. the bearings may seem to run at temperatures above normal. PAGE C − 4 OPERATION . Bearing temperatures can be measured accurately by placing a contact-type thermometer against the housing. Record this temperature for future reference.OM−05817 ULTRA V SERIES Checking bearing temperatures by hand is inaccurate. A sudden increase in bearing temperature is a warning that the bearings are at the point of failing to operate properly. Leaking or worn seal or pump gasket. Replace leaking or worn seal or gasket. Correct leak.ULTRA V SERIES OM−05817 TROUBLESHOOTING − SECTION D Review all SAFETY information in Section A. Lining of suction hose collapsed. plates. 5. Familiarize yourself with this manual. Replace leaking or worn seal or gasket. Check pump vacuum. 7. 6. Correct leak. Air leak in suction line. Replace suction hose. Add liquid to casing. See INSTALLATION. Check pump vacuum. Vent the pump slowly and cautiously. Clean or replace check valve. Lining of suction hose collapsed. Air leak in suction line. Allow the pump to completely cool if overheated. Check piping installation and install bypass line if needed. See PRIMING. Close the suction and discharge valves. Strainer clogged. 3. PAGE D − 1 . Check the temperature before opening any covers. Suction check valve contaminated or damaged. or plugs. 4. TROUBLE PUMP FAILS TO PRIME PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE TROUBLESHOOTING POSSIBLE CAUSE PROBABLE REMEDY Not enough liquid in casing. Lock out or disconnect the power source to ensure that the pump will remain inoperative. Leaking or worn seal or pump gasket. Replace suction hose. Drain the pump. Check strainer and clean if necessary. 2. Before attempting to open or service the pump: 1. Suction lift or discharge head too high. check that sheaves or couplings are correctly sized. Adjust discharge valve.OM−05817 ULTRA V SERIES TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE Strainer clogged. Check driver output. Install bypass line. Secure mounting hardware. Open discharge valve fully to increase flow rate. Discharge flow too slow. Locate and eliminate source of air bubble. Clean valve. Suction lift too high. and run power source at maximum governed speed. Pump speed too slow. Clean out debris. Suction check valve or foot valve clogged or binding. Discharge head too low. Check that impeller is properly centered and rotates freely. Check strainer and clean if necessary. Impeller clogged. replace damaged parts. Pump speed too high. Dilute if possible. Pumping entrained air. Dilute if possible. Reduce lift and/or friction losses in suction line. Suction intake not submerged at proper level or sump too small. Reduce suction lift and/or friction losses in suction line. Liquid solution too thick. Disassemble pump and check bearing(s). Replace worn or damaged parts. Pump or drive not securely mounted. Measure lift w/vacuum gauge. Free impeller of debris. check belts or couplings for slippage. Cavitation in pump. PUMP REQUIRES TOO MUCH POWER PUMP CLOGS FREQUENTLY EXCESSIVE NOISE PAGE D − 2 TROUBLESHOOTING . Impeller clogged or damaged. Liquid solution too thick. Impeller or other wearing parts worn or damaged. Check installation and correct submergence as needed. Bearing(s) frozen. Check driver output. Record vacuum and pressure gauge readings and consult local representative or factory. Discharge head too high. Leaks. Critical applications should be inspected more frequently. Repair or Replace as Necessary C = Clean R = Replace * Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually. reducing unscheduled down time. this section is intended only to provide general recommendations and practices for preventive maintenance. Flow) Bearing Lubrication Seal Lubrication (And Packing Adjustment. Also. The appearance of wearing parts should also be documented at each inspection for comparison as well. Record keeping is an essential component of a good preventive maintenance program. Unusual Noises or Vibrations. Adjust schedule as required for lower or higher duty cycles or extreme operating conditions. Clean. Preventive Maintenance Schedule Service Interval* Item General Condition (Temperature.ULTRA V SERIES OM−05817 PREVENTIVE MAINTENANCE Routine preventive maintenance of the pump will maintain peak operating performance. the part can be checked and replaced before failure occurs. Cracks. if records indicate that a certain part (such as the seal) fails at approximately the same duty cycle. and pump wear is directly affected by such things as the abrasive qualities. For new applications. Adjust. Changes in suction and discharge gauge readings (if so equipped) between regularly scheduled inspections can indicate problems that can be corrected before system damage or catastrophic failure occurs. Since pump applications are seldom identical. Speed. Regardless of the application however. a first inspection of wearing parts at 250 hours will give insight into the wear rate for your particular application. TROUBLESHOOTING PAGE D − 3 . following a routine preventive maintenance schedule will help assure troublefree performance and long life from your GormanRupp pump. Loose Hardware.Annually Annually I I I R I R I I C I I I C I I I I I Legend: I = Inspect.) Pump Performance (Gauges. pressure and temperature of the liquid being pumped. Subsequent inspections should be performed at the intervals shown on the chart below. Etc. If So Equipped) V-Belts (If So Equipped) Air Release Valve Plunger Rod (If So Equipped) Front Impeller Clearance (Wear Plate) Rear Impeller Clearance (Seal Plate) Check Valve Pressure Relief Valve (If So Equipped) Pump and Driver Alignment Shaft Deflection Bearings Bearing Housing Piping Driver Lubrication − See Mfgr’s Literature Daily Weekly Monthly Semi. specific gravity.OM−05817 ULTRA V SERIES PUMP MAINTENANCE AND REPAIR − SECTION E MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE. MAINTENANCE & REPAIR Contact the Gorman-Rupp Company to verify performance or part numbers. your performance may be different due to such factors as viscosity. elevation. If your pump serial number is followed by an N". your pump is NOT a standard production model. Since pump installations are seldom identical. PAGE E − 1 . and impeller trim. temperature. Including /WW Based on 70F (21C) clear water at sea level with minimum suction lift. Pump speed and operating condition points must be within the continuous performance range shown on the curves. STANDARD PERFORMANCE FOR PUMP MODEL V6A60-B. OM−05817 ULTRA V SERIES PARTS PAGE SECTION DRAWING Figure 1. Pump Model V6A60−B (Including /WW) PAGE E − 2 MAINTENANCE & REPAIR . your pump is NOT a standard production model. ITEM PART NAME NO. PART NUMBER MAT’L CODE 1 2 PUMP CASING 38224−612 10000 REPAIR ROTATING ASSY 44163−453 −−− /WW REP ROTATING ASSY 44163−454 −−− 3 DRIVE SCREW BM#04−03 17000 4 NAME PLATE 38818−149 13000 5 STUD C1213 15991 6 PIPE PLUG P20 10009 7 WEAR PLATE ASSY 46451−759 24150 8 O-RING 25152−453 −−− 9 LOCK WASHER J06 15991 10 HEX NUT D06 15991 11 LOCK COLLAR 38115−551 23030 12 COVER PLATE ASSY 42111−832 −−− −WARNING PLATE 2613EV 13990 −DRIVE SCREW BM#04−03 17000 −PRESS RELIEF VALVE 26662−007 −−− −WARNING DECAL 38816−302 −−− 13 LOCK WASHER J08 15991 14 ADJUSTING SCREW 31871−070 1500G 15 HEX HD CAPSCREW B0804 15991 16 BACK COVER NUT 31871−073 15000 17 HEX HD CAPSCREW B0605 15991 18 HANDLE 12354 13010 O-RING S1676 −−− 19 20 FLAT HD CAPSCREW F0604 17000 21 PIPE PLUG P04 15079 22 NPT SUCT FLG/VLV SEAT 38641−533 10000 GASKET 38683−659 19370 23 24 FLAP VALVE ASSY 46411−154 24010 25 FLAP VALVE COVER 38346−620 17040 26 HEX HD CAPSCREW B0604 15991 27 SQUARE HD BOLT A1014 15991 28 FILL PORT COVER ASSY 42111−437 −−− −FILL PORT GASKET 50G 19210 −WARNING PLATE 38816−097 13990 −DRIVE SCREW BM#04−03 17000 29 HEX HD CAPSCREW B1010S 15991 30 CLAMP BAR 38111−004 11010 31 HEX HD CAPSCREW B0806 15991 32 SPACER 33221−022 17040 33 O-RING 25152−381 −−− 34 PIPE PLUG P08 15079 NOT SHOWN: SUCTION SPOOL PARTS (/WW MODEL ONLY) −SPOOL FLANGE 12799 10010 −FLANGE GASKET 25113−038 18000 −FLANGE PIPE PLUG P20 10009 −FLANGE PIPE PLUG P04 10009 −FLG CAPSCREW B1216 15991 QTY 1 1 1 4 1 4 1 1 1 12 4 4 1 1 4 1 1 8 4 4 4 2 1 2 2 2 1 1 1 1 6 2 1 1 1 2 1 1 4 4 1 2 1 1 1 1 8 ITEM PART NAME NO. PART NUMBER MAT’L CODE −FLG LOCK WASHER J12 SUCTION STICKER 6588AG ROTATION DECAL 2613M LUBRICATION DECAL 38817−084 ULTRA V" DECAL 38816−342 WARNING DECAL 2613FE DISCHARGE STICKER 6588BJ G-R DECAL GR−03 PRIMING STICKER 6588AH INSTRUCTION TAG 38817−023 INSTRUCTION TAG 38817−011 OPTIONAL: DISASSEMBLY TOOL 48711−020 FLAP VALVES:  −FLUOROCARBON 46411−155 −BUNA-N 46411−156 −EPDM 46411−157 FLANGE KITS: 8" X 6" NPT SUCTION/DISCHARGE FLANGE KIT 48213−118 −8" NPT SUCTION FLANGE KIT 48213−154 −6" NPT DISCHARGE FLANGE KIT 48213−155 8" X 6" ASA SUCTION/DISCHARGE SPOOL KIT 48213−151 −8" ASA SUCTION SPOOL KIT 48213−150 −6" ASA DISCHARGE SPOOL KIT 48213−116 8" X 6" METRIC SUCTION/DISCHARGE SPOOL KIT 48213−117 −8" METRIC SUCTION SPOOL KIT 48213−152 −6" METRIC DISCHARGE SPOOL KIT 48213−153 G-R HARD IRON PARTS: −WEAR PLATE ASSY 46451−759 SST PARTS: −WEAR PLATE ASSY 46451−759 HI TEMP SHUT−DOWN KITS: −145F 48313−186 −130F 48313−256 −120F 48313−257 HIGH TEMP SHUT-DOWN THERMOSTAT KIT 145F 48313−172 AIR RELEASE VALVES: −10# COMP SPRING GRP33−07A −25# COMP SPRING GRP33−07 −80# COMP SPRING GRP33−07B QTY 15991 −−− −−− −−− −−− −−− −−− −−− −−− −−− −−− 8 1 1 1 1 1 1 1 1 1 1 −−− 1 24010 24010 24010 1 1 1 −−− 1 −−− 1 −−− 1 −−− 1 −−− 1 −−− 1 −−− 1 −−− 1 −−− 1 24160 1 24170 1 −−− −−− −−− 1 1 1 −−− 1 −−− −−− −−− 1 1 1 INDICATES PARTS RECOMMENDED FOR STOCK  DUPONT VITON OR EQUIVALENT MAINTENANCE & REPAIR PAGE E − 3 . Contact the Gorman-Rupp Company to verify part numbers.OM−05817 ULTRA V SERIES PARTS LIST Pump Model V6A60−B (Including /WW) (From S/N 1321070 Up) If your pump serial number is followed by an N". OM−05817 ULTRA V SERIES SECTION DRAWING Figure 2. Repair Rotating Assemblies PAGE E − 4 MAINTENANCE & REPAIR . 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 31 32 33 34 35 36 NOT SHOWN: PART NAME PART NUMBER MAT’L CODE QTY IMPELLER IMP ADJ SHIM SET CARTRIDGE SEAL ASSY SEAL PLATE GASKET OIL SEAL LOCK WASHER HEX HD CAPSCREW BEARING HOUSING SOC HD PIPE PLUG VENTED PIPE PLUG RED PIPE BUSING AIR VENT PIPE PLUG SIGHT GAUGE PIPE PLUG HEX HD CAPSCREW LOCK WASHER OIL SEAL BEARING CAP GASKET RETAINING RING THRUST WASHER BALL BEARING SHAFT KEY IMPELLER SHAFT BALL BEARING O-RING IMPELLER CAPSCREW IMPELLER WASHER DRIVE SCREW S/N PLATE O-RING O-RING SPACER SHIPPING PLUG 38615−102 48261−057 46513−155 38272−262 38687−059 25227−771 J08 B0806 38251−521 PC20 4823A AP0802 S1530 P12 S1471 P04 B0606 J06 S1907 38322−230 38683−474 S720 31133−268 23422−414 N0812 38514−826 23422−019 25154−131 DM1004S 31514−015 BM#04−03 2613GG 25152−381 S1676 33221−022 11495B 11010 −−− −−− 10000 20000 −−− 15991 15991 10000 10009 15079 15079 −−− 15079 −−− 15079 15991 15991 −−− 10000 18000 −−− 15000 −−− 15990 16000 −−− −−− 15991 17000 17000 13990 −−− −−− 17040 15079 1 1 1 1 1 2 4 4 1 1 1 1 1 2 2 2 6 6 1 1 1 1 1 1 1 1 1 REF 1 1 2 1 1 1 4 2 INSTRUCTION TAG ROTATION DECAL 6588U 2613M −−− −−− 1 1 38615−102 38272−262 1102H 1102H 1 1 38615−102 38272−262 38514−826 DM1004S 46513−158 17070 17070 1706H 17090 −−− 1 1 1 1 1 OPTIONAL: G-R HARD IRON PARTS: −IMPELLER −SEAL PLATE SST PARTS: −IMPELLER −SEAL PLATE −IMPELLER SHAFT −IMP CAPSCREW −CART SEAL ASSY INDICATES PARTS RECOMMENDED FOR STOCK MAINTENANCE & REPAIR PAGE E − 5 . Rotating Assemblies for /WW models also include all standard parts listed below. ITEM NO.OM−05817 ULTRA V SERIES PARTS LIST Repair Rotating Assemblies Note: Order the complete Repair Rotating Assembly from the Pump Model Assembly Parts List on page E−3. Back Cover And Wear Plate Removal (Figure 1) The wear plate (7) is easily accessible and may be serviced by removing the back cover assembly (12). Check the temperature before opening any covers. 4. PAGE E − 6 Before attempting to open or service the pump: 1. 7. it is the responsibility of the owner/maintenance personnel to ensure that only safe. Familiarize yourself with this manual. or plugs. However. this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit. This manual will alert personnel to known procedures which require special attention. Follow the instructions on all tags. Clean and reinstall the drain plug. Before attempting to service the pump. Pull the check valve assembly from the slot in the pump casing (1). The following instructions assume complete disassembly is required. and that any procedures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such practices. Allow the pump to completely cool if overheated. Therefore. Many service functions may be performed by draining the pump and removing the back cover assembly.OM−05817 ULTRA V SERIES PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Review all SAFETY information in Section A. plates. 5. This pump requires little service due to its rugged. established maintenance procedures are used. Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or damage to equipment. and to those which could be dangerous to personnel. remove the pump casing drain plug (6) and drain the pump. to those which could damage equipment. Remove the back cover nuts (16) and pry the back cover and assembled wear plate from the pump casing (1). minimum-maintenance design. Close the suction and discharge valves. Before attempting to service the pump. 3. 6. Close all valves in the suction and discharge lines. 2. disconnect or lock out the power source and take precautions to ensure that it will remain inoperative. disengage the hardware (9 and 26) and remove the check valve cover (25). Vent the pump slowly and cautiously. NOTE An alternate method of removing the back cover MAINTENANCE & REPAIR . if it becomes necessary to inspect or replace the wearing parts. follow these instructions which are keyed to the sectional views (see Figures 1 and 2) and the accompanying parts lists. consult the literature supplied with the power source. Suction Check Valve Removal (Figure 1) If the check valve assembly (24) is to be serviced. However. For power source disassembly and repair. Disconnect or lock out the power source to ensure that the pump will remain inoperative. or contact your local power source representative. the piping and/or power source must be disconnected. label and decals attached to the pump. Drain the pump. If major repair is required. Remove the impeller capscrew and washer (29 and 30).ULTRA V SERIES OM−05817 from the pump casing is to remove the back cover nuts (16) and two diagonally opposing locking collars (11). Immobilize the impeller by wedging a block wood between the vanes and the pump casing. and screw the handles into PAGE E − 7 . Install a lathe dog on the drive end of the shaft (26) with the V" notch positioned over the shaft key. key and wood block. The impeller (1) should be loosened while the rotating assembly is still secured to the pump casing. Rotating Assembly Tool NOTE Do not remove the impeller until the rotating assembly has been removed from the pump casing. Inspect the back cover O-rings (8 and 19) and replace it if damaged or worn. (Figure 1) Disengage the hardware (13 and 31) securing the rotating assembly to the pump casing and remove the spacers (32). All threads are 1/2-inch NPT. MAINTENANCE & REPAIR To install the tool. 6 IN. Install two 1/2−16 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. Do not pre-assemble the tool. With the impeller rotation still blocked. (356 MM) LONG Figure 4. and replace it if badly scored or worn. Use caution not to damage the shaft or keyway. (152 MM) LONG APPROX. Turn Counterclockwise Lathe Dog Arm Inspect the wear plate. remove the lathe dog. When the impeller breaks loose. Before loosening the impeller. the power source must be removed to provide clearance. To remove the wear plate. Figure 2) from the bearing housing. Install the tee. NOTE An optional disassembly tool is available from the factory. Clean and reinstall the seal cavity drain plug. Loosening Impeller (Figure 2) The rotating assembly may be serviced without disconnecting the suction or discharge piping. remove the seal cavity drain plug and drain the seal lubricant. A similar tool may be assembled using 1/2-inch pipe (schedule 80 steel or malleable iron) and a standard tee (see Figure 4). Separate the rotating assembly by pulling straight away from the pump casing. follow the instructions packed with it. disengage the hardware (9 and 10). see Figure 3 and use a long piece of heavy bar stock to pry against the arm of the lathe dog in a counterclockwise direction (when facing the drive end of the shaft). V" Notch Heavy Bar Stock Shaft Key Impeller Shaft Lathe Dog Setscrew Rotating Assembly Removal Figure 3. however. and screw the longest length of pipe into the vent hole until fully engaged. If the tool is used. This will prevent the oil in the seal cavity from escaping when the impeller is loosened. 14 IN. remove the vented plug (11. TEE APPROX. install the shaft key (25). If removed. Use caution when unscrewing the impeller. 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). the bearing housing should not require disPAGE E − 8 Most cleaning solvents are toxic and flammable. Remove the bearing housing drain plug and drain the lubricant. Seal Removal Pry or press the oil seals (6) from the bearing housing. After removing the shaft and bearings. Remove the impeller adjusting shims (2). (Figure 2) Slide the shaft sleeve and rotating portion of the seal off the shaft as a unit. refer to Seal Installation. Use caution when lifting the rotating assembly to avoid injury to personnel or damage to the assembly. Inspect the parts for wear or damage and replace as necessary. Read and follow all precautions printed on solvent containers. ULTRA V SERIES assembly. If no further disassembly is required. sparks. shaft and all component parts (except the bearings) with a soft cloth soaked in cleaning solvent. Use them only in a well ventilated area free from excessive heat. Disengage the hardware (17 and 18) and slide the bearing cap (20) and oil seal (19) off the shaft. MAINTENANCE & REPAIR . or measure and record their thickness for ease of reassembly. Clean and reinstall the drain plug. Shaft and bearing disassembly in the field is not recommended.OM−05817 the tee. To prevent damage during removal from the shaft. unscrew the impeller from the shaft. tie and tag the shims. Impeller Removal (Figure 2) With the rotating assembly removed from the pump casing. O-rings. Remove the shaft sleeve O-ring (28). Use a wooden dowel or other suitable tool to press on the back side of the stationary seat until the seat. It is strongly recommended that the bearings be replaced any time the shaft and bearings are removed. and stationary element can be removed. Clean the bearing housing. Use a pair of stiff wires with hooked ends to remove the stationary element and seat. it is recommended that bearings be cleaned and inspected in place. Remove the bearing cap gasket (21) and press the oil seal from the bearing cap. Position the seal plate on a flat surface with the impeller side down. Shaft and Bearing Removal and Disassembly (Figure 2) When the pump is properly operated and maintained. These operations should be performed only in a properlyequipped shop by qualified personnel. Place a block of wood against the impeller end of the shaft (26) and tap the shaft and assembled bearings (24 and 27) from the bearing housing. tension on the shaft seal spring will be released as the impeller is removed. Remove the O-rings (19 and 33). Inspect the impeller and replace if cracked or badly worn. clean and inspect the bearings in place as follows. Disassemble the shaft and bearings only when there is evidence of wear or damage. and flame. Heat the bearings to a uniform temperature no higher than 250F (120C). Do not spin dry bearings. shaft and all component parts (except the bearings) with a soft cloth soaked in cleaning solvent. If movement has occurred. or bearing housing if the proper bearing fit is not achieved. Inspect the shaft for distortion. MAINTENANCE & REPAIR OM−05817 Position the inboard oil seal (6) in the bearing housing bore with the lip positioned as shown in Figure 2. or for thread damage on the impeller end. replace the bearings. to prevent the bearings from cooling and sticking on the shaft. and flame. Failure to do so will greatly shorten bearing life. The bearing tolerances provide a tight press fit onto the shaft and a snug slip fit into the bearing housing. To prevent damage during removal from the shaft. use a suitably sized sleeve. If rotation is rough or the bearing balls are discolored. This may scratch the balls or races and cause premature bearing failure. it is recommended that bearings be cleaned and inspected in place. sparks. remove the outboard bearing retaining ring (22) and thrust washer (23). If bearing replacement is required. This should be done quickly. and slide the bearings onto the shaft. The bearings may be heated to ease installation.D. and an arbor (or hydraulic) press to install the bearings on the shaft. It is strongly recommended that the bearings be replaced any time the shaft and bearings are removed. Detail B. both the oil and the container must be absolutely clean. in one continuous motion. Replace the shaft if defective. it must be thoroughly filtered. NOTE The inboard bearing (27) comes from the manufacturer with a retaining ring installed on the bearing O. This retaining ring must be removed prior to installation. Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat. check to ensure that they have not moved away from the shaft shoulders in shrinking. Dry the bearings with filtered compressed air and coat with light oil. Dress small nicks and burrs with a fine file or emery cloth. Read and follow all precautions printed on solvent containers. shaft. Use a bearing puller to remove the bearings from the shaft. Press the oil seal into the housing until the face is just flush with the counterbored surface toward the inside of the housing. nicks or scratches. Inspect the parts for wear or damage as necessary. electric oven.ULTRA V SERIES Clean the bearings thoroughly in fresh cleaning solvent. If the oil has been previously used. Bearings should never be heated with a direct flame or directly on a hot plate. An induction heater. Rotate the bearings by hand to check for roughness or binding and inspect the bearing balls. If heating the bearings is not practical. NOTE If a hot oil bath is used to heat the bearings. hot oil bath. Bearings must be kept free of all dirt and foreign material. or hot plate may be used to heat the bearings. Replace the bearings. use a suitably sized sleeve and a press to reposition the bearings against the shaft shoulders. one at a time. PAGE E − 9 . After the bearings have been installed and allowed to cool. Shaft and Bearing Reassembly and Installation (Figure 2) Clean the bearing housing. until they are fully seated. It is recommended that a sleeve be positioned against the inboard oil seal (6) to prevent the lip of the oil seal from rolling as the shaft and bearing are installed in the bearing housing. of the sleeve should be just smaller than the bearing housing bore. Press the oil seal into the housing until the face is just flush with the machined surface on the housing. and flame. Detail B. sparks. remove it from the container and inspect the precision finished faces to ensure that they are free of any foreign matter. and remove any that exist. balls. push against the outer race. Lubricate the bearing housing as indicated in LUBRICATION. of the sleeve should be just larger than the O. When installing the shaft and bearings into the bearing bore. Inspect the stationary seat bore in the seal plate for dirt. scoring. and slide the shaft and assembled bearings into the bearing housing until the retaiining ring on the outboard bearing seats against the bearing housing. Press only on the inner race. while the I. MAINTENANCE & REPAIR . This could result in premature failure. Reusing an old seal could result in premature failure. Be careful not to damage the oil seal lip on the shaft keyway. replace the complete seal. never mix old and new seal parts. carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly. To ease installation of the seal. lubricate the lip seal area of the shaft. The seal is not normally reused because wear patterns on the finished faces cannot be realigned during reassembly. shaft sleeve O-ring and the external stationary seat O-ring with a very small amount of light lubricating oil. If a replacement seal is being used. Most cleaning solvents are toxic and flammable. and other damage that might cause leakage. grooves. nicks and burrs. Replace the bearing cap gasket (21) and secure the bearing cap with the hardware (17 and 18). of the lip seal area of the shaft. If necessary to reuse an old seal in an emergency. or ball cage. Read and follow all precautions printed on solvent containers. If any components are worn.OM−05817 ULTRA V SERIES Seal Installation (V and VS Models) (Figures 2 and 4) When installing the bearings onto the shaft. Install the thrust washer (23) and secure the outboard bearing (24) to the shaft with the snap ring (22). The O. Use them only in a well ventilated area free from excessive heat. See Figure 4 for seal part identification. Inspect the seal components for wear. Detail C. Press the oil seal (19) into the bearing cap (20) with the lip positioned as shown in Figure 2.D.D. Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent.D. Remove the lip seal sleeve. Wear patterns on the finished faces cannot be realigned during reassembly. Position the outboard oil seal (6) in the bearing housing bore with the lip positioned as shown in Figure 2. With the lip seal sleeve in place. PAGE E − 10 A new seal assembly should be installed any time the old seal is removed from the pump. Never hit the balls or ball cage. never press or hit against the outer race. The stationary seat bore must be completely clean before installing the seal. lubricate the shaft sleeve. is a little larger than the O. install the seal plate gasket (5). remove the seal from the container. Install the full set of impeller shims (2) provided with the seal. If the seal plate was removed. and continue to slide the O-ring down the shaft until it seats against the shaft shoulder. from between the seal faces. of the shaft.D. Slide the tube over the shaft threads. Lubricate the external stationary seat O-ring with light oil. PAGE E − 11 . and remove the mylar storage tabs. These storage tabs must be removed before installing the seal.D. Remove the tube. This seal is not designed for operation at temperatures above 160F (71C). Clean and inspect the impeller as described in Impeller Installation and Adjustment. Position the seal plate over the shaft and secure it to the bearing housing with the hardware (7 and 8). then slide the O-ring off the tube and onto the shaft. Slide the seal assembly onto the shaft until the external stationary seat O-ring engages the bore in the seal plate. and screw the impeller onto the shaft until it is seated against the seal (see Figure 5). stretch the O-ring over a piece of plastic tubing that the I. MAINTENANCE & REPAIR Some cartridge seal assemblies are equipped with mylar storage tabs between the seal faces. if so equipped. Cartridge Seal Assembly When installing a new cartridge seal assembly.ULTRA V SERIES OM−05817 RETAINER SEAL PLATE SPRING O-RINGS IMPELLER SEAL SLEEVE O-RING BELLOWS IMPELLER SHAFT ROTATING ELEMENT STATIONARY ELEMENT INTEGRAL SHAFT SLEEVE IMPELLER SHIMS STATIONARY SEAT DRIVE BAND Figure 4. To prevent damaging the shaft sleeve O-ring (27) on the shaft threads. Do not use at higher operating temperatures. NOTE A firm resistance will be felt as the impeller presses the stationary seat into the seal plate bore. and the shaft sleeve will break the nylon shear ring. and attempting to separate them could damage the bellows. This will press the stationary seat into the seal plate bore. carefully separate the rotating and stationary seal faces from the bellows retainer and stationary seat. A push tube made from a piece of plastic pipe would aid this installation. If any components are worn. scoring. Press this stationary subassembly into the seal plate bore until it seats squarely against the bore shoulder. shims. of the pipe should be slightly larger than the O. STATIONARY SEAT FULLY SEATED IN SEAL PLATE BORE SHEAR RING (SHEARED) Figure 6. lint-free tissue. Wipe lightly in a concentric pattern to avoid scratching the faces. Handle the seal parts with extreme care to prevent damage. If necessary. Be careful not to contaminate precision finished faces. Seal Fully Installed As the stationary seat becomes fully seated. and sleeve are fully seated against the shaft shoulder (see Figure 6). MAINTENANCE & REPAIR . and remove impeller adjusting shims to obtain the PAGE E − 12 A new seal assembly should be installed any time the old seal is removed from the pump. grooves. even fingerprints on the faces can shorten seal life. Inspect the integral shaft sleeve for nicks or cuts on either end. SHEAR RING (UNSHEARED) Figure 5.D. or the sleeve is damaged. Continue to screw the impeller onto the shaft until the impeller.D. This allows the sleeve to slide down the shaft until seated against the shaft shoulder. Carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly. and other damage that might cause leakage. the seal spring compresses. Measure the impeller-to-seal plate clearance. If necessary to reuse an old seal in an emergency. The I. Wear patterns on the finished faces cannot be realigned during reassembly. replace the complete seal. Seal Partially Installed Continue to screw the impeller onto the shaft. Reusing an old seal could result in premature failure. The rubber bellows will adhere to the sleeve during use. Inspect the seal components for wear. Install the stationary seal element in the stationary seat. of the shaft sleeve.OM−05817 ULTRA V SERIES O-RING ENGAGED WITH SEAL PLATE BORE proper clearance as described in Impeller Installation and Adjustment. Do not attempt to separate the rotating portion of the seal from the shaft sleeve when reusing an old seal. clean the faces with a non-oil based solvent and a clean. never mix old and new seal parts. After the rotating assembly is installed in the pump casing. Measure this clearance. Back Cover Installation And Adjustment (Figures 1 and 7) If the wear plate (7) was removed for replacement. spring.13 mm) of wear plate clearance. Clean any scale or debris from the contacting surfaces in the pump casing that might interfere or prevent a good seal with the back cover. PAGE E − 13 . of each locking collar (11).D. and replace it if cracked or badly worn. The recommended clearance between the wear plate and the impeller is . kg. Inspect the impeller and shaft threads for dirt or damage. Ease the rotating assembly into the pump casing using the installation tool. Install the rotating assembly adjusting spacers (32) and secure the rotating assembly to the pump casing with the hardware (13 and 31). Apply ‘NeverSeez’ or equivalent to the shaft threads and screw the impeller onto the shaft until tight. Proceed with Impeller Installation and Adjustment. To set the impeller and wear plate clearance. or 12. and rotating element) onto the shaft until the seal faces contact.02 mm) between the impeller and the seal plate is recommended for maximum pump efficiency.4 m.025 to .005 inch (0. The wear plate must be concentric to prevent binding when the back cover is installed.25 to 0. torque the capscrew to 90 ft.64 to 1. Impeller Installation And Adjustment Rotating Assembly Installation (Figure 2) (Figure 1) Inspect the impeller. and clean or dress the threads as required. bellows and retainer. The shaft and impeller threads must be completely clean before reinstalling the impeller. refer to the Back Cover Installation And Adjustment. There are 18 detents on the I. A clearance of . and check the threads for dirt. (1080 in. and add or remove impeller adjusting shims as required. carefully center it on the back cover and secure it with the hardware (9 and 10). MAINTENANCE & REPAIR Install the O-rings (19 and 33) and lubricate them with light grease. 2 grease.010 to . spring centering washer.ULTRA V SERIES OM−05817 Slide the rotating portion of the seal (consisting of the integral shaft sleeve. NOTE Proceed with Rotating Assembly Installation before installing the impeller capscrew and washer (29 and 30). making future removal difficult or impossible without damage to the impeller or shaft. lbs. immediately back the impeller off. Even the slightest amount of dirt on the threads can cause the impeller to seize to the shaft. coat the threads of the impeller capscrew (29) with ‘Never-Seez’ or equivalent compound.040 inch (0. Replace the back cover O-rings (8 and 19) and lubricate them with a generous amount of No. Be careful not to damage the O-ring. Indexing the collars one detent on the adjusting screws represents approximately .020 inch (0. Install the same thickness of impeller adjusting shims (2) as previously removed. lbs. NOTE At the slightest sign of binding.50 mm). and install the impeller washer (30) and capscrew.). Clearance between the impeller and wear plate is adjusted using four adjusting screws and locking collars. Do not try to force the impeller onto the shaft. The rotating assembly must be installed in the pump casing in order to torque the impeller capscrew. index them three detents counterclockwise. Suction Check Valve Installation (Figure 1) Inspect the check valve assembly (24) and replace it if badly worn. NOTE If the suction or discharge flanges were removed. Perform the back cover adjustment procedure described above to obtain the proper face clearance. When all of the adjustment has been used on the back cover side of the pump. turn the two free adjusting screws until they engage the pump casing. Over time it may be necessary to repeat the adjustment process to compensate for normal wear between the impeller and wear plate. and reinstall the collars on the adjusting screws. Use the collars to turn the adjusting screws clockwise until the holes in the locking collars realign with the tapped screw holes in the back cover plate. 3 Form-A-Gasket’ or equivalent compound to the mating surfaces.OM−05817 USE TWO REMAINING ADJUSTING SCREWS AND LOCKING COLLARS TO SET FACE CLEARANCE ULTRA V SERIES USE TWO OPPOSING BACK COVER NUTS TO PRESS BACK COVER INTO PUMP CASING INDEX COLLARS 3 DETENTS COUNTERCLOCKWISE. PAGE E − 14 Remove the first two back cover nuts from their studs. With the wear plate just touching the impeller.2 mm) of adjustment may be obtained by removing the rotating assembly spacers (32). Secure the locking collars to the back cover plate with the hardware (13 and 15). replace the respective gaskets. then reinstall the hardware securing the rotating assembly to the pump casing. Be sure the wear plate does not scrape against the impeller. MAINTENANCE & REPAIR . 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. Reinstall the back cover nuts. and secure them to the pump casing with the attaching hardware. Loosen the back cover nuts used to press the back cover into the pump casing one full turn. Remove the rotating assembly adjusting shims. Install the locking collars and hardware (13 and 15). apply ‘Permatex Aviation No. PRESSURE RELIEF VALVE MAINTENANCE (Figure 1) The back cover is equipped with a pressure relief valve to provide additional safety for the pump and operator (refer to Liquid Temperature And Overheating in OPERATION). Install the two remaining back cover nuts snugly against the adjusting screws. Turn the adjusting screws clockwise until they engage the pump casing.125 inch (3. an additional 0. Remove the back cover. Tighten the back cover nuts evenly to avoid binding. Pull the collars off the adjusting screws. Installing and Adjusting Back Cover Screw the four adjusting screws (14) into the tapped holes in the back cover plate until they are just flush with the machined surface on the back side of the cover plate. Position the check valve in the mounting slot in the pump casing (1) with the G-R" logo facing away from the inside of the pump casing. THEN TURN CLOCKWISE UNTIL SCREW HOLES ALIGN Figure 7. Position the check valve cover (25) over the check valve slot and secure with the hardware (9 and 26). Align the back cover plate over the studs (5) and slide it into the pump casing. Allow an installed pump to completely cool before draining liquid from the pump casing. Use two back cover nuts (16) on diagonally opposing studs to press the back cover into the pump casing until the wear plate just touches the impeller when the shaft is turned by hand. For cold weather operation. Do not over-lubricate. Figure 2) in the shaft keyway and reconnect the power source. consult the factory or a lubricant supplier for the recommended grade of oil. Section C. before putting the pump back into service. This is especially important in areas where variable hot and cold temperatures are common. Check the oil level regularly through the bearing cavity sight gauge (15) and maintain it at the middle of the gauge.9 liters) of SAE No. causing severe injury to personnel. Never replace this valve with a substitute which has not been specified or provided by the Gorman-Rupp Company. When lubrication is required. Bearings (Figure 2) The bearing housing was fully lubricated when shipped from the factory. on the relief valve threads. NOTE The white reflector in the sight gauge must be positioned horizontally to provide proper drainage. the valve should be removed for inspection and cleaning. resulting in premature bearing failure. or any time the pump overheats and activates the valve. Over-lubrication can cause the bearings to over-heat. add SAE No. 30 non-detergent oil to the middle of the seal level sight gauge (15) and maintain it at the middle of the gauge. Make certain that all piping connections are tight. 30 non-detergent oil through the hole for the air vent (13). properly supported and secure. Change the oil more frequently if the pump is operated continuously or installed in an environment with rapid temperature change. Install the suction and discharge lines and open all valves. Do not operate the pump without the guards in place over the rotating parts. apply ‘Loctite Pipe Sealant With Teflon No. OM−05817 reinstall the vented plug. remove the vented plug (11) and fill the seal cavity with approximately 132 ounces (3. Remove the fill cover assembly (28) and fill the pump casing with clean liquid. PAGE E − 15 . drain the bearing housing once each year and refill with approximately 24 ounces (710 ml) of clean oil. see LUBRICATION.ULTRA V SERIES It is recommended that the pressure relief valve assembly be replaced at each overhaul. Maintain the oil at this level. Exposed rotating parts can catch clothing. Under normal conditions. or tools. Reinstall the fill cover. Clean and MAINTENANCE & REPAIR Monitor the condition of the bearing lubricant regularly for evidence of rust or moisture condensation. or equivalent compound. Periodically. Be sure the pump and power source have been properly lubricated. or contact your local power source representative. 592’. fingers. Final Pump Assembly (Figure 1) Install the key (25. Be sure to install any guards used over the rotating members. NOTE The white reflector in the sight gauge must be positioned horizontally to provide proper drainage. Power Source Consult the literature supplied with the power source. install the clamp bar (30) and secure it with the capscrew (29). LUBRICATION Seal Assembly (Figure 2) Before starting the pump. Position the valve as shown in Figure 1 with the discharge port pointing down. Refer to OPERATION. When reinstalling the relief valve. com/warranty or call: 519−631−2870 THE GORMAN-RUPP COMPANY  MANSFIELD.: 419−755−1280 International: +1−419−755−1352 For Canadian Warranty Information. OHIO GORMAN-RUPP OF CANADA LIMITED  ST. Please Visit www. ONTARIO. CANADA .grcanada.S. Please Visit www.grpumps.com/warranty or call: U.S. THOMAS. and International Warranty Information.For U.