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GORMAN-RUPP PUMPS U Series, Installation, Operation And Maintenance Manual

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GORMAN-RUPP PUMPS U Series Installation, Operation And Maintenance Manual Download Page 19

SUPER U SERIES

OM-05668

OPERATION

PAGE C - 4

against the housing. Record this temperature for
future reference.

A sudden increase in bearing temperature is a
warning that the bearings are at the point of failing
to operate properly. Make certain that the bearing
lubricant is of the proper viscosity and at the cor­
rect level (see 

LUBRICATION

 in 

MAINTENANCE

AND REPAIR

). Bearing overheating can also be

caused by shaft misalignment and/or excessive vi­
bration.

When pumps are first started, the bearings may
seem to run at temperatures above normal. Con­
tinued operation should bring the temperatures
down to normal levels.

Summary of Contents for U Series

Page 1: ...N RUPP COMPANY MANSFIELD OHIO www grpumps com GORMAN RUPP OF CANADA LIMITED ST THOMAS ONTARIO CANADA Printed in U S A 2004 The Gorman Rupp Company INSTALLATION OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST SUPER U SERIES PUMP MODEL U6A60S B INCLUDING F FM ...

Page 2: ...erial 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 ...

Page 3: ... Sumps PAGE B 3 Suction Line Positioning PAGE B 4 DISCHARGE LINES PAGE B 4 Siphoning PAGE B 4 Valves PAGE B 4 Bypass Lines PAGE B 5 AUTOMATIC AIR RELEASE VALVE PAGE B 6 Theory of Operation PAGE B 6 Air Release Valve Installation PAGE B 6 ALIGNMENT PAGE B 7 Coupled Drives PAGE B 8 V Belt Drives PAGE B 8 OPERATION SECTION C PAGE C 1 PRIMING PAGE C 1 STARTING PAGE C 1 Rotation PAGE C 1 OPERATION PAGE...

Page 4: ...emoval PAGE E 6 Rotating Assembly Removal PAGE E 7 Impeller Removal PAGE E 8 Seal Removal PAGE E 8 Shaft and Bearing Removal and Disassembly PAGE E 8 Shaft and Bearing Reassembly and Installation PAGE E 9 Seal Installation PAGE E 11 Impeller Installation PAGE E 14 Rotating Assembly Installation PAGE E 14 Suction Back Cover Installation And Adjustment PAGE E 15 PRESSURE RELIEF VALVE MAINTENANCE PAG...

Page 5: ...or pump integrity are compromised by such prac tices If there are any questions regarding the pump or its application which are not covered in this man ual or in other literature accompanying this unit please contact your Gorman Rupp distributor or The Gorman Rupp Company P O Box 1217 Mansfield Ohio 44901 1217 Phone 419 755 1011 or Gorman Rupp of Canada Limited 70 Burwell Road St Thomas Ontario N5...

Page 6: ...ore attempting to open or service the pump 1 Familiarize yourself with this man ual 2 Disconnect or lock out the power source to ensure that the pump will remain inoperative 3 Allow the pump to completely cool if overheated 4 Check the temperature before opening any covers plates or plugs 5 Close the suction and discharge valves 6 Vent the pump slowly and cau tiously 7 Drain the pump This pump is ...

Page 7: ...rge valve pump components will deteriorate and the liquid could come to a boil build pressure and cause the pump casing to rupture or explode Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or dam age to equipment Suction and dis charge hoses and piping must be re moved from the pump before lifting ...

Page 8: ... the liquid is supplied to the pump under pressure some of the information such as mounting line configuration and priming must be tailored to the specific application Since the pressure supplied to the pump is critical to performance and safety be sure to limit the incoming pressure to 50 of the maximum permissible operating pressure as shown on the pump performance curve For further assistance c...

Page 9: ...stributor or the factory to deter mine the repair or updating policy Do not put the pump into service until appropriate action has been taken POSITIONING PUMP Lifting Pump unit weights will vary depending on the mounting and drive provided Check the shipping tag on the unit packaging for the actual weight and use lifting equipment with appropriate capacity Drain the pump and remove all customer in...

Page 10: ...n to the pump at any point along the suction run air pockets will be created Fittings Suction lines should be the same size as the pump inlet If reducers are used in suction lines they should be the eccentric type and should be in stalled with the flat part of the reducers uppermost to avoid creating air pockets Valves are not nor mally used in suction lines but if a valve is used install it with ...

Page 11: ... submergence required may be reduced by installing a standard pipe increaser fitting at the end of the suction line The larger opening size will reduce the inlet velocity Calculate the required submergence using the following formula based on the increased opening size area or diameter Figure 2 Recommended Minimum Suction Line Submergence vs Velocity DISCHARGE LINES Siphoning Do not terminate the ...

Page 12: ...maintenance In high discharge head applications more than 30 feet an excessive amount of liquid may be by passed and forced back to the wet well under the full working pressure of the pump this will reduce overall pumping efficiency Therefore it is recom mended that a Gorman Rupp Automatic Air Re lease Valve be installed in the bypass line Gorman Rupp Automatic Air Release Valves are reliable and ...

Page 13: ...h standard 1 inch NPT pipe threads DISCHARGE PIPE DISCHARGE CHECK VALVE PUMP DISCHARGE SELF PRIMING CENTRIFUGAL PUMP SUCTION LINE SUPPORT BRACKET CLEAN OUT COVER INSTALL AIR RELEASE VALVE IN HORIZONTAL POSITION 90 LONG RADIUS ELBOW WET WELL OR SUMP BLEED LINE 1 25 4 MM DIA MIN CUSTOMER FUR NISHED EXTEND 6 152 MM BELOW PUMP OFF LIQUID LEVEL Figure 3 Typical Automatic Air Release Valve Installation ...

Page 14: ...e aligned to the axis of the pump shaft in both the horizontal and vertical planes Most couplings require a specific gap or clearance between the driving and the driven shafts Refer to the coupling manufacturer s service literature 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 The coupling is in al...

Page 15: ... Driven Pumps Tighten the belts in accordance with the belt manu facturer s instructions If the belts are too loose they will slip if the belts are too tight there will be excessive power loss and possible bearing failure Select pulleys that will match the proper speed ra tio overspeeding the pump may damage both pump and power source Do not operate the pump without the guard in place over the rot...

Page 16: ...for the first time 2 The pump has not been used for a consider able length of time 3 The liquid in the pump casing has evapo rated Once the pump casing has been filled the pump will prime and reprime as necessary After filling the pump casing reinstall and tighten the fill plug Do not attempt to operate the pump unless all connect ing piping is securely installed Other wise liquid in the pump forc...

Page 17: ... valve for long periods of time If operated against a closed discharge throttling valve pump components will deteriorate and the liquid could come to a boil build pressure and cause the pump casing to rupture or explode Leakage No leakage should be visible at pump mating sur faces or at pump connections or fittings Keep all line connections and fittings tight to maintain maxi mum pump efficiency L...

Page 18: ...d abruptly damaging shock waves can be transmitted to the pump and piping system Close all connecting valves slowly On engine driven pumps reduce the throttle speed slowly and allow the engine to idle briefly be fore stopping If the application involves a high discharge head gradually close the discharge throttling valve before stopping the pump After stopping the pump lock out or disconnect the p...

Page 19: ...ng to operate properly Make certain that the bearing lubricant is of the proper viscosity and at the cor rect level see LUBRICATION in MAINTENANCE AND REPAIR Bearing overheating can also be caused by shaft misalignment and or excessive vi bration When pumps are first started the bearings may seem to run at temperatures above normal Con tinued operation should bring the temperatures down to normal ...

Page 20: ...MP FAILS TO PRIME Suction check valve contaminated or damaged Clean or replace check valve Air leak in suction line Lining of suction hose collapsed Correct leak Replace suction hose Leaking or worn seal or pump gasket Check pump vacuum Replace leaking or worn seal or gasket Suction lift or discharge head too high Check piping installation and in stall bypass line if needed See INSTALLATION Strain...

Page 21: ...ck Dilute if possible Bearing s frozen Disassemble pump and check bearing s Liquid solution too thick Dilute if possible Discharge flow too slow Open discharge valve fully to in crease flow rate and run power source at maximum governed speed Suction check valve or foot valve clogged or binding Clean valve PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE Strainer clogged Check strainer and cle...

Page 22: ...ble free performance and long life from your Gorman Rupp pump For specific questions con cerning your application contact your Gorman Rupp distributor or the Gorman Rupp Company Record keeping is an essential component of a good preventive maintenance program Changes in suction and discharge gauge readings if so equipped between regularly scheduled inspec tions can indicate problems that can be co...

Page 23: ...ar Impeller Clearance Seal Plate I Check Valve I Pressure Relief Valve If So Equipped C Pump and Driver Alignment I Shaft Deflection I Bearings I Bearing Housing I Piping I Driver Lubrication See Mfgr s Literature Legend I Inspect Clean Adjust Repair or Replace as Necessary C Clean R Replace Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually Adjust sche...

Page 24: ...t sea level with minimum suction lift Since pump installations are seldom identical your performance may be dif ferent due to such factors as viscosity specific gravity elevation temperature and impeller trim If your pump serial number is followed by an N your pump is NOT a standard production model Contact the Gorman Rupp Company to verify per formance or part numbers Pump speed and operating con...

Page 25: ...OM 05668 SUPER U SERIES MAINTENANCE REPAIR PAGE E 2 PARTSPAGE SECTION DRAWING TOP VIEW PRESSURE EQUALIZING PASSAGE LEAVE OPEN Figure 1 Pump Model U6A60S B Including F FM ...

Page 26: ...E PLUG P08 15079 1 34 STUD C1213 15991 4 35 BACK COVER NUT 31871 073 15000 4 36 ADJUSTING SCREW 31871 070 1500G 4 37 LOCKING COLLAR 38115 551 15001 4 38 HEX HD CAPSCREW B0804 1 2 15991 4 39 LOCK WASHER J08 15991 4 40 SUCTION BACK COVER 38243 479 10000 1 41 VICTAULIC COUPLING S1562 1 42 EXTENSION PIPE ASSY 46351 021 1 43 FLANGE 1758 10010 1 44 6 EXTENSION PIPE 31673 011 15070 1 45 PRESSURE RELIEF V...

Page 27: ...OM 05668 SUPER U SERIES MAINTENANCE REPAIR PAGE E 4 SECTION DRAWING DRIVE END VIEW Figure 2 44163 413 Repair Rotating Assembly ...

Page 28: ...14 825 16040 1 24 RETAINING RING S215 1 25 BALL BEARING 23422 412 1 26 BEARING CAVITY DRAIN PLUG P04 15079 1 27 SEAL CAVITY DRAIN PLUG P04 15079 1 28 OIL SEAL S1917 1 29 OIL SEAL S1917 1 30 PIPE PLUG P04 15079 1 31 IMPELLER WASHER 10278 15030 1 32 SOCKET HEAD CAPSCREW DM10045 15991 1 33 SEAL PLATE O RING 25152 381 1 34 BEARING HOUSING O RING 25152 453 1 35 SHIPPING PLUG 11495B 15079 1 36 SHIPPING ...

Page 29: ... source and take precautions to ensure that it will remain inoperative Close all valves in the suction and discharge lines For power source disassembly and repair consult the literature supplied with the power source or contact your local power source representative Before attempting to open or service the pump 1 Familiarize yourself with this man ual 2 Disconnect or lock out the power source to e...

Page 30: ... or key way When the impeller breaks loose remove the lathe dog key and wood block NOTE Do not remove the impeller until the rotating assem bly has been removed from the pump casing Turn Counterclockwise Lathe Dog Arm V Notch Shaft Key Impeller Shaft Lathe Dog Setscrew Heavy Bar Stock Figure 3 Loosening Impeller Figure 1 Remove the inner hardware 14 and 15 from the pump ring 11 Install three of th...

Page 31: ... from the bearing housing 6 Position the seal plate on a flat surface with the impeller side down Use a wooden dowel or other suitable tool to press on the back side of the stationary seat until the seat O rings and stationary element can be re moved If no further disassembly is required refer to Seal Installation Shaft and Bearing Removal and Disassembly Figure 2 When the pump is properly operate...

Page 32: ... into the bearing housing Replace the bearings shaft or bearing housing if the proper bearing fit is not achieved If bearing replacement is required remove the out board bearing snap ring 24 and use a bearing puller to remove the bearings from the shaft Shaft and Bearing Reassembly and Installation Figure 2 Clean the bearing housing shaft and all compo nent parts except the bearings with a soft cl...

Page 33: ...n shrinking If movement has occurred use a suitably sized sleeve and a press to reposition the bearings against the shaft shoulders If heating the bearings is not practical use a suit ably sized sleeve and an arbor or hydraulic press to install the bearings on the shaft When installing the bearings onto the shaft never press or hit against the outer race balls or ball cage Press only on the inner ...

Page 34: ...ary seat bore in the seal plate for dirt nicks and burrs and remove any that exist The stationary seat bore must be completely clean before installing the seal A new seal assembly should be installed any time the old seal is removed from the pump Wear patterns on the finished faces cannot be realigned during reassembly Reusing an old seal could result in prema ture failure The seal is not normally...

Page 35: ...m Slide the tube over the shaft threads then slide the O ring off the tube and onto the shaft Remove the tube and continue to slide the O ring down the shaft until it seats against the shaft shoulder When installing a new cartridge seal assembly remove the seal from the container and remove the mylar storage tabs if so equipped from be tween the seal faces Most new cartridge seal assemblies are eq...

Page 36: ...d seal is removed from the pump Wear patterns on the finished faces cannot be realigned during reassembly Reusing an old seal could result in prema ture failure Handle the seal parts with extreme care to prevent damage Be careful not to contaminate precision finished faces even fingerprints on the faces can shorten seal life If necessary clean the faces with a non oil based solvent and a clean lin...

Page 37: ...sure this clearance and add or remove impeller adjust ing shims as required NOTE If the rotating assembly has been installed in the pump casing this clearance may be measured by reaching through the priming port with a feeler gauge Proceed with Rotating Assembly Installation be fore installing the impeller capscrew and washer 31 and 32 The rotating assembly must be in stalled in the pump casing in...

Page 38: ...s the impeller when the shaft is turned by hand Tighten the back cover nuts evenly to avoid binding With the wear plate just touching the impeller turn the two free adjusting screws until they engage the pump casing Position the locking collars over the adjusting screws so the holes in the collars for the locking screws align approximately with the holes in the cover plate Loosen the back cover nu...

Page 39: ...d fill the pump casing with clean liquid Reinstall the fill cover and tighten it Refer to OPERATION Section C before putting the pump back into service LUBRICATION Seal Assembly Figure 2 Check the oil level regularly through the sight gauge 20 and maintain it at the middle of the gauge When lubrication is required add SAE No 30 non detergent oil through the hole for the vented plug 11 Clean and re...

Page 40: ...OM 05668 SUPER U SERIES MAINTENANCE REPAIR PAGE E 17 Power Source Consult the literature supplied with the power source or contact your local power source repre sentative ...

Page 41: ...w grpumps com warranty or call U S 419 755 1280 International 1 419 755 1352 For Canadian Warranty Information Please Visit www grcanada com warranty or call 519 631 2870 THE GORMAN RUPP COMPANY MANSFIELD OHIO GORMAN RUPP OF CANADA LIMITED ST THOMAS ONTARIO CANADA ...

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