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GORMAN-RUPP PUMPS ULTRA V Series, Installation, Operation, And Maintenance Manual With Parts List

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GORMAN-RUPP PUMPS ULTRA V Series Installation, Operation, And Maintenance Manual With Parts List Download Page 34

ULTRA V SERIES

OM-06295

MAINTENANCE & REPAIR

PAGE E - 7

PARTS LIST

46143-094 Deutz D914L6 Power Unit

ITEM 
NO.

PART NAME

PART 
NUMBER

MAT'L
CODE

QTY

1

DEUTZ F914L6 ENGINE

29217-361

---

1

2

BASE/FUEL TANK

41553-007

24150

1

3

LIFTING BAIL KIT

48274-801

---

1

4

CONTROL PANEL KIT

48313-794

---

1

5

BATTERY BOX ASSY

42432-001

---

1

6

FUEL PICKUP

29332-145

---

2

7

HOSE ASSY 

46341-796

---

1

8

MALE CONNECTOR

S1447

---

1

9

HOSE CLAMP

26518-642

---

2

10

HOSE BARB FITTING

26523-333

---

2

11

3/8” ID x 40” LG. HOSE 

18513-302

---

1

12

FUEL GAUGE

29332-135

---

1

13

POS BATTERY CABLE

47311-142

---

1

14

NEG BATTERY CABLE

47311-118

---

1

15

R.H. ENGINE SIDE RAIL

34458-038

15080

1

16

OIL DRAIN ASSY

46342-033

---

1

17

L.H. ENGINE SIDE RAIL

34441-069

15080

1

18

LOCKWASHER

J08

15991

4

19

HEX HD CAPSCREW

B0816

15991

4

20

HEX NUT

D08

15991

4

21

EXHAUST ELBOW

31912-036

15210

1

22

WEATHER CAP

S1387

---

1

23

MUFFLER GUARD ASSY

42331-035

---

1

24

HEX HD CAPSCREW

B1007

15991

4

25

FLAT WASHER

K10

15991

8

26

LOCKWASHER

J10

15991

4

27

HEX NUT

D10

15991

4

NOT SHOWN:

WARNING DECAL

38816-203

---

4

INSTRUCTION DECAL

38818-144

---

1

FLOAT SWITCH

48312-980

---

1

ENGINE STARTUP TAG

38816-269

---

1

ENGINE OPERATING DECAL

38816-347

---

1

WARNING DECAL

2613FE

---

1

CAUTION DECAL

2613FJ

---

1

WARNING DECAL

38816-345

---

1

OPTIONAL:

HEATED 30MIC ENGINE FUEL FILTER KIT

48122-914

---

1

DUAL FLOAT SWITCH KIT

48312-981

---

1

EPS W/TRANDUCER AUTOSTART CONTROL PANEL

48122-534

---

1

Summary of Contents for ULTRA V Series

Page 1: ...MAN RUPP COMPANY MANSFIELD OHIO www grpumps com GORMAN RUPP OF CANADA LIMITED ST THOMAS ONTARIO CANADA Printed in U S A 2009 The Gorman Rupp Company INSTALLATION OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST ULTRA V SERIES PUMP MODEL V6A60 D914L6 ...

Page 2: ...L NUMBER Please record your pump model and serial number in the spaces provided below Your Gorman Rupp distributor needs this information when you require parts or service Pump Model Serial Number The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 3: ...PAGE B 4 Suction Lines In Sumps PAGE B 4 Suction Line Positioning PAGE B 4 FLOAT SWITCHES PAGE B 5 Installation PAGE B 5 OPTIONAL SUBMERSIBLE TRANSDUCER PAGE B 6 DISCHARGE LINES PAGE B 7 Siphoning PAGE B 7 Valves PAGE B 7 Bypass Lines PAGE B 7 AUTOMATIC AIR RELEASE VALVE PAGE B 8 Theory of Operation PAGE B 8 Air Release Valve Installation PAGE B 9 ALIGNMENT PAGE B 10 OPERATION SECTION C PAGE C 1 P...

Page 4: ... Pump End Assy PAGE E 9 Repair Rotating Assy PAGE E 11 Coupling Kit PAGE E 12 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E 13 Suction Check Valve Removal PAGE E 13 Back Cover And Wear Plate Removal PAGE E 13 Separating Intermediate And Drive Assembly From Engine PAGE E 14 Loosening Impeller PAGE E 14 Rotating Assembly Removal PAGE E 15 Impeller Removal PAGE E 15 Seal Removal PAGE E 15 Shaft and...

Page 5: ... and industry stan dards For information or technical assistance on the en gine contact the engine manufacturer s local dealer or representative 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 write The Gorman Rupp Company P O Box 1217 Mansfield Ohio 4...

Page 6: ... pump is equipped with an automat ic starting system and is subject to au tomatic restart Keep hands and cloth ing away from the unit to prevent injury during automatic operation Disconnect the positive battery cable before per forming any maintenance Failure to do so may result in serious personal injury This pump is designed to handle dirty water containing specified entrained solids Do not atte...

Page 7: ...mbustion en gines presents an extreme explosion and fire hazard Make certain that all fuel lines are securely connected and free of leaks Never refuel a hot or run ning engine Avoid overfilling the fuel tank Always use the correct type of fuel Never tamper with the governor to gain more power The governor establishes safe operating limits that should not be exceeded The maximum continuous operatin...

Page 8: ...g pressure to 50 of the maximum permissible operating pressure as shown on the pump performance curve For further assistance contact your Gorman Rupp distributor or the Gorman Rupp Company Pump Dimensions See Figure 1 for the approximate physical dimen sions of this pump OUTLINE DRAWING SUCTION 8 00 NOMINAL WITH 8 HOLES 88 22 4 DIA EQUALLY SPACED ON A 11 75 298 4 DIA B C DISCHARGE 6 00 NOMINAL WIT...

Page 9: ...Installation Unless otherwise specified on the pump order the engine battery was not included with the unit Re fer to the following specifications when selecting a battery Table 1 Battery Specifications Crank 0 F Reserve Capacity Minutes 80 F Overall Dims Inches 850 120 10 25L Cold Amps Approx Amp Hr Rating 75 6 75W 8 88H x x Voltage 12 Volts Refer to the information accompanying the battery and o...

Page 10: ...e used for suction and discharge lines however the materials must be compatible with the liquid being pumped If hose is used in suction lines it must be the rigid wall rein forced type to prevent collapse under suction Us ing piping couplings in suction lines is not recom mended Line Configuration Keep suction and discharge lines as straight as possible to minimize friction losses Make mini mum us...

Page 11: ...ions when selecting and applying the pipe dope The pipe dope should be compatible with the liquid being pumped Suction Lines In Sumps If a single suction line is installed in a sump it should be positioned away from the wall of the sump at a distance equal to 1 1 2 times the diame ter of the suction line If there is a liquid flow from an open pipe into the sump the flow should be kept away from th...

Page 12: ...ion hose is used it may be extended to lay along the bottom of the wet well or sump and the float can be attached to the hose above the point where it bends along the bot tom Direct the suction line toward the flow and the float s away from the flow If a stand pipe is available attach the float switch cable to the standpipe in the sump at the approxi mate desired liquid level b In a single float s...

Page 13: ...lower the transducer into the wet well or sump do not drop it to the bottom To avoid clogging sus pend the transducer off the bottom b Be sure to provide sufficient room in the wet well or sump so that the transducer does not get drawn into the suction line To prevent this a flexible suction hose may be extended to lay along the bottom of the wet well or sump The transducer can then be attached to...

Page 14: ...nded that a throttling valve and a system check valve be in stalled in the discharge line to protect the pump from excessive shock pressure and reverse rota tion when it is stopped If the application involves a high discharge head gradually close the discharge throttling valve before stopping the pump Bypass Lines Self priming pumps are not air compressors Dur ing the priming cycle air from the su...

Page 15: ...of the Auto matic Air Release Valve Consult your Gorman Rupp distributor or contact the Gorman Rupp Company for selection of an Automatic Air Release Valve to fit your application Except in certain specific applications to prevent flooding during service of an auto matic air release valve in a below ground lift station if a manual shut off valve is in stalled anywhere in a bypass line it must be a...

Page 16: ...LEVEL Figure 5 Typical Automatic Air Release Valve Installation Connect the valve outlet to a bleed line which slopes back to the wet well or sump The bleed line must be the same size as the outlet opening or larger depending on which Air Release Valve is be ing used If piping is used for the bleed line avoid the use of elbows whenever possible NOTE For multiple pump installations it is recommende...

Page 17: ...the pump is securely mounted Check that the pump is properly lubri cated see LUBRICATION in MAINTENANCE AND REPAIR This pump is self priming but the pump should never be operated unless there is liquid in the pump casing Never operate this pump unless there is liquid in the pump casing The pump will not prime when dry Extended operation of a dry pump will destroy the seal assembly Add liquid to th...

Page 18: ... the AUTO START position by pressing the white MAN button on the control The Single Lightning Bolt light on the control will illu minate in conjunction with an audible alarm before the unit starts The unit can then be stopped manu ally by pressing the OFF SET button In the auto start mode the Single Lightning Bolt light will illuminate in conjunction with an audible alarm when the liquid level in ...

Page 19: ...utput delay time 5 30 seconds in 5 second increments h LO BAT Indicator shows battery voltage level is below 12VDC i Lo tpt Shows status of Low Tem perature Thermostat con tacts 2 LEDs a When the green LED is lighted the unit is showing level on the LCD display b When the A output LED is lighted the A output relay is closed c When the B output LED is lighted the B output relay is closed NOTE LED s...

Page 20: ... The user may wish to check Setpoints Off On and Horn output A output delay times Bump ing the switch will display all of the informa tion desired NOTE One second delays in contact opening closing is a result of time sampling of the pressure signal to fil ter false signals that could cause nuisance trip ping of the contacts NOTE If the Hrn dLy is changed during the actual A out put delay cycle the...

Page 21: ...be left closed during operation A pump which has lost prime may continue to operate without reaching prime causing dan gerous overheating and possible explo sive rupture of the pump casing Per sonnel could be severely injured Lines With a Bypass If a Gorman Rupp Automatic Air Release Valve has been installed the valve will automatically open to allow the pump to prime and automatically close after...

Page 22: ...mp or installed by the user check the strainer regularly and clean it as necessary The strainer should also be checked if pump flow rate begins to drop If a vacuum suction gauge has been in stalled monitor and record the readings regularly to detect strainer blockage Never introduce air or steam pressure into the pump casing or piping to remove a blockage This could result in personal injury or da...

Page 23: ...fore putting the unit back into service Consult the factory for ad ditional information OPERATION IN EXTREME HEAT The safety shutdown system will automatically stop the unit if engine operating temperature ex ceeds design limits If engine over temperature shutdown occurs allow the unit to cool before re starting If engine overheating continues check the engine lubricant level and viscosity Consult...

Page 24: ...lacing a contact type thermometer against the housing Record this temperature for future reference A sudden increase in bearing temperatures 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 Section E Bear ing overheating can also be caused by shaft misalignm...

Page 25: ...so may result in serious personal injury TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP FAILS TO PRIME Not enough liquid in casing Suction check valve contaminated or damaged Air leak in suction line Lining of suction hose collapsed Leaking or worn seal or pump gas ket Suction lift or discharge head too high Strainer clogged Add liquid to casing See PRIMING Clean or replace check valve Correct leak R...

Page 26: ...ischarge valve Dilute if possible Disassemble pump and check bearing s PUMP CLOGS FREQUENTLY Discharge flow too slow Suction check valve or foot valve clogged or binding Liquid solution too thick Open discharge valve fully to in crease flow rate and run engine at maximum governed speed Clean valve Dilute if possible EXCESSIVE NOISE Cavitation in pump Pumping entrained air Pump or drive not securel...

Page 27: ...ately the same duty cycle the part can be checked and replaced before failure occurs reducing unscheduled down time For new applications a first inspection of wearing parts at 250 hours will give insight into the wear rate for your particular application Subsequent inspec tions should be performed at the intervals shown on the chart below Critical applications should be inspected more frequently G...

Page 28: ...level with minimum suction lift Since pump installations are seldom identical your performance may be dif ferent due to such factors as viscosity specific grav ity 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 conditio...

Page 29: ...ULTRA V SERIES OM 06295 MAINTENANCE REPAIR PAGE E 2 SECTION DRAWING PARTSPAGE Figure 1 Pump Model V6A60 D914L6 ...

Page 30: ...143 094 1 3 PUMP MOUNTING KIT 48157 039 1 NOT SHOWN G R DECAL GR 06 4 WARNING DECAL 2613FE 1 OPTIONAL 12V BATTERY 29331 506 1 WHEEL KIT GRP30 262 1 TANDEM HIGHWAY TRAILERS W SURGE BRAKES 2 5 16 BALL HITCH W FOOT PAD 29313 011 1 2 5 16 BALL HITCH W DOLLY WHEEL 29313 012 1 3 I D LUNETTE EYE W FOOT PAD 29313 013 1 3 I D LUNETTE EYE W DOLLY WHEEL 29313 014 1 TANDEM HIGHWAY TRAILERS W ELECTRIC BRAKES 2...

Page 31: ...ULTRA V SERIES OM 06295 MAINTENANCE REPAIR PAGE E 4 SECTION DRAWING Figure 2 Pump 48157 039 Mounting Kit ...

Page 32: ...unting Kit ITEM NO PART NAME PART NUMBER MAT L CODE QTY 1 PUMP MOUNT 41581 051 24150 1 2 HEX HD CAPSCREW 22645 164 12 3 LOCK WASHER 21171 511 12 4 HEX NUT D10 15991 8 5 LOCKWASHER J10 15991 8 6 FLAT WASHER K10 15991 4 7 HEX HD CAPSCREW B1007 15991 4 8 HEX HD CAPSCREW B1010 15991 4 ...

Page 33: ...ULTRA V SERIES OM 06295 MAINTENANCE REPAIR PAGE E 6 SECTION DRAWING Figure 3 46143 094 Deutz D914L6 Power Unit ...

Page 34: ...5 R H ENGINE SIDE RAIL 34458 038 15080 1 16 OIL DRAIN ASSY 46342 033 1 17 L H ENGINE SIDE RAIL 34441 069 15080 1 18 LOCKWASHER J08 15991 4 19 HEX HD CAPSCREW B0816 15991 4 20 HEX NUT D08 15991 4 21 EXHAUST ELBOW 31912 036 15210 1 22 WEATHER CAP S1387 1 23 MUFFLER GUARD ASSY 42331 035 1 24 HEX HD CAPSCREW B1007 15991 4 25 FLAT WASHER K10 15991 8 26 LOCKWASHER J10 15991 4 27 HEX NUT D10 15991 4 NOT ...

Page 35: ...ULTRA V SERIES OM 06295 MAINTENANCE REPAIR PAGE E 8 SECTION DRAWING Figure 4 V6A60 SAE 3 11 5 Pump End Assembly ...

Page 36: ...PORT GASKET 50G 19210 1 WARNING PLATE 38816 097 13990 1 DRIVE SCREW BM 04 03 17000 2 29 CLAMP BAR 38111 004 11010 1 30 HEX HD CAPSCREW B1010S 15991 1 31 6 ELBOW 38647 905 10010 1 32 HEX HD CAPSCREW B1208 15991 8 33 LOCK WASHER J12 15991 8 34 PIPE PLUG P16 10009 1 35 DISCH ELBOW GASKET 25113 036 1 36 HEX HD CAPSCREW B0806 15991 4 37 COUPLING KIT 48112 019 1 38 SPACER 33221 022 17040 4 39 O RING 251...

Page 37: ...ULTRA V SERIES OM 06295 MAINTENANCE REPAIR PAGE E 10 SECTION DRAWING Figure 5 44163 495 Repair Rotating Assembly ...

Page 38: ...RAIN PLUG P04 15079 1 16A BRG CAVITY DRAIN PLUG P04 15079 2 17 HEX HD CAPSCREW 21632 938 6 18 LOCK WASHER J06 15991 6 19 OIL SEAL S1907 1 20 DRIVE FLANGE 38545 016 10000 1 21 INTERMEDIATE GUARD 42381 509 24152 2 22 GASKET 38683 474 1 23 HEX HD CAPSCREW B0604 15991 6 24 RETAINING RING S720 1 25 THRUST WASHER 31133 268 15000 1 26 BALL BEARING 23422 414 1 27 SHAFT KEY N0809 15990 1 28 IMPELLER SHAFT ...

Page 39: ...ure E 6 48112 019 Coupling Kit PARTS LIST ITEM NO PART NAME PART NUMBER MAT L CODE QTY 1 BUSHING 24131 498 1 2 COUPLING 24391 102 1 3 LOCKWASHER 21171 536 8 4 SOCKET HD CAPSCREW BD0606 1 2 15991 8 4 SOCKET HD CAPSCREW 22644 218 8 FOR SAE APPLICATIONS FOR METRIC APPLICATIONS ...

Page 40: ...instructions assume complete disassem bly is required Before attempting to service the pump disconnect or lock out the power source and take precautions to ensure that it will remain inoperative Close all valves in the suction and discharge lines For engine disassembly and repair consult the lit erature supplied with the engine or contact your local engine representative Before attempting to open ...

Page 41: ... 2 will remain on the shaft To remove the coupling from the shaft unscrew the two allen head setscrews from the bushing 1 Screw one of the setscrews into the puller hole on the circumference of the bushing As the coupling and bushing separate remove the bushing and slide the coupling off the shaft Remove the shaft key 27 Figure 5 It is not necessary to remove the outer ring of the coupling from th...

Page 42: ...igure 8 Rotating Assembly Tool To install the tool remove the vented plug 11 Fig ure 5 from the bearing housing and screw the longest length of pipe into the vent hole until fully engaged Install the tee and screw the handles into the tee Use caution when lifting the rotating assem bly to avoid injury to personnel or damage to the assembly Remove the seal plate and bearing housing O rings 31 and 3...

Page 43: ...or press the oil seals 6 and 6A from the bear ing housing After removing the shaft and bearings clean and inspect the bearings in place as follows To prevent damage during removal from the shaft it is recommended that bearings be cleaned and inspected in place It is strongly recommended that the bearings be replaced any time the shaft and bear ings are removed Clean the bearing housing shaft and a...

Page 44: ...ectric oven or hot plate may be used to heat the bearings Bear ings should never be heated with a direct flame or directly on a hot plate NOTE If a hot oil bath is used to heat the bearings both the oil and the container must be absolutely clean If the oil has been previously used it must be thor oughly filtered Heat the bearings to a uniform temperature no higher than 250 F 120 C and slide the be...

Page 45: ...eal lip on the shaft keyway Lubricate the bearing housing as indicated in LU BRICATION Seal Installation Figures 5 9 10 and 11 Most cleaning solvents are toxic and flammable Use them only in a well ven tilated area free from excessive heat sparks and flame Read and follow all precautions printed on solvent contain ers Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent In...

Page 46: ...ing the shaft sleeve O ring 29 on the shaft threads cover the threads with electri cal or duct tape Slide the O ring over the shaft until it seats against the shaft shoulder Remove the tape covering the threads Check to ensure that the shaft threads are free of any tape residue and clean as required before proceeding with seal installation When installing a new cartridge seal assembly remove the s...

Page 47: ... from the bellows retainer and sta tionary seat 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 Handle the seal parts with extreme care to prevent damage Be careful not to contaminate precision finished faces even fingerprints on th...

Page 48: ...he pump casing this clearance may be measured by reaching through the priming port with a feeler gauge Rotating Assembly Installation Figure 4 NOTE If the pump has been completely disassembled it is recommended that the suction check valve and back cover assembly be reinstalled at this point The back cover assembly must be in place to adjust the impeller face clearance Install the seal plate and b...

Page 49: ...nd 15 Install the two remaining back cover nuts snugly against the adjusting screws Remove the first two back cover nuts from their studs Turn the adjusting screws clockwise until they engage the pump casing Install the locking collars and hardware 14 and 15 Reinstall the back cover nuts Be sure the wear plate does not scrape against the impeller Over time it may be necessary to repeat the adjust ...

Page 50: ... por tion of the coupling with a non petroleum based lubricant such as vegetable oil or glycerin or a sili con based lubricant such as WD40 or equivalent Do not use petroleum based lubricants or any oth er substance which may soften or otherwise dam age the rubber Install the intermediate guards 21 Figure 5 and secure the drive flange to the engine bellhousing with the hardware 2 and 3 Figure 2 Fi...

Page 51: ...t be posi tioned horizontally to provide proper drainage Bearings Figure 5 The bearing housing was fully lubricated when shipped from the factory Check the oil level regu larly through the sight gauge 15A and maintain it at the middle of the gauge When lubrication is re quired add SAE No 30 non detergentoil through the hole for the air vent 13 Do not over lubricate Over lubrication can cause the b...

Page 52: ...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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