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GORMAN-RUPP PUMPS ULTRA V V4A60-B, Installation, Operation, And Maintenance Manual With Parts List

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GORMAN-RUPP PUMPS ULTRA V V4A60-B Installation, Operation, And Maintenance Manual With Parts List Download Page 1

OM‐05816‐01

November 1, 2005

Rev. L  03‐01‐19

THE GORMAN‐RUPP COMPANY 

 MANSFIELD, OHIO

www.grpumps.com

GORMAN‐RUPP OF CANADA LIMITED

 

 ST. THOMAS, ONTARIO, CANADA

 

    

Printed in U.S.A.

2005 The Gorman‐Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

ULTRA V PUMP

 

MODEL

V4A60-B

INCLUDING:  /WW

Summary of Contents for ULTRA V V4A60-B

Page 1: ...RMAN RUPP COMPANY MANSFIELD OHIO www grpumps com GORMAN RUPP OF CANADA LIMITED ST THOMAS ONTARIO CANADA Printed in U S A 2005 The Gorman Rupp Company INSTALLATION OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST ULTRA V PUMP MODEL V4A60 B INCLUDING WW ...

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: ...ction Line Positioning PAGE B 3 DISCHARGE LINES PAGE B 4 Siphoning PAGE B 4 Valves PAGE B 4 Bypass Lines PAGE B 4 AUTOMATIC AIR RELEASE VALVE PAGE B 5 Air Release Valve Installation PAGE B 6 ALIGNMENT PAGE B 6 Coupled Drives PAGE B 7 Drive Belts PAGE B 7 DRIVE BELT TENSIONING PAGE B 8 General Rules of Tensioning PAGE B 8 OPERATION SECTION C PAGE C 1 PRIMING PAGE C 1 STARTING PAGE C 1 Rotation PAGE...

Page 4: ...GE E 7 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 10 Impeller Installation And Adjustment PAGE E 13 Rotating Assembly Installation PAGE E 14 Back Cover Installation And Adjustment PAGE E 14 Suction Check Valve Installation PAGE E...

Page 5: ...ion or technical assistance on the power source contact the power source manufac turer 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 The Gorman Rupp Company P O Box 1217 Mansfield Ohio 44901 1217 Phone 419 755 1011 or...

Page 6: ...s 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 designed to handle liquids containing large entrained solids or slurries Do not attempt to pump vola tile corrosive or flammable materials which may damage the pump or endan ger personnel as a result of pump fail ure After the pump has been positioned make certain that th...

Page 7: ...oses and piping must be re moved from the pump before lifting Do not attempt to disengage any part of an overheated pump unit Vapor pres sure within the pump casing can eject these parts with great force when they are disengaged Allow the pump to completely cool before servicing it Pumps and related equipment must be in stalled and operated according to all na tional local and industry standards ...

Page 8: ...g hard ware Since gaskets tend to shrink after dry ing check for loose hardware at mating sur faces c Carefully read all warnings and cautions con tained in this manual or affixed to the pump and perform all duties indicated Note the di rection of rotation indicated on the pump Check that the pump shaft rotates counter clockwise when facing the impeller Only operate this pump in the direction in d...

Page 9: ...ype 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 use of elbows and fittings which substan tially increase friction loss If elbows are necessary use the long radius type to minimize friction loss Connections to Pump Before tightening...

Page 10: ...es 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 the suc tion inlet because the inflow will carry air down into the sump and air entering the suction line will re duce pump ...

Page 11: ...e 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 Bypass Lines Self priming pumps are not air compressors Dur ing the priming cycle air from the suction line must be vented to atmosphere on the discharge side If the discharge line is open this air will be vented through the discharge However if ...

Page 12: ...low ground lift station a pipe union and manu al shut off valve may be installed in the bleed line to allow service of the valve without shutting down the station and to eliminate the possibility of flooding If a manual shut off valve is installed anywhere in the air release piping it must be a full opening ball type valve to prevent plugging by solids If a manual shut off valve is installed in a ...

Page 13: ...e 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 recommended that each Air Release Valve be fitted with an inde pendent bleeder line directed back to the wet well If multiple Air Release Valves are installed in a sys tem do not direct b...

Page 14: ...of the coupling hub every 90 The coupling is in alignment when the hub ends are the same distance apart at all points see Fig ure 3 Figure 3 Aligning Spider Type Couplings Figure 4 Aligning Non Spider Type Couplings Align non spider type couplings by using a feeler gauge or taper gauge between the coupling halves every 90 The coupling is in alignment when the hubs are the same distance apart at al...

Page 15: ...s can catch cloth ing fingers or tools causing severe in jury to personnel DRIVE BELT TENSIONING General Rules of Tensioning For new drive belts check the tension after 5 20 and 50 hours of operation and re tension as re quired Thereafter check and re tension if required monthly or at 500 hour intervals whichever comes first Ideal drive belt tension is the lowest tension at which the belt will not...

Page 16: ...ime 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 forced out under pr...

Page 17: ... flow rate Do not operate the pump against a closed discharge throttling 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 li...

Page 18: ...n air leak exists Before checking for the source of the leak check the point of installation of the vacuum gauge STOPPING Never halt the flow of liquid suddenly If the liquid being pumped is stopped abruptly damaging shock waves can be transmitted to the pump and piping system Close all connecting valves slowly If the application involves a high discharge head gradually close the discharge throttl...

Page 19: ...g 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 nor...

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: ...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 General Conditio...

Page 23: ...sea level with minimum suction lift Since pump installations are seldom identical your performance may be differ ent 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 condi...

Page 24: ...SERIES MAINTENANCE REPAIR PAGE E 2 PARTSPAGE SECTION DRAWING 33 31 13 2 32 34 9 11 29 30 12 17 22 35 35 4 26 16 14 18 3 7 7 13 19 37 1 21 10 24 5 28 15 27 27 8 6 7 23 25 36 20 20 Figure 1 Pump Model V4A60 B Including WW ...

Page 25: ... GASKET 50G 19210 1 WARNING PLATE 38816 097 13990 1 DRIVE SCREW BM 04 03 17000 2 29 HEX HEAD CAP SCREW B1010S 15991 1 30 CLAMP BAR 38111 004 11010 1 31 HEX HEAD CAP SCREW B0806 15991 4 32 SPACER 33221 022 17040 4 33 O RING S1676 1 34 O RING 25152 273 1 35 PIPE PLUG P08 15079 2 36 DRIVE SCREW BM 04 03 17000 4 37 NAMEPLATE BLANK 38819 002 13000 1 NOT SHOWN INSTR TAG 38817 023 1 ULTRA V DECAL 38816 3...

Page 26: ...6 13 13 15 14 14 8 7 9 4 1 5 30 31 32 33 33 6 28 3 2 27 SEAL DETAIL ÎÎ ÎÎ ÎÎ ÎÎ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÇÇ ÇÇ ÇÇ ÇÇ Ç Ç ÌÌ ÌÌ ÌÌ Ì Ì ÎÎ ÎÎ ÇÇ ÇÇ ÇÇ Ç Ï Ï Ï ÌÌ ÌÌ ÌÌÎ Î Ì ÌÌ Ì Ì Ì Ì Ì Î Î ÌÌÌÌ ÌÌÌÌ ÌÌÌÌ ÌÌÌÌ ÇÇ ÇÇ ÇÇ ÇÇ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ Ï ÌÌ ÌÌ ÌÌ ÌÌ ÎÎ ÎÎ ÎÎ ÎÎ Ï Ï ÇÇÇ ÇÇÇ ÇÇÇ ÏÏÏ ÏÏÏ ÏÏÏ ÏÏÏ ÏÏÏ ÏÏÏ Figure 2 Repair Rotating Assemblies ...

Page 27: ... 10009 1 16 PIPE PLUG P04 15079 2 17 HEX HEAD CAP SCREW B0606 15991 6 18 LOCK WASHER J06 15991 6 19 BEARING CAP 38322 230 10000 1 20 GASKET 38683 474 18000 1 21 RETAINING RING S720 1 22 THRUST WASHER 31133 268 15000 1 23 BALL BEARING 23287 014 1 24 KEY N0812 15990 1 25 IMPELLER SHAFT 38514 828 16000 1 26 BALL BEARING 23251 019 1 27 O RING 25154 026 REF 28 FLAT HEAD SOCKET SCREW F1004S 1500G 1 29 I...

Page 28: ...p and removing the back cover assembly If major repair is required the piping and or power source must be disconnected The following 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 power source dis...

Page 29: ...ing col lars 12 Install two 1 2 13 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 Inspect the wear plate and replace it if badly scored or worn To remove the wear plate disen gage the hardware 7 and 8 Inspect the back cover O rings 6 and 9 and re place it if damaged or worn Rotating Assembly Removal Figure 2 The rotating a...

Page 30: ...emoval Figure 2 With the rotating assembly removed from the pump casing unscrew the impeller from the shaft Use caution when unscrewing the impeller ten sion on the shaft seal spring will be released as the impeller is removed Inspect the impeller and re place if cracked or badly worn Remove the impeller adjusting shims 2 tie and tag the shims or measure and record their thick ness for ease of rea...

Page 31: ...rings thoroughly in fresh cleaning solvent Dry the bearings with filtered compressed air and coat with light oil Bearings must be kept free of all dirt and foreign material Failure to do so will great ly shorten bearing life Do not spin dry bearings This may scratch the balls or races and cause premature bearing fail ure Rotate the bearings by hand to check for rough ness or binding and inspect th...

Page 32: ... When installing the bearings onto the shaft never press or hit against the outer race balls or ball cage Press only on the inner race Install the thrust washer 22 and secure the out board bearing 23 to the shaft with the snap ring 21 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 i...

Page 33: ...ilure If necessary to reuse an old seal in an emer gency carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly Inspect the seal components for wear scoring grooves and other damage that might cause leak age If any components are worn replace the com plete seal never mix old and new seal parts If a replacement seal is being used remove it from the container and ins...

Page 34: ...ernal stationary seat O ring with light oil Slide the seal assembly onto the shaft until the external stationary seat O ring engages the bore in the seal plate Clean and inspect the impeller as described in Im peller Installation and Adjustment Install the full set of impeller shims 2 provided with the seal and screw the impeller onto the shaft until it is seated against the seal see Figure 6 O RI...

Page 35: ...parts Install the stationary seal element in the stationary seat Press this stationary subassembly into the seal plate bore until it seats squarely against the bore shoulder A push tube made from a piece of plastic pipe would aid this installation The I D of the pipe should be slightly larger than the O D of the shaft sleeve Slide the rotating portion of the seal consisting of the integral shaft s...

Page 36: ...nd the impeller is 010 to 020 inch 0 25 to 0 50 mm Replace the back cover O rings 6 and 9 and lubri cate them with a generous amount of No 2 grease Clean any scale or debris from the contacting sur faces in the pump casing that might interfere or prevent a good seal with the back cover USE TWO REMAINING ADJUSTING SCREWS AND LOCKING COLLARS TO SET FACE CLEARANCE USE TWO OPPOSING BACK COVER NUTS TO ...

Page 37: ...ating surfaces and secure them to the pump casing with the attaching hardware 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 Over heating in OPERATION It is recommended that the pressure relief valve as sembly be replaced at each overhaul or any time the pump o...

Page 38: ...lubricate Over lubrication can cause the bearings to over heat resulting in premature bear ing failure NOTE The white reflector in the sight gauge must be posi tioned horizontally to provide proper drainage Under normal conditions drain the bearing hous ing once each year and refill with approximately 24 ounces 710 ml of clean oil Change the oil more frequently if the pump is operated continuously...

Page 39: ...For Warranty Information Please Visit www grpumps com warranty or call U S 419 755 1280 Canada 519 631 2870 International 1 419 755 1352 GORMAN RUPP PUMPS ...

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