GORMAN-RUPP 1289525 Page 4 Installation, Operation And Maintenance Manual Download

Page: 4 / 39

TABLE OF CONTENTS

(continued)

TROUBLESHOOTING - SECTION D

PAGE D - 1

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PREVENTIVE MAINTENANCE

PAGE D - 3

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PUMP MAINTENANCE AND REPAIR - SECTION E

PAGE E - 1

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PERFORMANCE CURVE

PAGE E - 1

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PARTS LISTS:

Pump Model

PAGE E - 3

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Repair Rotating Assemblies

PAGE E - 5

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PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

PAGE E - 6

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Suction Check Valve Removal

PAGE E - 6

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Back Cover And Wear Plate Removal

PAGE E - 6

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Rotating Assembly Removal

PAGE E - 7

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Impeller Removal

PAGE E - 8

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Seal Removal

PAGE E - 8

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Shaft and Bearing Removal and Disassembly

PAGE E - 8

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Shaft and Bearing Reassembly and Installation

PAGE E - 9

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Seal Installation

PAGE E - 10

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Impeller Installation And Adjustment

PAGE E - 13

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Rotating Assembly Installation

PAGE E - 13

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Back Cover Installation And Adjustment

PAGE E - 13

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Suction Check Valve Installation

PAGE E - 14

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PRESSURE RELIEF VALVE MAINTENANCE

PAGE E - 14

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Final Pump Assembly

PAGE E - 15

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LUBRICATION

PAGE E - 15

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Seal Assembly

PAGE E - 15

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Bearings

PAGE E - 15

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Power Source

PAGE E - 15

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Summary of Contents for 1289525

Page 1: ...01 October 13 2005 Rev E 08 21 14 GORMAN RUPP PUMPS www grpumps com e2014 Gorman Rupp Pumps Printed in U S A INSTALLATION OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST ULTRA V PUMP MODEL V3A60 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: ...sitioning 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 C 1 OPERATIO...

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

Page 5: ...ny P O Box 1217 Mansfield Ohio 44901 1217 Phone 419 755 1011 or Gorman Rupp of Canada Limited 70 Burwell Road St Thomas Ontario N5P 3R7 Phone 519 631 2870 For information or technical assistance on the power source contact the power source manufac turer s local dealer or representative HAZARD AND INSTRUCTION DEFINITIONS The following are used to alert maintenance per sonnel to procedures which req...

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: ...nts will not be damaged when lifting Suction and dis charge hoses and piping must be re moved from the pump before lifting Lift the pump or component only as high as necessary and keep personnel away from suspended objects 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 ...

Page 8: ...and tighten loose attaching 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 ...

Page 9: ...e 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 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...

Page 10: ...ines 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 pum...

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: ...elow 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: ...f 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 a...

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: ...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 Strainer clogged Check strainer and clean if neces sary Not enough liquid ...

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: ...OM 05815 ULTRA V SERIES MAINTENANCE REPAIR PAGE E 2 PARTSPAGE ILLUSTRATION Figure 1 Pump Model V3A60 B Including WW ...

Page 25: ... HEX HD CAPSCREW B0504 15991 4 31 FILL PORT COVER ASSY 42111 437 1 FILL PORT GASKET 50G 19210 1 WARNING PLATE 38816 097 13990 1 DRIVE SCREW BM 04 03 17000 2 32 CLAMP BAR 38111 004 11010 1 33 HEX HD CAPSCREW B1010S 15991 1 34 HEX HD CAPSCREW B0805 1 2 15991 4 35 SPACER 33221 022 17040 4 36 PIPE PLUG P08 15079 2 NOT SHOWN SUCTION SPOOL PARTS WW MODEL ONLY SPOOL FLANGE 12066A 10010 1 FLANGE GASKET 25...

Page 26: ...OM 05815 ULTRA V SERIES MAINTENANCE REPAIR PAGE E 4 ILLUSTRATION Figure 2 Repair Rotating Assemblies ...

Page 27: ...3 PIPE PLUG P12 15079 1 14 SIGHT GAUGE S1471 1 14A SIGHT GAUGE S1471 1 15 PIPE PLUG P04 15991 2 16 HEX HD CAPSCREW B0605 15991 4 17 LOCK WASHER J06 15991 4 18 BEARING CAP 38322 220 10000 1 19 GASKET 38683 271 18000 1 20 RETAINING RING S442 1 21 BALL BEARING S375 1 22 SHAFT KEY N0608 15990 1 23 IMPELLER SHAFT 38514 827 16000 1 24 BALL BEARING S1088 1 25 O RING 25154 022 REF 26 IMPELLER WASHER 31167...

Page 28: ...ssume 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 disassembly and repair consult the literature supplied with the power source or contact your local power source representative Before attempting to op...

Page 29: ... the seal lubricant This will prevent the oil in the seal cavity from escaping when the impeller is loosened Clean and reinstall the seal cavity drain plug Immobilize the impeller by wedging a block wood between the vanes and the pump casing Remove the impeller capscrew and washer 26 and 27 If removed install the shaft key 22 Install a lathe dog on the drive end of the shaft 23 with the V notch po...

Page 30: ...gasket 5 from the bearing housing 7 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 Remove the shaft sleeve O ring 25 If no further disassembly is required refer to Seal Installation Shaft and Bearing Removal and Disassembly ...

Page 31: ...ing retaining ring 20 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 cloth soaked in cleaning solvent Inspect the parts for wear or damage as necessary Most cleaning solvents are toxic and flammable Use them only in a well ven tilated area free...

Page 32: ...om rolling as the shaft and bearing are installed in the bearing housing The O D of the sleeve should be just smaller than the bearing housing bore while the I D of the sleeve should be just larger than the O D of the lip seal area of the shaft With the lip seal sleeve in place lubricate the lip seal area of the shaft and slide the shaft and as sembled bearings into the bearing housing until the r...

Page 33: ...e com plete seal never mix old and new seal parts If a replacement seal is being used remove it from the container and inspect the precision finished faces to ensure that they are free of any foreign matter To ease installation of the seal lubricate the shaft sleeve shaft sleeve O ring and the external station ary seat O ring with a very small amount of light lu bricating oil See Figure 5 for seal...

Page 34: ...resses the stationary seat into the seal plate bore STATIONARY SEAT FULLY SEATED IN SEAL PLATE BORE SHEAR RING SHEARED Figure 7 Seal Fully Installed As the stationary seat becomes fully seated the seal spring compresses and the shaft sleeve will break the nylon shear ring This allows the sleeve to slide down the shaft until seated against the shaft shoulder Continue to screw the impeller onto the ...

Page 35: ...ean before reinstalling the im peller Even the slightest amount of dirt on the threads can cause the impeller to seize to the shaft making future removal difficult or impossible without damage to the im peller or shaft Install the same thickness of impeller adjusting shims 2 as previously removed Apply Never Seez or equivalent to the shaft threads and screw the impeller onto the shaft until tight ...

Page 36: ...mpeller 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 nuts used...

Page 37: ...ers Do not operate the pump without the guards in place over the rotating parts Exposed rotating parts can catch cloth ing fingers or tools causing severe in jury to personnel Install the suction and discharge lines and open all valves Make certain that all piping connections are tight properly supported and secure Be sure the pump and power source have been properly lubricated see LUBRICATION Rem...

Page 38: ... bearing lubri cant regularly for evidence of rust or mois ture condensation This is especially im portant in areas where variable hot and cold temperatures are common For cold weather operation consult the factory or a lubricant supplier for the recommended grade of oil Power Source Consult the literature supplied with the power source or contact your local power source repre sentative ...

Page 39: ...l Warranty Information Please Visit www 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 GORMAN RUPP PUMPS ...

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