GORMAN-RUPP PUMPS ULTRA V Series Guía de aplicación

OM‐06295‐01

August 5, 2009

Rev. E 08‐03‐17

THE GORMAN‐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

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:

The engine exhaust from this

product contains chemicals

known to the State of California to

cause cancer, birth defects or

other reproductive harm.

TABLE OF CONTENTS

INTRODUCTION PAGE I - 1.................................................

SAFETY ‐ SECTION A PAGE A - 1............................................

INSTALLATION - SECTION B PAGE B - 1....................................

Pump Dimensions PAGE B - 1.....................................................

PREINSTALLATION INSPECTION PAGE B - 2............................................

Battery Specifications And Installation PAGE B - 2....................................

POSITIONING PUMP PAGE B - 2.......................................................

Lifting PAGE B - 2.................................................................

Mounting PAGE B - 3.............................................................

Clearance PAGE B - 3.............................................................

SUCTION AND DISCHARGE PIPING PAGE B - 3.........................................

Materials PAGE B - 3..............................................................

Line Configuration PAGE B - 3......................................................

Connections to Pump PAGE B - 3..................................................

Gauges PAGE B - 3...............................................................

SUCTION LINES PAGE B - 3...........................................................

Fittings PAGE B - 4...............................................................

Strainers PAGE B - 4..............................................................

Sealing 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......................................

PRIMING PAGE C - 1.................................................................

STARTING PAGE C - 2................................................................

Manual Starting PAGE C - 2........................................................

Automatic Starting PAGE C - 2.....................................................

OPTIONAL EPS CONTROL PAGE C - 3.................................................

Features PAGE C - 3..............................................................

Functional Description PAGE C - 3..................................................

EPS Functions PAGE C - 4.........................................................

EPS Calibration PAGE C - 4........................................................

Zero Adjustment PAGE C - 4.......................................................

Span Adjustment PAGE C - 5......................................................

Level Adjustment PAGE C - 5......................................................

TABLE OF CONTENTS

(continued)

Horn Delay PAGE C - 5............................................................

OPERATION PAGE C - 5..............................................................

Lines With a Bypass PAGE C - 5....................................................

Lines Without a Bypass PAGE C - 5.................................................

Leakage PAGE C - 5..............................................................

Liquid Temperature And Overheating PAGE C - 6.....................................

Strainer Check PAGE C - 6.........................................................

Pump Vacuum Check PAGE C - 6..................................................

STOPPING PAGE C - 6................................................................

Manual Stopping PAGE C - 6.......................................................

Automatic Stopping PAGE C -6....................................................

Safety Shutdown System PAGE C - 7...............................................

OPERATION IN EXTREME HEAT PAGE C - 7............................................

Cold Weather Preservation PAGE C - 7..............................................

BEARING TEMPERATURE CHECK PAGE C - 8..........................................

TROUBLESHOOTING - SECTION D PAGE D - 1..............................

PREVENTIVE MAINTENANCE PAGE D - 3...............................................

PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................

STANDARD PERFORMANCE CURVE PAGE E - 1........................................

PARTS LISTS:

Pump Model PAGE E - 3..........................................................

Pump Mounting Kit PAGE E - 5.....................................................

Power Unit Kit PAGE E - 7.........................................................

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 Bearing Removal and Disassembly PAGE E - 16.............................

Shaft and Bearing Reassembly and Installation PAGE E - 17............................

Seal Installation PAGE E - 18........................................................

Impeller Installation PAGE E - 21.....................................................

Rotating Assembly Installation PAGE E - 21...........................................

Back Cover Installation And Adjustment PAGE E - 21..................................

Suction Check Valve Installation PAGE E - 22.........................................

Securing Pump End To Engine PAGE E - 22..........................................

PRESSURE RELIEF VALVE MAINTENANCE PAGE E - 23..................................

Final Pump Assembly PAGE E - 24..................................................

LUBRICATION PAGE E - 24.............................................................

Seal Assembly PAGE E - 24.........................................................

Bearings PAGE E - 24..............................................................

Engine PAGE E - 24................................................................

ULTRA V SERIES OM-06295

PAGE I - 1INTRODUCTION

INTRODUCTION

Thank You for purchasing a Gorman‐Rupp pump.

Read this manual carefully to learn how to safely

install and operate your pump. Failure to do so

could result in personal injury or damage to the

pump.

This pump is an Ultra V Series, semi‐open impel

ler, self‐priming centrifugal model with a suction

check valve. The pump also is designed with exter

nal shimless adjusters for setting the wear plate to

impeller clearance. The pump is close coupled to a

Deutz D914L6 diesel engine, and is designed for

handling dirty water containing specified entrained

solids and slurries. The basic material of construc

tion is gray iron, with ductile iron impeller and steel

wearing parts.

Because pump installations are seldom identical,

this manual cannot possibly provide detailed in

structions and precautions for every aspect of

each specific application. Therefore, it is the re

sponsibility of the owner/installer of the pump to

ensure that applications not addressed in this

manual are performed only after establishing that

neither operator safety nor pump integrity are com

promised by the installation. Pumps and related

equipment must be installed and operated ac

cording to all national, local 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 44901-1217

Phone: (419) 755-1011

or:

Gorman‐Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631-2870

The following are used to alert maintenance per

sonnel to procedures which require special atten

tion, to those which could damage equipment, and

to those which could be dangerous to personnel:

Immediate hazards which WILL result in

severe personal injury or death. These

instructions describe the procedure re

quired and the injury which will result

from failure to follow the procedure.

Hazards or unsafe practices which

COULD result in severe personal injury

or death. These instructions describe

the procedure required and the injury

which could result from failure to follow

the procedure.

Hazards or unsafe practices which COULD

result in minor personal injury or product

or property damage. These instructions

describe the requirements and the possi

ble damage which could result from failure

to follow the procedure.

NOTE

Instructions to aid in installation, operation, and

maintenance or which clarify a procedure.

ULTRA V SERIES OM-06295

PAGE A - 1SAFETY

SAFETY ‐ SECTION A

This information applies to Ultra V Se

riesRengine driven pumps. Refer to the

manual accompanying the engine be

fore attempting to begin operation.

Because pump installations are seldom

identical, this manual cannot possibly

provide detailed instructions and pre

cautions for each specific application.

Therefore, it is the owner/installer's re

sponsibility to ensure that applications

not addressed in this manual are per

formed only after establishing that nei

ther operator safety nor pump integrity

are compromised by the installation.

Before attempting to open or service the

pump:

1. Familiarize yourself with this man

ual.

2. Switch off the engine ignition and

disconnect the positive battery

cable 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 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 attempt to pump volatile,

corrosive, or flammable liquids which

may damage the pump or endanger per

sonnel as a result of pump failure.

Use lifting and moving equipment in

good repair and with adequate capacity

to prevent injuries to personnel or dam

age to equipment. The bail is intended

for use in lifting the pump assembly

only. Suction and discharge hoses and

piping must be removed from the pump

before lifting.

After the unit has been installed, make

certain that the pump and all piping or

hose connections are tight, properly

supported and secure before operation.

Do not operate the pump against a

closed discharge valve for long periods

of time. If operated against a closed dis

charge valve, pump components will

deteriorate, and the liquid could come

to a boil, build pressure, and cause the

pump casing to rupture or explode.

ULTRA V SERIESOM-06295

PAGE A - 2 SAFETY

Do not remove plates, covers, gauges,

pipe plugs, or fittings from an over

heated pump. Vapor pressure within the

pump can cause parts being disen

gaged to be ejected with great force. Al

low the pump to cool before servicing.

Do not operate an internal combustion

engine in an explosive atmosphere.

When operating internal combustion

engines in an enclosed area, make cer

tain that exhaust fumes are piped to the

outside. These fumes contain carbon

monoxide, a deadly gas that is color

less, tasteless, and odorless.

Fuel used by internal combustion 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

operating speed for this pump is 1950

RPM.

Pumps and related equipment must be in

stalled and operated according to all na

tional, local and industry standards.

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.

ULTRA V SERIES OM-06295

PAGE B - 1INSTALLATION

INSTALLATION - SECTION B

Review all SAFETY information in Section A.

Since pump installations are seldom identical, this

section offers only general recommendations and

practices required to inspect, position, and ar

range the pump and piping.

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.

If installed in a flooded suction application where

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, 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 WITH 8 HOLES

.88/[22,4] DIA EQUALLY SPACED

ON A 9.50/[241,3] DIA B.C.

18.00/[457,2] RECOMMENDED FORREMOVAL OF BACK COVER PLATE

10.50/[266,7] REQUIRED FOR REMOVAL OF BACK COVER PLATE

.69/[17,5] DIA THRU

7 HOLES EACH SIDE

.69/[17,5] DIA THRU

4 HOLES

51.75

[ 1314,4 ]

62.50

[ 1587,5 ]

37.81

[ 960,5 ]

52.85

[ 1342,4 ]

44.25

[ 1124,0 ]

14.75

[ 374,6 ]

29.50

[ 749,3 ]

5.50

[ 139,7 ]

22.12

[ 562,0 ]

2.75

[ 69,8 ]

25.88

[ 657,2 ]

11.93

[ 303,0 ]

12.00

[ 304,8 ]

104.00

[ 2641,6 ]

95.50

[ 2425,7 ]

25.23

[ 640,9 ]

31.94

[ 811.3 ]

2.75

[ 69,8 ] TYP

14.75

[ 374.6 ]

.75

[ 19.0 ]

8.00

[ 203,2 ]

Figure 1. Pump Model V6A60-D914L6

OM-06295 ULTRA V SERIES

PAGE B - 2 INSTALLATION

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested be

fore shipment from the factory. Before installation,

inspect the pump for damage which may have oc

curred during shipment. Check as follows:

a. Inspect the pump assembly for cracks, dents,

damaged threads, and other obvious dam

age.

b. Check for 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 tags, decals, and markings

on the pump assembly, and perform all duties

indicated.

d. Check levels and lubricate as necessary. Re

fer to LUBRICATION in the MAINTENANCE

AND REPAIR section of this manual and per

form duties as instructed.

e. If the pump and engine have been stored for

more than 12 months, some of the compo

nents or lubricants may have exceeded their

maximum shelf life. These must be inspected

or replaced to ensure maximum pump serv

ice.

If the maximum shelf life has been exceeded, or if

anything appears to be abnormal, contact your

Gorman‐Rupp distributor or the factory to deter

mine the repair or updating policy. Do not put the

pump into service until appropriate action has

been taken.

Battery Specifications And 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

Voltage

12 Volts

Refer to the information accompanying the battery

and/or electrolyte solution for activation and charg

ing instructions.

Before installing the battery, clean the positive and

negative cable connectors, and the battery termi

nals. Secure the battery by tightening the

holddown brackets. The terminals and clamps

may be coated with petroleum jelly to retard corro

sion. Connect and tighten the positive cable first,

then the negative cable.

POSITIONING PUMP

Use lifting and moving equipment in

good repair and with adequate capacity

to prevent injuries to personnel or dam

age to equipment. The bail is intended

for use in lifting the pump assembly

only. Suction and discharge hoses and

piping must be removed from the pump

before lifting.

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‐installed

equipment such as suction and discharge hoses

or piping before attempting to lift existing, installed

units.

ULTRA V SERIES OM-06295

PAGE B - 3INSTALLATION

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.

Mounting

Locate the pump in an accessible place as close as

practical to the liquid being pumped. Level mount

ing is essential for proper operation.

The pump may have to be supported or shimmed

to provide for level operation or to eliminate vibra

tion.

If the pump has been mounted on a moveable

base, make certain the base is stationary by setting

the brake and blocking the wheels before attempt

ing to operate the pump.

To ensure sufficient lubrication and fuel supply to

the engine, do not position the pump and engine

more than 15off horizontal for continuous opera

tion. The pump and engine may be positioned up

to 30off horizontal for intermittent operation

only; however, the engine manufacturer should be

consulted for continuous operation at angles

greater than 15.

Clearance

When positioning the pump, allow a minimum

clearance of 18 inches (457,2 mm) in front of the

back cover to permit removal of the cover and easy

access to the pump interior.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in

creased suction lift, discharge elevation, and fric

tion losses. See the performance curve and notes

on Page E‐1 to be sure your overall application al

lows pump to operate within the safe operation

range.

Materials

Either pipe or hose maybe 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 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 a connecting flange, align it ex

actly with the pump port. Never pull a pipe line into

place by tightening the flange bolts and/or cou

plings.

Lines near the pump must be independently sup

ported to avoid strain on the pump which could

cause excessive vibration, decreased bearing life,

and increased shaft and seal wear. If hose‐type

lines are used, they should have adequate support

to secure them when filled with liquid and under

pressure.

Gauges

Most pumps are drilled and tapped for installing

discharge pressure and vacuum suction gauges.

If these gauges are desired for pumps that are not

tapped, drill and tap the suction and discharge

lines not less than 18 inches (457,2 mm) from the

suction and discharge ports and install the lines.

Installation closer to the pump may result in erratic

readings.

SUCTION LINES

To avoid air pockets which could affect pump prim

ing, the suction line must be as short and direct as

possible. When operation involves a suction lift, the

line must always slope upward to the pump from

the source of the liquid being pumped; if the line

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