GORMAN-RUPP PUMPS 46146-041, Installation, Operation, And Maintenance Manual With Parts List

Page 1: ...GORMAN RUPP COMPANY MANSFIELD OHIO www grpumps com GORMAN RUPP OF CANADA LIMITED ST THOMAS ONTARIO CANADA Printed in U S A 2006 The Gorman Rupp Company INSTALLATION OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST ULTRA V PUMP MODEL VS6A60 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: ... 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 DRIVE ARRANGEMENTS PAGE B 7 Dual Motor Drives PAGE B 7 Single Motor Belt Drives PAGE B 7 Single Motor Combination Drives PAGE B 8 HIGH PUMP TEMPERATURE SHUTDOWN FOR STAGED APPLICATIONS PAGE B 9 ALIGNMENT PAGE B 9 Coupled Drives PAGE B 9 Drive Belts P...

Page 4: ...GE E 10 Support Plare Removal PAGE E 11 Back Cover And Wear Plate Removal PAGE E 11 Rotating Assembly Removal PAGE E 11 Impeller Removal PAGE E 12 Seal Removal PAGE E 12 Shaft and Bearing Removal and Disassembly PAGE E 12 Pump Casing and Transition Chamber Removal PAGE E 13 Pump Casing and Transition Chamber Installation PAGE E 14 Shaft and Bearing Reassembly and Installation PAGE E 14 Seal Instal...

Page 5: ...to known proce dures which require special attention to those which could damage equipment and to those which could be dangerous to personnel However this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit Therefore it is the responsibility of the owner maintenance per sonnel to ensure that only safe established ma...

Page 6: ... 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 the...

Page 7: ... a suction check valve in the first stage of the VS Series pump model can cause over pressurization of the first stage pump casing resulting in possible explosion of the pump and se rious injury or death to presonnel 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 t...

Page 8: ...e 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 pump in the dire...

Page 9: ...riction 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 ...

Page 10: ... 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 efficiency If it is necessary to position inflow close to the suc tion inlet install a baffle between the inflow and the suction inlet at a distance 1 1 2 times th...

Page 11: ...ne use a valve as large as the largest pipe to minimize friction losses Never install a throttling valve in a suction line With high discharge heads it is recommended 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 Bypass Lines Self priming pumps are not air compressors D...

Page 12: ...ation If the installation involves a flooded suction such as a below 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...

Page 13: ...to escape through the Air Release Valve When air in the sys tem is purged pressure opens the second dis charge check valve for full operation When the liquid level in the sump lowers enough to de activate the automatic liquid level device and stop the pumps the first discharge check valve closes and creates an air tight seal thus maintain ing liquid in the pump casing and suction line to al low th...

Page 14: ...arrangements for staged pumps Consult the factory for information regard ing your specific application Dual Motor Drives It is recommended that each pump be directly driv en by its own electric motor either through cou plings see Figure 3 or a belt arrangement see Figure 4 Each motor should be independently operated through a reduced voltage solid state RVSS start er a variable frequency drive VFD...

Page 15: ...n certain arrangements must be used in order to ensure proper operation Figure 6 shows a recommended alternate single motor combination drive arrangement where the first stage pump shaft is direct coupled to the motor and the second stage pump shaft is driven by belts and an idler located between the two shafts In this arrangement shaft and or bearing loads are shared between the two pumps Figure ...

Page 16: ...must be mounted so that their shafts are aligned with and parallel to each other It is imperative that alignment be checked after the pump and piping are installed and before opera tion NOTE Check Rotation Section C before final alignment of the pump When mounted at the Gorman Rupp factory driver and pump are aligned before shipment Misalign ment will occur in transit and handling Pumps must be ch...

Page 17: ...LIGNED SHAFTS NOT IN LINE ALIGNED SHAFTS PARALLEL AND SHEAVES IN LINE Figure 11 Alignment of V Belt 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 ma...

Page 18: ...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 19: ... 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 20: ...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 21: ...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 22: ...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 23: ...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 24: ...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 25: ...e 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 condition points must be within the continuous per formance range sh...

Page 26: ...OM 06014 ULTRA V SERIES MAINTENANCE REPAIR PAGE E 2 PARTSPAGE SECTION DRAWING Figure 1 Pump Model VS6A60 B Including WW ...

Page 27: ...TE PUMP ASSY 46146 001 1 8 HEX HD CAPSCREW B0807 15991 4 9 SUPPORT PLATE 34455 011 15080 1 10 DRIVE SCEW BM 04 03 17000 4 11 NAME PLATE 38818 149 13000 1 NOT SHOWN LUBRICATION DECAL 38817 084 1 G R DECAL GR 03 1 ULTRA V DECAL 38816 342 1 ROTATION DECAL 2613M 1 INSTRUCTION TAG 38817 023 1 WARNING DECAL 2613FE 1 DISCHARGE STICKER 6588BJ 1 SUCTION STICKER 6588AG 1 PRIMING STICKER 6588AH 1 INSTRUCTION...

Page 28: ...OM 06014 ULTRA V SERIES MAINTENANCE REPAIR PAGE E 4 SECTION DRAWING Figure 2 Pump Assemblies 46146 041 and 46146 042 ...

Page 29: ...LATE 38816 097 13990 1 DRIVE SCREW BM 04 03 17000 2 27 HEX HD CAPSCREW B1010S 15991 1 28 CLAMP BAR 38111 004 11010 1 29 HEX HD CAPSCREW B0806 15991 4 30 SPACER 33221 022 17040 4 31 O RING 25152 381 1 32 PIPE PLUG P08 15079 2 NOT SHOWN SUCTION SPOOL PARTS VS6A60 B WW ONLY SPOOL FLANGE 12799 10010 1 FLANGE GASKET 25113 038 1 FLANGE PIPE PLUG P20 10009 1 SUCTION STICKER 6588AG 1 ROTATION DECAL 2613M ...

Page 30: ...OM 06014 ULTRA V SERIES MAINTENANCE REPAIR PAGE E 6 SECTION DRAWING Figure 3 46146 001 Ultra Mate Pump Assembly ...

Page 31: ...804 15991 4 11 LOCK WASHER J06 15991 6 12 HEX HD CAPSCREW B0605 15991 2 13 HANDLE 12354 13010 1 14 HAND NUT 31871 073 15000 4 15 ADJUSTING SCREW 31871 070 1500G 4 16 O RING S1676 2 17 HEX NUT D06 15991 4 18 O RING 25152 453 1 19 WEAR PLATE ASSY 46451 759 24150 1 20 STUD C1213 15991 4 21 HEX HD CAPSCREW B0807 15991 11 22 O RING 25152 280 1 23 O RING 25152 381 1 24 SPACER 33221 022 17040 4 25 HEX HD...

Page 32: ...OM 06014 ULTRA V SERIES MAINTENANCE REPAIR PAGE E 8 SECTION DRAWING Figure 4 Repair Rotating Assemblies ...

Page 33: ...12 15079 2 15 SIGHT GAUGE S1471 2 16 PIPE PLUG P04 15079 2 17 HEX HD CAPSCREW B0606 15991 1 18 LOCK WASHER J06 15991 1 19 OIL SEAL S1907 1 20 BEARING CAP 38322 230 10000 1 21 GASKET 38683 474 18000 1 22 RETAINING RING S720 1 23 THRUST WASHER 31133 268 15000 1 24 BALL BEARING 23422 414 1 25 SHAFT KEY N0812 15990 1 26 IMPELLER SHAFT 38514 826 16000 1 27 O RING 25154 131 1 28 BALL BEARING 23422 019 1...

Page 34: ...ed 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 disassembly and repair consult the literature supplied with the power source or contact your local power source represe...

Page 35: ...g assembly may be serviced without disconnecting the suction or discharge piping however the power source must be removed to provide clearance The impeller 1 should be loosened while the rotat ing assembly is still secured to the pump casing Before loosening the impeller remove the seal cav ity drain plug and drain the seal lubricant This will prevent the oil in the seal cavity from escaping when ...

Page 36: ...ion of the seal off the shaft as a unit Use a pair of stiff wires with hooked ends to remove the stationary element and seat An alternate method of removing the stationary seal components is to remove the hardware 7 and 8 and separate the seal plate 4 and gasket 5 from the bearing housing 9 Position the seal plate on a flat surface with the impeller side down Use a wooden dowel or other suitable t...

Page 37: ...ess fit onto the shaft and a snug slip fit 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 retaining ring 22 and thrust wash er 23 Use a bearing puller to remove the bear ings from the shaft Pump Casing and Transition Chamber Removal Ultra Mate Second Stage Model Only Fi...

Page 38: ... weight may result in damage to the pump or failure of the lifting device Shaft and Bearing Reassembly and Installation Figure 4 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 from e...

Page 39: ...g seats against the bearing housing Remove the lip seal sleeve When installing the shaft and bearings into the bearing bore push against the outer race Never hit the balls or ball cage Position the outboard oil seal 6 in the bearing housing bore with the lip positioned as shown in Figure 4 Detail B Press the oil seal into the hous ing until the face is just flush with the machined surface on the h...

Page 40: ...gure 8 Cartridge Seal Assembly This seal is not designed for operation at temperatures above 160 F 71 C Do not use at higher operating temperatures If the seal plate was removed install the seal plate gasket 5 Position the seal plate over the shaft and secure it to the bearing housing with the hard ware 7 and 8 To prevent damaging the shaft sleeve O ring 27 on the shaft threads stretch the O ring ...

Page 41: ... fully seated against the shaft shoulder see Figure 10 Measure the impeller to seal plate clearance and remove impeller adjusting shims to obtain the proper clearance as described in Impeller Instal lation and Adjustment If necessary to reuse an old seal in an emer gency carefully separate the rotating and station ary seal faces from the bellows retainer and sta tionary seat A new seal assembly sh...

Page 42: ...arance of 025 to 040 inch 0 64 to 1 02 mm between the impeller and the seal plate is recom mended for maximum pump efficiency Measure this clearance and add or remove impeller adjust ing shims as required NOTE Proceed with Rotating Assembly Installation be fore installing the impeller capscrew and washer 29 and 30 The rotating assembly must be in stalled in the pump casing in order to torque the i...

Page 43: ... the tapped screw holes in the back cover plate Secure the locking collars to the back cover plate with the hardware 11 and 13 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 11 and 13 Reinstall the back c...

Page 44: ...nstall the vented plug Maintain the oil at this level NOTE The white reflector in the sight gauge must be posi tioned horizontally to provide proper drainage Bearings Figure 4 The bearing housing was fully lubricated when shipped from the factory Check the oil level regu larly through the bearing cavity sight gauge 15 and maintain it at the middle of the gauge When lubrication is required add SAE ...

Page 45: ...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 ...