C OM-01824-OB02

October 2, 1990
Rev. C 10/11/02

INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST

U-SERIES PUMP

MODEL
MODELS

U6A60---B
JS4D20---E9.4 230V 3P
JS4D20---E9.4 230V 3P
JS4D20---E9.4 230V 3P
JS4D20---E9.4 230V 3P
INCLUDING: /F,JS4D20---E9.4
JS4D20---E9.4 230V 3P
/FM 230V 3P

THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
www.gormanrupp.com
eCopyright by the Gorman-Rupp Company
 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
POSITIONING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 2
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 2
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 2
SUCTION AND DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 2
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 --- 3
Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 3
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 3
Suction Lines In Sumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 3
Suction Line Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 4
DISCHARGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 4
Siphoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 4
Bypass Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 5
AUTOMATIC AIR RELEASE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 6
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 6
Air Release Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 7
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 7
Coupled Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 8
V-Belt Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B --- 8

OPERATION --- SECTION C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 1

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

STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 1
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 2
Lines With a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 2
Lines Without a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 2
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 2
Liquid Temperature And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 2
Strainer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 3
Pump Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 3
STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 3
Cold Weather Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 3
BEARING TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C --- 3

i
 TABLE OF CONTENTS
(continued)

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

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

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

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

PARTS LISTS:
Pump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 3
Repair Rotating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 5
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 6
Back Suction Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 6
Rotating Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 6
Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 8
Seal Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 8
Shaft and Bearing Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 8
Shaft and Bearing Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 9
Seal Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 10
Impeller Installation And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 13
Rotating Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 13
Back Suction Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 14
Final Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 14
PRESSURE RELIEF VALVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 14
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 15
Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 15
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 15
Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E --- 15

ii
 U SERIES OM -- 01824

INTRODUCTION

Thank You for purchasing a Gorman-Rupp pump. manual are performed only after establishing that
Read this manual carefully to learn how to safely neither operator safety nor pump integrity are com-
install and operate your pump. Failure to do so promised by the installation. Pumps and related
could result in personal injury or damage to the equipment must be installed and operated ac-
pump. cording to all national, local and industry stan-
dards.
This Installation, Operation, and Maintenance
manual is designed to help you achieve the best The following are used to alert maintenance per-
performance and longest life from your Gorman- sonnel to procedures which require special atten-
Rupp pump. tion, to those which could damage equipment, and
to those which could be dangerous to personnel:
This pump is a U Series, semi-open impeller, self-
priming centrifugal model with a suction check
valve. It is designed for high-efficiency distribution
of non-volatile, non-corrosive liquids containing
specified entrained solids. The basic material of
construction of wetted parts is cast iron, with duc- Immediate hazards which WILL result in
tile iron impeller and alloy steel impeller shaft. The severe personal injury or death. These
back cover is designed for straight-in suction, and instructions describe the procedure re-
is connected to a 6-inch extension pipe assembly quired and the injury which will result
by a shoulder-type, quick-disconnect coupling. from failure to follow the procedure.
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: Hazards or unsafe practices which
COULD result in severe personal injury
The Gorman-Rupp Company or death. These instructions describe
P.O. Box 1217 the procedure required and the injury
Mansfield, Ohio 44901-- 1217 which could result from failure to follow
Phone: (419) 755-- 1011 the procedure.
or:
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-- 2870
Hazards or unsafe practices which COULD
result in minor personal injury or product
For information or technical assistance on the or property damage. These instructions
power source, contact the power source manufac- describe the requirements and the possi-
turer’s local dealer or representative. ble damage which could result from failure
to follow the procedure.
Because pump installations are seldom identical,
this manual cannot possibly provide detailed in- NOTE
structions and precautions for every aspect of Instructions to aid in installation, operation,and
each specific application. Therefore, it is the re- maintenance, or which clarify a procedure.
sponsibility of the owner/installer of the pump to
ensure that applications not addressed in this

INTRODUCTION PAGE I -- 1
U SERIES OM -- 01824

SAFETY --- SECTION A

This information applies to U Series ba- not attempt to pump volatile, corrosive,
sic pumps. Gorman-Rupp has no con- or flammable materials, or any liquids
trol over or particular knowledge of the which may damage the pump or endan-
power source which will be used. Refer ger personnel as a result of pump fail-
to the manual accompanying the power ure.
source before attempting to begin
operation.
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and pre- After the pump has been installed, make
cautions for each specific application. certain that the pump and all piping con-
Therefore, it is the owner/installer’s re- nections are tight, properly supported
sponsibility to ensure that applications and secure before operation.
not addressed in this manual are per-
formed only after establishing that nei-
ther operator safety nor pump integrity
are compromised by the installation.
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-
Before attempting to open or service the jury to personnel.
pump:
1. Familiarize yourself with this man-
ual.
2. Disconnect or lock out the power
source to ensure that the pump will Do not operate the pump against a
remain inoperative. closed discharge valve for long periods
3. Allow the pump to completely cool of time. If operated against a closed dis-
if overheated. charge valve, pump components will
4. Check the temperature before deteriorate, and the liquid could come
opening any covers, plates, or to a boil, build pressure, and cause the
plugs. pump casing to rupture or explode.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau-
tiously.
7. Drain the pump.
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-
This pump is designed to handle most gaged to be ejected with great force. Al-
non-volatile, non-corrosive liquids con- low the pump to completely cool before
taining specified entrained solids. Do servicing.
SAFETY PAGE A -- 1
 OM -- 01824 U SERIES

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
Use lifting and moving equipment in piping must be removed from the pump
good repair and with adequate capacity before lifting.

PAGE A -- 2 SAFETY
U SERIES OM -- 01824

INSTALLATION --- SECTION B

Review all SAFETY information in Section A. specific application. Since the pressure supplied
to the pump is critical to performance and safety,
Since pump installations are seldom identical, this be sure to limit the incoming pressure to 50% of
section offers only general recommendations and the maximum permissible operating pressure as
practices required to inspect, position, and ar- shown on the pump performance curve.
range the pump and piping.
For further assistance, contact your Gorman-Rupp
Most of the information pertains to a standard
distributor or the Gorman-Rupp Company.
static lift application where the pump is posi-
tioned above the free level of liquid to be pumped.

If installed in a flooded suction application where Pump Dimensions

the liquid is supplied to the pump under pressure,
some of the information such as mounting, line See Figure 1 for the approximate physical dimen-
configuration, and priming must be tailored to the sions of this pump.

OUTLINE DRAWING

NOTE: OPTIONAL ASA OR DIN DISCHARGE SPOOL FLANGE AVAILABLE

Figure 1. Pump Model U6A60-B

INSTALLATION PAGE B -- 1
 OM -- 01824 U SERIES

PREINSTALLATION INSPECTION POSITIONING PUMP

The pump assembly was inspected and tested be- Lifting

fore shipment from the factory. Before installation,
inspect the pump for damage which may have oc- Use lifting equipment with a capacity of at least
curred during shipment. Check as follows: 5,000 pounds (2268 kg). This pump weighs ap-
proximately 1,000 pounds (453,6 kg), not includ-
a. Inspect the pump for cracks, dents, damaged ing the weight of accessories and base. Customer
threads, and other obvious damage. installed equipment such as suction and dis-
charge piping must be removed before attempting
b. Check for and tighten loose attaching hard- to lift.
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- The pump assembly can be seriously
tained in this manual or affixed to the pump, damaged if the cables or chains used to lift
and perform all duties indicated. Note the di- and move the unit are improperly wrapped
rection of rotation indicated on the pump. around the pump.
Check that the pump shaft rotates counter-
clockwise when facing the impeller. 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

Only operate this pump in the direction in- to provide for level operation or to eliminate vibra-
dicated by the arrow on the pump body tion.
and on the accompanying decal. Refer to
Rotation in Operation, Section C.
Clearance
d. Check levels and lubricate as necessary. Re-
fer to LUBRICATION in the MAINTENANCE The extension pipe assembly provided with this
AND REPAIR section of this manual and per- pump is integral to pump design and must be in
form duties as instructed. place when the pump is positioned. When installed
on the pump, the extension pipe assembly will pro-
vide an automatic clearance of 24 inches (610
e. If the pump and power source have been mm) in front of the back cover; this will permit re-
stored for more than 12 months, some of the moval of the rotating assembly through the back of
components or lubricants may have ex- the pump.
ceeded their maximum shelf life. These must
be inspected or replaced to ensure maxi-
mum pump service.
SUCTION AND DISCHARGE PIPING

If the maximum shelf life has been exceeded, or if Pump performance is adversely effected by in-
anything appears to be abnormal, contact your creased suction lift, discharge elevation, and fric-
Gorman-Rupp distributor or the factory to deter- tion losses. See the performance curve and oper-
mine the repair or updating policy. Do not put the ating range shown on Page E-1 to be sure your
pump into service until appropriate action has overall application allows pump to operate within
been taken. the safe operation range.

PAGE B -- 2 INSTALLATION
U SERIES OM -- 01824

Materials the source of the liquid being pumped; if the line

slopes down to the pump at any point along the
Either pipe or hose maybe used for suction and suction run, air pockets will be created.
discharge lines; however, the materials must be
compatible with the liquid being pumped. If hose is Fittings
used in suction lines, it must be the rigid-wall, rein-
forced type to prevent collapse under suction. Us- Suction lines should be the same size as the pump
ing piping couplings in suction lines is not recom- inlet. If reducers are used in suction lines, they
mended. should be the eccentric type, and should be in-
stalled with the flat part of the reducers uppermost
Line Configuration to avoid creating air pockets. Valves are not nor-
mally used in suction lines, but if a valve is used,
Keep suction and discharge lines as straight as install it with the stem horizontal to avoid air pock-
possible to minimize friction losses. Make mini- ets.
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. Strainers

If a strainer is furnished with the pump, be certain

Connections to Pump to use it; any spherical solids which pass through a
strainer furnished with the pump will also pass
Before tightening a connecting flange, align it ex- through the pump itself.
actly with the pump port. Never pull a pipe line into
place by tightening the flange bolts and/or cou- If a strainer is not furnished with the pump, but is
plings. installed by the pump user, make certain that the
total area of the openings in the strainer is at least
Lines near the pump must be independently sup- three or four times the cross section of the suction
ported to avoid strain on the pump which could line, and that the openings will not permit passage
cause excessive vibration, decreased bearing life, of solids larger than the solids handling capability
and increased shaft and seal wear. If hose-type of the pump.
lines are used, they should have adequate support
to secure them when filled with liquid and under This pump is designed to handle up to 1 1/4 inch
pressure. (31,8 mm) diameter spherical solids.

Gauges Sealing

Most pumps are drilled and tapped for installing Since even a slight leak will affect priming, head,
discharge pressure and vacuum suction gauges. If and capacity, especially when operating with a
these gauges are desired for pumps that are not high suction lift, all connections in the suction line
tapped, drill and tap the suction and discharge should be sealed with pipe dope to ensure an air-
lines not less than 18 inches (457,2 mm) from the tight seal. Follow the sealant manufacturer’s rec-
suction and discharge ports and install the lines. ommendations when selecting and applying the
Installation closer to the pump may result in erratic pipe dope. The pipe dope should be compatible
readings. with the liquid being pumped.

SUCTION LINES Suction Lines In Sumps

To avoid air pockets which could affect pump prim- If a single suction line is installed in a sump, it
ing, the suction line must be as short and direct as should be positioned away from the wall of the
possible. When operation involves a suction lift, the sump at a distance equal to 1 1/2 times the diame-
line must always slope upward to the pump from ter of the suction line.

INSTALLATION PAGE B -- 3
 OM -- 01824 U SERIES

If there is a liquid flow from an open pipe into the tance equal to at least 3 times the diameter of the
sump, the flow should be kept away from the suc- suction pipe.
tion inlet because the inflow will carry air down into
the sump, and air entering the suction line will re- Suction Line Positioning
duce pump efficiency.
The depth of submergence of the suction line is
If it is necessary to position inflow close to the suc- critical to efficient pump operation. Figure 2 shows
tion inlet, install a baffle between the inflow and the recommended minimum submergence vs. veloc-
suction inlet at a distance 1 1/2 times the diameter ity.
of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into
NOTE
The pipe submergence required may be reduced
the suction inlet.
by installing a standard pipe increaser fitting at the
end of the suction line. The larger opening size will
If two suction lines are installed in a single sump, reduce the inlet velocity. Calculate the required
the flow paths may interact, reducing the efficiency submergence using the following formula based
of one or both pumps. To avoid this, position the on the increased opening size (area or diameter).
suction inlets so that they are separated by a dis-

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

DISCHARGE LINES phoning action causing damage to the pump
could result.

Siphoning Valves

If a throttling valve is desired in the discharge line,

Do not terminate the discharge line at a level lower use a valve as large as the largest pipe to minimize
than that of the liquid being pumped unless a si- friction losses. Never install a throttling valve in a
phon breaker is used in the line. Otherwise, a si- suction line.

PAGE B -- 4 INSTALLATION
U SERIES OM -- 01824

With high discharge heads, it is recommended that must be secured against being drawn into
a throttling valve and a system check valve be in- the pump suction inlet.
stalled in the discharge line to protect the pump
from excessive shock pressure and reverse rota- It is also recommended that pipe unions be in-
tion when it is stopped. stalled at each 90_ elbow in a bypass line to ease
disassembly and maintenance.

In high discharge head applications (more than

30 feet), an excessive amount of liquid may be by-
passed and forced back to the wet well under the
If the application involves a high discharge full working pressure of the pump; this will reduce
head, gradually close the discharge overall pumping efficiency. Therefore, it is recom-
throttling valve before stopping the pump. mended that a Gorman-Rupp Automatic Air Re-
lease Valve be installed in the bypass line.
Bypass Lines Gorman-Rupp Automatic Air Release Valves are
reliable, and require minimum maintenance. See
Self-priming pumps are not air compressors. Dur- AUTOMATIC AIR RELEASE VALVE in this section
ing the priming cycle, air from the suction line must for installation and theory of operation of the Auto-
be vented to atmosphere on the discharge side. If matic Air Release Valve. Consult your Gorman-
the discharge line is open, this air will be vented Rupp distributor, or contact the Gorman-Rupp
through the discharge. However, if a check valve Company for selection of an Automatic Air Release
has been installed in the discharge line, the dis- Valve to fit your application.
charge side of the pump must be opened to atmos-
pheric pressure through a bypass line installed be- If the installation involves a flooded suction such as
tween the pump discharge and the check valve. A a below-ground lift station. A pipe union and manu-
self-priming centrifugal pump will not prime if al shut-off valve may be installed in the bleed line to
there is sufficient static liquid head to hold the dis- allow service of the valve without shutting down the
charge check valve closed. station, and to eliminate the possibility of flooding.
If a manual shut-off valve is installed anywhere in
NOTE the air release piping, it must be a full-opening ball
The bypass line should be sized so that it does not type valve to prevent plugging by solids.
affect pump discharge capacity; however, the by-
pass line should be at least 1 inch in diameter to
minimize the chance of plugging.

In low discharge head applications (less than 30

If a manual shut-off valve is installed in
feet), it is recommended that the bypass line be run a bypass line, it must not be left closed
back to the wet well, and located 6 inches below during operation. A closed manual shut-
the water level or cut-off point of the low level off valve may cause a pump which has
pump. In some installations, this bypass line may
lost prime to continue to operate with-
be terminated with a six-to-eight foot length of 1 1/4
inch I.D. smooth-bore hose; air and liquid vented
out reaching prime, causing dangerous
during the priming process will then agitate the overheating and possible explosive
hose and break up any solids, grease, or other rupture of the pump casing. Personnel
substances likely to cause clogging. could be severely injured.

Allow an over-heated pump to cool be-

fore servicing. Do not remove plates,
covers, gauges, or fittings from an over-
A bypass line that is returned to a wet well heated pump. Liquid within the pump
INSTALLATION PAGE B -- 5
 OM -- 01824 U SERIES

can reach boiling temperatures, and va-

por pressure within the pump can cause
parts being disengaged to be ejected
with great force. After the pump cools,
drain the liquid from the pump by re-
moving the casing drain plug. Use cau-
tion when removing the plug to prevent
injury to personnel from hot liquid.

Figure 4. Valve in Closed Position

AUTOMATIC AIR RELEASE VALVE When the pump is fully primed, pressure resulting
from flow against the valve diaphragm com-
presses the spring and closes the valve (Figure 4).
The valve will remain closed, reducing the bypass
When properly installed and correctly adjusted to of liquid to 1 to 5 gallons per minute, until the pump
the specific hydraulic operating conditions of the loses its prime or stops.
application, the Gorman-Rupp Automatic Air Re-
lease Valve will permit air to escape through the by-
pass line, and then close automatically when the
pump is fully primed and pumping at full capacity.

Some leakage (1 to 5 gallons per min-

ute) will occur when the valve is fully
Theory of Operation closed. Be sure the bypass line is di-
rected back to the wet well or tank to
prevent hazardous spills.
Figures 3 and 4 show a cross-sectional view of the
Automatic Air Release Valve, and a corresponding
When the pump shuts down, the spring returns the
description of operation.
diaphragm to its original position. Any solids that
may have accumulated in the diaphragm chamber
settle to the bottom and are flushed out during the
next priming cycle.

NOTE
The valve will remain open if the pump does not
reach its designed capacity or head. Valve closing
pressure is dependent upon the discharge head of
the pump at full capacity. The range of the valve
closing pressure is established by the tension rate
of the spring as ordered from the factory. Valve clos-
ing pressure can be further adjusted to the exact
system requirements by moving the spring retain-
Figure 3. Valve in Open Position ing pin up or down the plunger rod to increase or
decrease tension on the spring. Contact your Gor-
man-Rupp distributor or the Gorman-Rupp Compa-
During the priming cycle, air from the pump casing ny for information about an Automatic Air Release
flows through the bypass line, and passes through Valve for your specific application.
the Air Release Valve to the wet well (Figure 3).

PAGE B -- 6 INSTALLATION
U SERIES OM -- 01824

Air Release Valve Installation NOTE

The Automatic Air Release Valve must be inde- If the Air Release Valve is to be installed on a staged
pendently mounted in a horizontal position and pump application, contact the factory for specific
connected to the discharge line of the self-priming installation instructions.
centrifugal pump (see Figure 5).

DISCHARGE PIPE
CLEAN-OUT
COVER

INSTALL AIR RELEASE VALVE

IN HORIZONTAL POSITION
DISCHARGE
CHECK VALVE
90_ LONG
RADIUS
ELBOW

SUPPORT PUMP DISCHARGE

BRACKET

SELF-PRIMING
CENTRIFUGAL
PUMP
BLEED LINE 1”
(25,4 MM) DIA. MIN.
(CUSTOMER
FURNISHED)
EXTEND 6” SUCTION
(152,4 MM) LINE
BELOW LIQUID
LEVEL SURFACE

WET WELL
OR SUMP

Figure 5. Typical Automatic Air Release Valve Installation

The valve inlet line must be installed between the manifold pipe. Contact your Gorman-Rupp distrib-
pump discharge port and the non-pressurized side utor or the Gorman-Rupp Company for information
of the discharge check valve. The valve inlet is at about installation of an Automatic Air Release Valve
the large end of the valve body, and is provided for your specific application.
with standard 1 inch NPT pipe threads.

The valve outlet is located at the opposite end of

ALIGNMENT
the valve, and is also equipped with standard 1
inch NPT pipe threads. The outlet should be con-
The alignment of the pump and its power source is
nected to a bleed line which slopes back to the wet
critical for trouble-free mechanical operation. In
well or sump. The bleed line must be the same size
either a flexible coupling or V-belt driven system,
as the inlet piping, or larger. If piping is used for the
the driver and pump must be mounted so that their
bleed line, avoid the use of elbows whenever pos-
shafts are aligned with and parallel to each other. It
sible.
is imperative that alignment be checked after the
pump and piping are installed, and before opera-
NOTE tion.
It is recommended that each Air Release Valve be
fitted with an independent bleeder line directed NOTE
back to the wet well. If multiple Air Release Valves Check Rotation, Section C, before final alignment
are installed in a system, they must be fitted with in- of the pump.
dependent bleeder lines; never use a common

INSTALLATION PAGE B -- 7
 OM -- 01824 U SERIES

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 checked and realigned before operation.
Before checking alignment, tighten the foundation
bolts. The pump casing feet and/or pedestal feet,
and the driver mounting bolts should also be tightly
secured.
Figure 6A. Aligning Spider-Type Couplings

When checking alignment, disconnect

the power source to ensure that the
pump will remain inoperative.

Adjusting the alignment in one direction Figure 6B. Aligning Non-Spider

may alter the alignment in another direc- Type Couplings
tion. Check each procedure after altering
alignment. Align non-spider type couplings by using a feeler
gauge or taper gauge between the coupling halves
every 90 degrees. The coupling is in alignment
Coupled Drives when the hubs are the same distance apart at all
points (see Figure 6B).

Check parallel adjustment by laying a straightedge

When using couplings, the axis of the power
across both coupling rims at the top, bottom, and
source must be aligned to the axis of the pump
side. When the straightedge rests evenly on both
shaft in both the horizontal and vertical planes.
halves of the coupling, the coupling is in horizontal
Most couplings require a specific gap or clearance
parallel alignment. If the coupling is misaligned,
between the driving and the driven shafts. Refer to
use a feeler gauge between the coupling and the
the coupling manufacturer’s service literature.
straightedge to measure the amount of misalign-
ment.
Align spider insert type couplings by using calipers
to measure the dimensions on the circumference V-Belt Drives
of the outer ends of the coupling hub every 90 de-
grees. The coupling is in alignment when the hub When using V-belt drives, the power source and
ends are the same distance apart at all points (see the pump must be parallel. Use a straightedge
Figure 6A). along the sides of the pulleys to ensure that the pul-

PAGE B -- 8 INSTALLATION
U SERIES OM -- 01824

leys are properly aligned (see Figure 6C). In drive Tighten the belts in accordance with the belt manu-
systems using two or more belts, make certain that facturer’s instructions. If the belts are too loose,
the belts are a matched set; unmatched sets will they will slip; if the belts are too tight, there will be
cause accelerated belt wear. excessive power loss and possible bearing failure.
Select pulleys that will match the proper speed ra-
tio; overspeeding the pump may damage both
pump and power source.

Do not operate the pump without the

shield and/or guard in place over the ro-
tating parts. Exposed rotating parts can
MISALIGNED:
SHAFTS
MISALIGNED: ALIGNED: SHAFTS catch clothing, fingers, or tools, causing
SHAFTS PARALLEL AND
NOT PARALLEL NOT IN LINE SHEAVES IN LINE severe injury to personnel.
Figure 6C. Alignment of V-Belt Driven Pumps

INSTALLATION PAGE B -- 9
U-SERIES OM -- 01824

OPERATION --- SECTION C

Review all SAFETY information in Section A. Add liquid to the pump casing when:
1. The pump is being put into service for the
Follow the instructions on all tags, labels and de- first time.
cals attached to the pump. 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 has been filled, the pump will
This pump is designed to handle most prime and reprime as necessary.
non-volatile, non-corrosive liquids,
containing specified entrained solids.
Do not attempt to pump volatile, corro-
sive, or flammable materials, or any liq-
uids which may damage the pump or en- After filling the pump casing, reinstall
danger personnel as a result of pump and tighten the fill plug. Do not attempt
failure. to operate the pump unless all connect-
ing piping is securely installed. Other-
wise, liquid in the pump forced out un-
der pressure could cause injury to per-
sonnel.
Pump speed and operating conditions To fill the pump, remove the pump casing fill cover
must be within the performance range or fill plug in the top of the casing, and add clean
shown on Page E-1. liquid until the casing is filled. Replace the fill cover
or fill plug before operating the pump.

PRIMING
NOTE
There is a threaded passage through the interior
Install the pump and piping as described in IN- wall of the pump casing just in front of the blind
STALLATION. Make sure that the piping connec- flange at the back of the pump. This passage is de-
tions are tight, and that the pump is securely signed to equalize pressure in the casing when the
mounted. Check that the pump is properly lubri- pump is in operation, and must be kept clear.
cated (see LUBRICATION in MAINTENANCE
AND REPAIR).
STARTING
This pump is self-priming, but the pump should
never be operated unless there is liquid in the Consult the operations manual furnished with the
pump casing. power source.

Starting procedures will vary slightly depending on

the pump application, type of priming device, and
type of drive.

Never operate this pump unless there is Rotation

liquid in the pump casing. The pump will
not prime when dry. Extended operation of The correct direction of pump rotation is counter-
a dry pump will destroy the seal assembly. clockwise when facing the impeller. The pump

OPERATION PAGE C -- 1
OM -- 01824 U-SERIES

could be damaged and performance adversely af- pressure, and cause the pump casing to
fected by incorrect rotation. If pump performance rupture or explode.
is not within the specified limits (see the curve on
page E-1), check the direction of power source ro- Leakage
tation before further troubleshooting.
No leakage should be visible at pump mating sur-
OPERATION faces, or at pump connections or fittings. Keep all
line connections and fittings tight to maintain maxi-
mum pump efficiency.
Lines With a Bypass
Liquid Temperature And Overheating
If a Gorman-Rupp Automatic Air Release Valve has
been installed, the valve will automatically open to The maximum liquid temperature for this pump is
allow the pump to prime, and automatically close 160_ F (71_ C). Do not apply it at a higher operat-
after priming is complete (see INSTALLATION for ing temperature.
Air Release Valve operation).
Overheating can occur if operated with the valves
If the bypass line is open, air from the suction line in the suction or discharge lines closed. Operating
will be discharged through the bypass line back to against closed valves could bring the liquid to a
the wet well during the priming cycle. Liquid will boil, build pressure, and cause the pump to rup-
then continue to circulate through the bypass line ture or explode. If overheating occurs, stop the
while the pump is in operation. pump and allow it to cool before servicing it. Refill
the pump casing with cool liquid.

Lines Without a Bypass

Open all valves in the discharge line and start the

power source. Priming is indicated by a positive
reading on the discharge pressure gauge or by a Allow an over-heated pump to cool be-
quieter operation. The pump may not prime imme- fore servicing. Do not remove plates,
diately because the suction line must first fill with covers, gauges, or fittings from an over-
liquid. If the pump fails to prime within five minutes, heated pump. Liquid within the pump
stop it and check the suction line for leaks. can reach boiling temperatures, and va-
por pressure within the pump can cause
After the pump has been primed, partially close the parts being disengaged to be ejected
discharge line throttling valve in order to fill the line with great force. After the pump cools,
slowly and guard against excessive shock pres- drain the liquid from the pump by re-
sure which could damage pipe ends, gaskets, moving the casing drain plug. Use cau-
sprinkler heads, and any other fixtures connected tion when removing the plug to prevent
to the line. When the discharge line is completely
injury to personnel from hot liquid.
filled, adjust the throttling valve to the required flow
rate. As a safeguard against rupture or explosion due to
heat, this pump is equipped with a pressure relief
valve which will open if vapor pressure within the
pump casing reaches a critical point. If overheating
does occur, stop the pump immediately and allow
it to cool before servicing it. Approach any over-
Do not operate the pump against a heated pump cautiously. It is recommended that
closed discharge throttling valve for the pressure relief valve assembly be replaced at
long periods of time. If operated against each overhaul, or any time the pump casing over-
a closed discharge throttling valve, heats and activates the valve. Never replace this
pump components will deteriorate, and valve with a substitute which has not been speci-
the liquid could come to a boil, build fied or provided by the Gorman-Rupp Company.

PAGE C -- 2 OPERATION
U-SERIES OM -- 01824

Strainer Check head, gradually close the discharge throt-

tling valve before stopping the pump.
If a suction strainer has been shipped with the
pump or installed by the user, check the strainer After stopping the pump, disconnect or lock out
regularly, and clean it as necessary. The strainer the power source to ensure that the pump will re-
should also be checked if pump flow rate begins to main inoperative.
drop. If a vacuum suction gauge has been in-
stalled, monitor and record the readings regularly
Cold Weather Preservation
to detect strainer blockage.

Never introduce air or steam pressure into the In below freezing conditions, drain the pump to
pump casing or piping to remove a blockage. This prevent damage from freezing. Also, clean out any
could result in personal injury or damage to the solids by flushing with a hose. Operate the pump
equipment. If backflushing is absolutely neces- for approximately one minute; this will remove any
sary, liquid pressure must be limited to 50% of the remaining liquid that could freeze the pump rotat-
maximum permissible operating pressure shown ing parts. If the pump will be idle for more than a
on the pump performance curve. few hours, or if it has been pumping liquids con-
taining a large amount of solids, drain the pump,
Pump Vacuum Check and flush it thoroughly with clean water. To prevent
large solids from clogging the drain port and pre-
With the pump inoperative, install a vacuum gauge venting the pump from completely draining, insert
in the system, using pipe dope on the threads. a rod or stiff wire in the drain port, and agitate the
Block the suction line and start the pump. At oper- liquid during the draining process. Clean out any
remaining solids by flushing with a hose.
ating speed the pump should pull a vacuum of 20
inches ((508,0 mm) or more of mercury. If it does
not, check for air leaks in the seal, gasket, or dis- BEARING TEMPERATURE CHECK
charge valve.
Bearings normally run at higher than ambient tem-
Open the suction line, and read the vacuum gauge
peratures because of heat generated by friction.
with the pump primed and at operation speed.
Temperatures up to 160_F (71_ C) are considered
Shut off the pump. The vacuum gauge reading will
normal for bearings, and they can operate safely to
immediately drop proportionate to static suction
at least 180_F (82_ C).
lift, and should then stabilize. If the vacuum reading
falls off rapidly after stabilization, an air leak exists.
Checking bearing temperatures by hand is inaccu-
Before checking for the source of the leak, check
rate. Bearing temperatures can be measured ac-
the point of installation of the vacuum gauge.
curately by placing a contact-type thermometer
against the housing. Record this temperature for
STOPPING future reference.

Never halt the flow of liquid suddenly. If the liquid A sudden increase in bearing temperature is a
being pumped is stopped abruptly, damaging warning that the bearings are at the point of failing
shock waves can be transmitted to the pump and to operate properly. Make certain that the bearing
piping system. Close all connecting valves slowly. lubricant is of the proper viscosity and at the cor-
rect level (see LUBRICATION in MAINTENANCE
On engine driven pumps, reduce the throttle
AND REPAIR). Bearing overheating can also be
speed slowly and allow the engine to idle briefly be- caused by shaft misalignment and/or excessive vi-
fore stopping. bration.

When pumps are first started, the bearings may

seem to run at temperatures above normal. Con-
tinued operation should bring the temperatures
If the application involves a high discharge down to normal levels.

OPERATION PAGE C -- 3
U SERIES OM -- 01824

TROUBLESHOOTING --- SECTION D

Review all SAFETY information in Section A.

Before attempting to open or service the

pump:
1. Familiarize yourself with this manual.
2. Lock out or disconnect the power
source to ensure that the pump will
remain inoperative.
3. Allow the pump to completely cool if
overheated.
4. Check the temperature before open-
ing any covers, plates, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO Not enough liquid in casing. Add liquid to casing. See PRIM-
PRIME ING.
Suction check valve contaminated or Clean or replace check valve.
damaged.
Air leak in suction line. Correct leak.
Lining of suction hose collapsed. 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.

PUMP STOPS OR Air leak in suction line. Correct leak.

FAILS TO DELIVER
RATED FLOW OR Lining of suction hose collapsed. Replace suction hose.
PRESSURE Leaking or worn seal or pump gasket. Check pump vacuum. Replace
leaking or worn seal or gasket.
Strainer clogged. Check strainer and clean if neces-
sary.

TROUBLESHOOTING PAGE D -- 1
 OM -- 01824 U SERIES

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP STOPS OR Suction intake not submerged at Check installation and correct sub-
FAILS TO DELIVER proper level or sump too small. mergence as needed.
RATED FLOW OR
PRESSURE (cont.) Impeller or other wearing parts worn Replace worn or damaged parts.
or damaged. Check that impeller is properly
centered and rotates freely.

Impeller clogged. Free impeller of debris.

Pump speed too slow. Check driver output; check belts

or couplings for slippage.
Discharge head too high. Install bypass line.
Suction lift too high. Measure lift w/vacuum gauge. Re-
duce lift and/or friction losses in
suction line.

PUMP REQUIRES Pump speed too high. Check driver output; check that
TOO MUCH sheaves or couplings are cor-
POWER
rectly sized.

Discharge head too low. Adjust discharge valve.

Liquid solution too thick. Dilute if possible.

Bearing(s) frozen. Disassemble pump and check

bearing(s).

PUMP CLOGS Liquid solution too thick. Dilute if possible.

FREQUENTLY
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 Clean valve.

clogged or binding.

EXCESSIVE NOISE Cavitation in pump. Reduce suction lift and/or friction

losses in suction line. Record vac-
uum and pressure gauge readings
and consult local representative or
factory.

Pumping entrained air. Locate and eliminate source of air

bubble.
Pump or drive not securely mounted. Secure mounting hardware.

Impeller clogged or damaged. Clean out debris; replace dam-

aged parts.

PAGE D -- 2 TROUBLESHOOTING
U SERIES OM -- 01824

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

BEARINGS RUN Bearing temperature is high, but Check bearing temperature regu-
TOO HOT within limits. larly to monitor any increase.
Low or incorrect lubricant. Check for proper type and level of
lubricant.

Suction and discharge lines not Check piping installation for

properly supported. proper support.
Drive misaligned. Align drive properly.

PREVENTIVE MAINTENANCE equipped) between regularly scheduled inspec-

tions can indicate problems that can be corrected
Since pump applications are seldom identical, and before system damage or catastrophic failure oc-
pump wear is directly affected by such things as curs. The appearance of wearing parts should also
the abrasive qualities, pressure and temperature be documented at each inspection for comparison
of the liquid being pumped, this section is intended as well. Also, if records indicate that a certain part
only to provide general recommendations and (such as the seal) fails at approximately the same
practices for preventive maintenance. Regardless duty cycle, the part can be checked and replaced
of the application however, following a routine pre- before failure occurs, reducing unscheduled down
ventive maintenance schedule will help assure time.
trouble-free performance and long life from your
Gorman-Rupp pump. For specific questions con-
For new applications, a first inspection of wearing
cerning your application, contact your Gorman-
parts at 250 hours will give insight into the wear rate
Rupp distributor or the Gorman-Rupp Company.
for your particular application. Subsequent inspec-
Record keeping is an essential component of a tions should be performed at the intervals shown
good preventive maintenance program. Changes on the chart below. Critical applications should be
in suction and discharge gauge readings (if so inspected more frequently.

TROUBLESHOOTING PAGE D -- 3
 OM -- 01824 U SERIES

Preventive Maintenance Schedule

Service Interval*
Item Daily Weekly Monthly Semi- Annually
Annually
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.) I
Pump Performance (Gauges, Speed, Flow) I
Bearing Lubrication I R
Seal Lubrication (And Packing Adjustment,
If So Equipped) I R
V-Belts (If So Equipped) I
Air Release Valve Plunger Rod (If So Equipped) I C
Front Impeller Clearance (Wear Plate) I
Rear Impeller Clearance (Seal Plate) I
Check Valve I
Pressure Relief Valve (If So Equipped) C
Pump and Driver Alignment I
Shaft Deflection I
Bearings I
Bearing Housing I
Piping I
Driver Lubrication --- See Mfgr’s Literature

Legend:
I = Inspect, Clean, Adjust, Repair or Replace as Necessary
C = Clean
R = Replace
* Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually.
Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.

PAGE D -- 4 TROUBLESHOOTING
U SERIES OM -- 01824

PUMP MAINTENANCE AND REPAIR --- SECTION E

MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPER-
ATING PERFORMANCE.

STANDARD PERFORMANCE FOR PUMP MODEL U6A60-B

Based on 70_ F (21_ C) clear water at sea level Contact the Gorman-Rupp Company to verify per-
with minimum suction lift. Since pump installations formance or part numbers.
are seldom identical, your performance may be dif-
ference due to such factors as viscosity, specific
gravity, elevation, temperature, and impeller trim.

Pump speed and operating condition

If your pump serial number is followed by an “N”, points must be within the continuous per-
your pump is NOT a standard production model. formance range shown on the curve.

MAINTENANCE & REPAIR PAGE E -- 1

 OM -- 01824 U SERIES

SECTION DRAWING

FILL COVER VIEW

PRESSURE EQUALIZING
PASSAGE - KEEP OPEN

Figure 1. Pump Model U6A60---B

PAGE E -- 2 MAINTENANCE & REPAIR
U SERIES OM -- 01824

PARTS LIST
Pump Model U6A60---B
(From S/N 958132 up)

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 part numbers.

ITEM PART NAME PART MAT’L QTY ITEM PART NAME PART MAT’L QTY
NO. NUMBER CODE NO. NUMBER CODE

1 PUMP CASING 38222--- 703 10000 1 43 --- EXTENSION PIPE 31673--- 011 15070 1
2 [ REPAIR ROTATING ASSY 44163--- 133 (FIG. 2) 1 44 SUCTION STICKER 6588AG --- --- --- 1
3 PIPE PLUG P04 15079 1 45 PRESS RELIEF VALVE 26662--- 006 --- --- --- 1
4 HEX HD CAPSCREW B1208 15991 8 46 ACCESSORY PLUG P08 15079 1
5 LOCKWASHER J12 15991 8 47 HEX HD CAPSCREW B1208 15991 8
6 DISCHARGE STICKER 6588BJ --- --- --- 1 48 LOCKWASHER J12 15991 8
7 DISCHARGE FLANGE 1758 10010 1 49 BLIND FLANGE ASSY 42111--- 349 --- --- --- 1
8 DISCH FLANGE GSKT 1679G 19370 1 50 --- 6” BLIND FLANGE NOT AVAILABLE 1
9 NAME PLATE 38818--- 026 13990 1 51 --- WARNING PLATE 2613EV 13990 1
10 DRIVE SCREW BM#04--- 03 17000 4 52 --- DRIVE SCREW BM#04--- 03 17000 4
11 ROT ASSY SHIM SET 48261--- 056 --- --- --- 6 53 BLIND FLANGE GSKT 25113--- 036 --- --- --- 1
12 CASING RING 31281--- 047 15020 1
13 HEX HD CAPSCREW B0806 15991 6 NOT SHOWN:
14 LOCKWASHER J08 15991 6 FILL HR TO PRIME STK 6588AH --- --- --- 1
15 HEX HD CAPSCREW B0805 15991 6 INSTRUCTION DECAL 11421 --- --- --- 1
16 LOCKWASHER J08 15991 6 INSTRUCTION LABEL 2316DK --- --- --- 1
17 FILL CVR PLT ASSY 42111--- 344 --- --- --- 1 WARNING DECAL 2613FE --- --- --- 1
18 --- COVER PLATE NOT AVAILABLE 1 WARNING DECAL 38816--- 302 --- --- --- 1
19 --- DRIVE SCREW BM#04--- 03 17000 2
20 --- WARNING PLATE 38816--- 097 13990 1 OPTIONAL:
21 --- FILL COVER GSKT 50G 19210 1 /F DISCHARGE FLANGE 11402B 10010 1
22 CLAMP BAR SCREW 31912--- 009 15000 1 /FM METRIC FLANGE:
23 MACHINE BOLT A1014 15991 2 --- SUCTION/DISCHARGE 38642--- 503 10000 2
24 CLAMP BAR 38111--- 004 11010 1 DISASSEMBLY TOOL 12858 --- --- --- 1
25 PIPE PLUG P04 15079 1 ADI WEAR PLATE 46451--- 740 --- --- --- 1
26 ROTATION DECAL 2613M --- --- --- 1
27 ROT ASSY O --- RING 25152--- 453 --- --- --- 1 316 SST OPTION KIT:
28 CASING DRAIN PLUG P16 10009 2 --- IMPELLER 38618--- 016 17040 1
29 SEAL PLATE O-RING 25152--- 381 --- --- --- 1 --- SEAL PLATE 38272--- 408 17040 1
30 WEAR PLATE ASSY 46451--- 737 --- --- --- 1 --- WEAR PLATE 46451--- 741 --- --- --- 1
31 WEAR PLATE O --- RING 25152--- 381 --- --- --- 1 --- PRESS RELIEF VALVE 46431--- 803 --- --- --- 1
32 LOCKWASHER J06 15991 4
33 HEX NUT D06 15991 4 CASING HEATERS:
34 BACK COVER O --- RING S1676 --- --- --- 1 --- 120V 47811--- 060 --- --- --- 1
35 BACK CVR DRAIN PLUG P08 15079 1 --- 240V 47811--- 061 --- --- --- 1
PRESS RELIEF VALVE:
36 SUCT BACK COVER 38243--- 444 10010 1
--- BRASS SEWAGE TYPE 46431--- 628 --- --- --- 1
37 STUD C1211 15991 2
38 LOCKWASHER J12 15991 2
AIR RELEASE VALVES:
39 HEX NUT D12 15991 2
40 VICTAULIC COUPLING S1562 --- --- --- 1 --- 10# COMP SPRING GRP33--- 07A --- --- --- 1
41 EXTENSION PIPE ASSY 46351--- 021 --- --- --- 1 --- 25# COMP SPRING GRP33--- 07 --- --- --- 1
42 --- SUCT FLANGE 1758 10010 1 --- 80# COMP SPRING GRP33--- 07B --- --- --- 1

INDICATES PARTS RECOMMENDED FOR STOCK

[ REPAIR ROTATING ASSEMBLY SHIPPED DRY OF LUBRICANT.

REFER TO LUBRICATION IN THIS SECTION FOR SPECIFICATIONS.

MAINTENANCE & REPAIR PAGE E -- 3

 OM -- 01824 U SERIES

SECTION DRAWING

DRIVE END VIEW

Figure 2. 44163---133 Repair Rotating Assembly

PAGE E -- 4 MAINTENANCE & REPAIR
U SERIES OM -- 01824

PARTS LIST
44163---133 Repair Rotating Assembly

ITEM PART MAT’L

NO. PART NAME NUMBER CODE QTY
1 IMPELLER 38618---016 11010 1
2 SEAL ASSEMBLY 46513---154 --- --- --- 1
3 SEAL PLATE 38272---408 10010 1
4 SEAL PLATE GSKT 12350G 20000 1
5 INBOARD OIL SEAL S1917 --- --- --- 1
6 HEX HD CAPSCREW B1006 15991 4
7 LOCKWASHER J10 15991 4
8 BEARING HOUSING 38251---407 10000 1
9 INBOARD BALL BEARING 23421---461 --- --- --- 1
10 VENTED SEAL CAVITY PLUG 4823A 15079 1
11 BRG HOUSING AIR VENT S1530 --- --- --- 1
12 OUTBOARD OIL SEAL S1917 --- --- --- 1
13 REDUCER PIPE BUSHING AP0802 15079 1
14 HEX HD CAPSCREW B0605 1/2 15991 6
15 LOCKWASHER J06 15991 6
16 BEARING CAP 38322---415 10010 1
17 IMPELLER SHAFT KEY N0612 15990 1
18 IMPELLER SHAFT 38515---579 16000 1
19 RETAINING RING S215 --- --- --- 1
20 OIL LEVEL SIGHT GAUGE S1471 --- --- --- 1
21 PIPE PLUG P12 15079 1
22 SEAL CAVITY DRAIN PLUG P08 15079 1
23 BEARING CAVITY DRAIN PLUG P08 15079 1
24 BEARING CAP O-RING S333 --- --- --- 1
25 OUTBOARD BALL BEARING 23422---412 --- --- --- 1
26 IMPELLER SHIM SET 5091 17090 REF
27 SHAFT SLEEVE O-RING 25154---026 --- --- --- REF
28 IMPELLER WASHER 10278 15030 1
29 IMPELLER CAPSCREW DM1004S 15991 1
30 SEAL PLATE O-RING 25152---381 --- --- --- 1
31 ROTATING ASSEMBLY O-RING 25152---453 --- --- --- 1
32 SHIPPING PLUG 11495B 15079 1
33 SHIPPING PLUG 11495B 15079 1

NOT SHOWN:
ADJ SHIM SET 48261---056 --- --- --- 6
ROTATION DECAL 2613M --- --- --- 1
INSTRUCTION TAG 6588U --- --- --- 1

OPTIONAL:
n KALREZr METAL BELLOWS SEAL ASSY 46512---185 --- --- --- 1
PERMALON COATED SEAL 46512---189 --- --- --- 1
ADI REPAIR ROTATING ASSY 44163---232 --- --- --- 1
ADI IMPELLER 38618---016 1102H 1
ADI SEAL PLATE 38272---408 1102H 1
SST IMPELLER WASHER 10278 17090 1
SST IMPELLER CAPSCREW DM1004S 17090 1

INDICATES PARTS RECOMMENDED FOR STOCK

n KALREZr AND VITONt ARE PRODUCTS OF THE DUPONT CORP

MAINTENANCE & REPAIR PAGE E -- 5

OM -- 01824 U SERIES

PUMP AND SEAL DISASSEMBLY 2. Disconnect or lock out the power

AND REASSEMBLY source to ensure that the pump will
remain inoperative.
Review all SAFETY information in Section A. 3. Allow the pump to completely cool
if overheated.
Follow the instructions on all tags, label and de- 4. Check the temperature before
cals attached to the pump. opening any covers, plates, or
plugs.
This pump requires little service due to its rugged,
5. Close the suction and discharge
minimum-maintenance design. However, if it be-
comes necessary to inspect or replace the wearing valves.
parts, follow these instructions which are keyed to 6. Vent the pump slowly and cau-
the sectional views (see Figures 1 and 2) and the tiously.
accompanying parts lists. 7. Drain the pump.
As described on the following pages, this manual
will alert personnel to known procedures which re-
quire special attention, to those which could dam-
age equipment, and to those which could be dan-
Use lifting and moving equipment in
gerous to personnel. However, this manual cannot
good repair and with adequate capacity
possibly anticipate and provide detailed precau-
tions for every situation that might occur during
to prevent injuries to personnel or dam-
maintenance of the unit. Therefore, it is the respon-
age to equipment. Suction and dis-
sibility of the owner/maintenance personnel to en- charge hoses and piping must be re-
sure that only safe, established maintenance pro- moved from the pump before lifting.
cedures are used, and that any procedures not ad-
Back Suction Cover Removal
dressed in this manual are performed only after es-
tablishing that neither personal safety nor pump in- (Figure 1)
tegrity are compromised by such practices. The wear plate (30) may be serviced by removing
the back suction cover (36). Before attempting to
Most service functions may be performed by drain-
service the pump, remove the pump casing and
ing the pump, disconnecting the suction piping
back cover drain plugs (28 and 35) and drain the
and removing the back suction cover. If major re-
pump. Clean and reinstall the drain plugs. Discon-
pair is required, the piping and/or power source
nect the extension pipe assembly (41) at the vic-
must be disconnected. The following instructions
taulic coupling (40).
assume complete disassembly is required.
Remove the hardware (38 and 39) and pull the
Before attempting to service the pump, disconnect back suction cover (36) and assembled wear plate
or lock out the power source to ensure that it will (30) from the pump casing (1). Inspect the wear
remain inoperative. Close all valves in the suction plate, and replace it if badly scored and worn. To
and discharge lines. remove the wear plate, disengage the hardware
(32 and 33) securing it to the back suction cover.
Inspect the wear plate O-ring (31) and the back
suction cover O-ring (34) and replace them if dam-
aged or worn.

Before attempting to open or service the Rotating Assembly Removal

pump: (Figure 2)
1. Familiarize yourself with this man- The rotating assembly may be removed from either
ual. side of the pump casing (1, Figure 1); however, it is

PAGE E -- 6 MAINTENANCE & REPAIR

U SERIES OM -- 01824

recommended that it be removed through the wise direction (when facing the drive end of the
back cover opening. shaft). Use caution not to damage the shaft or key-
way. When the impeller breaks loose, remove the
The impeller (1) should be loosened while the rotat- lathe dog and wood block.
ing assembly is still secured to the pump casing.
Before loosening the impeller, remove the seal cav- NOTE
ity drain plug (22) and drain the seal lubricant. This Do not remove the impeller until the rotating assem-
will prevent the oil in the seal cavity from escaping bly has been removed from the pump casing.
as the impeller is loosened. Clean and reinstall the
seal cavity drain plug.
(Figure 1)
Immobilize the impeller by wedging a block of
Remove the inner hardware (15 and 16) from the
wood between the vanes, and remove the impeller
pump casing ring (12). Install three of the inner
capscrew and washer (28 and 29).
capscrews in the jacking holes in the casing, and
Install a lathe dog on the drive end of the shaft (18) use them to press the rotating assembly into the
with the “V” notch positioned over the shaft key- pump casing until the bearing housing is free.
way.
Remove the jacking screws from the casing ring.
Remove the outer hardware (13 and 14) and shim
Turn sets (11). Separate the casing ring from the pump
Counterclockwise
casing. Tie and tag the shim sets for ease of reas-
sembly.

An optional disassembly tool for removing and in-

stalling the rotating assembly is available from the
Lathe Dog Arm
factory. If the removal tool is used, follow the direc-
tions packaged with it. If improvised tools are used,
be sure they are heavy enough for safe use and will
“V” Notch not damage the pump.
Heavy
Bar Stock Shaft Key
After the rotating assembly is loosened, screw a
Impeller Shaft
5/8-18 UNF X 16 inch long threaded rod into the
Lathe Dog tapped hole in the impeller shaft. Support the drive
end of the shaft with another set of handles or a
Setscrew
length of pipe (1 13/16” (46 mm) minimum I.D.) and
Figure 3. Loosening Impeller slide the complete rotating assembly through the
back cover opening as shown in Figure 4. Once
With the impeller rotation still blocked, see Figure 3 free, use a suitable hoist and sling to move the ro-
and use a long piece of heavy bar stock to pry tating assembly to a suitable work area for further
against the arm of the lathe dog in a counterclock- disassembly.

MAINTENANCE & REPAIR PAGE E -- 7

OM -- 01824 U SERIES

ADD PIPE
AS REQUIRED

Figure 4. Rotating Assembly Removal With Tool

Impeller Removal If no further disassembly is required, refer to Seal
Installation.
(Figure 2)
Shaft and Bearing Removal and Disassembly
Unscrew the impeller from the shaft in a counter-
clockwise direction (when facing the impeller). Use (Figure 2)
caution when unscrewing the impeller; tension on
When the pump is properly operated and main-
the shaft seal spring will be released as the impeller
tained, the bearing housing should not require dis-
is removed.
assembly. Disassemble the shaft and bearings
only when there is evidence of wear or damage.
Remove the impeller adjusting shims (26). Tie and
tag the shims or measure and record their thick-
ness for ease of reassembly.

Seal Removal and Disassembly Shaft and bearing disassembly in the field
is not recommended. These operations
(Figure 2)
should be performed only in a properly-
Carefully remove the seal spring. Slide the shaft equipped shop by qualified personnel.
sleeve and the rotating portion of the seal off the Remove the bearing housing drain plug (22) and
shaft as a unit. Use two stiff wires with hooked ends drain the lubricant. Clean and reinstall the drain
to remove the stationary portion of the seal. plug. Remove the rotating assembly O-ring (31).

Remove the shaft sleeve O-ring (27). Disengage the hardware (14 and 15) and remove
the bearing cap (16), O-ring (24) and oil seal (12)
An alternate method of removing the stationary from the shaft. Using an arbor (or hydraulic) press,
portion of the seal is to remove the hardware (6 and remove the oil seal from the bearing cap.
7) and separate the seal plate (3) and gasket (4)
Place a block of wood against the impeller end of
from the bearing housing (8). Remove the seal
the shaft and tap the shaft and assembled bear-
plate O-ring (30). Position the seal plate on a flat
ings (9 and 25) from the bearing housing. Press the
surface with the impeller side down. Use a wooden
inboard oil seal (5) from the bearing housing bore.
dowel or other suitable tool to press on the back
side of the stationary seat until the seat, O-rings After removing the shaft and bearings, clean and
and stationary element can be removed. inspect the bearings in place as follows.

PAGE E -- 8 MAINTENANCE & REPAIR

U SERIES OM -- 01824

and use a bearing puller to remove the inboard and

outboard bearings from the shaft.

To prevent damage during removal from Shaft and Bearing Reassembly and Installation
the shaft, it is recommended that bearings
(Figure 2)
be cleaned and inspected in place. It is
strongly recommended that the bearings Inspect the shaft for distortion, nicks or scratches,
be replaced any time the shaft and bear- or for thread damage on the impeller end. Dress
ings are removed. small nicks and burrs with a fine file or emery cloth.
Clean the bearing housing, shaft and all compo- Replace the shaft if defective.
nent parts (except the bearings) with a soft cloth
Position the inboard oil seal (5) in the bearing hous-
soaked in cleaning solvent. Inspect the parts for
ing bore with the lip positioned as shown in Figure
wear or damage and replace as necessary.
2. Press the oil seal into the housing until it is fully
seated.

Most cleaning solvents are toxic and

flammable. Use them only in a well-ven- To prevent damage during removal from
tilated area free from excessive heat, the shaft, it is recommended that bearings
sparks, and flame. Read and follow all be cleaned and inspected in place. It is
precautions printed on solvent contain- strongly recommended that the bearings
ers. be replaced any time the shaft and bear-
ings are removed.
Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed The bearings may be heated to ease installation.
air and coat with light oil. An induction heater, hot oil bath, electric 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
Bearings must be kept free of all dirt and If a hot oil bath is used to heat the bearings, both
foreign material. Failure to do so will great- the oil and the container must be absolutely
ly shorten bearing life. Do not spin dry clean. If the oil has been previously used, it must
bearings. This may scratch the balls or be thoroughly filtered.
races and cause premature bearing fail-
ure.
Heat the bearings to a uniform temperature no
Rotate the bearings by hand to check for rough- higher than 250_ F (120_ C), and slide the bear-
ness or binding and inspect the bearing balls. If ro- ings onto the shaft, one at a time, until they are fully
tation is rough or the bearing balls are discolored, seated. This should be done quickly, in one con-
replace the bearings. tinuous motion, to prevent the bearings from cool-
ing and sticking on the shaft.
The bearing tolerances provide a tight press 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 Use caution when handling hot bear-
bearing retaining ring (19) from the impeller shaft, ings to prevent burns.
MAINTENANCE & REPAIR PAGE E -- 9
OM -- 01824 U SERIES

NOTE dicated by the following illustration.

Position the inboard bearing (9) on the shaft as in-

BALL LOADING BALL LOADING

GROOVE POSITIONED GROOVE POSITIONED
AWAY FROM IMPELLER TOWARD IMPELLER
LOADING
LOADING GROOVE
GROOVE
DIRECTION OF DIRECTION OF
THRUST THRUST

INSTALLATION OF NEW DEPARTURE OR INSTALLATION OF MRC/SKF 5300M OR

BCA/FEDERAL MOGAL 5300W SERIES BEARINGS FAFNIR 5300W SERIES BEARINGS
(OPEN OR ENCLOSED IMPELLERS) (OPEN OR ENCLOSED IMPELLERS)

Figure 5. Inboard Bearing Positioning

After the bearings have been installed and allowed Press the outboard oil seal (12) into the bearing
to cool, check to ensure that they have not moved cap (16) with the lip positioned as shown in Figure
away from the shaft shoulders in shrinking. If 2. Replace the bearing cap O-ring (24), and secure
movement has occurred, use a suitable sized the bearing cap with the hardware (14 and 15). Be
sleeve and a press to reposition the bearings careful not to damage the oil seal lip on the shaft
against the shaft shoulders. keyway.

If heating the bearings is not practical, use a suit- Replace the rotating assembly O-ring (31).
able sized sleeve, and an arbor (or hydraulic) press
to install the bearings on the shaft.
NOTE
Impeller shaft endplay should be between .003
and .005 inch (.076 to .127 mm). Tighten the bear-
ing cap hardware tight enough to prevent leakage
and obtain the correct endplay. Do not over-tight-
en.
When installing the bearings onto the
shaft, never press or hit against the outer Lubricate the bearing housing as indicated in LU-
race, balls, or ball cage. Press only on the BRICATION.
inner race.
Secure the outboard bearing (25) on the shaft with Seal Reassembly and Installation
the bearing retaining ring (19). (Figures 2 and 6)

Slide the shaft (18) and assembled bearings (9 and Clean the seal cavity and shaft with a cloth soaked
25) into the bearing housing (8) until the retaining in fresh cleaning solvent.
ring on the outboard bearing seats against the
bearing housing. Use caution not to roll or damage
the lip of the oil seal (5).

Most cleaning solvents are toxic and

flammable. Use them only in a well ven-
tilated area free from excessive heat,
When installing the shaft and bearings into sparks, and flame. Read and follow all
the bearing bore, push against the outer precautions printed on solvent contain-
race. Never hit the balls or ball cage. ers.
PAGE E -- 10 MAINTENANCE & REPAIR
U SERIES OM -- 01824

Clean the seal cavity and shaft with a cloth soaked A new seal assembly should be installed
in fresh cleaning solvent. Inspect the stationary any time the old seal is removed from the
seat bore in the seal plate for dirt, nicks and burrs, pump. Wear patterns on the finished faces
and remove any that exist. The stationary seat bore cannot be realigned during reassembly.
must be completely clean before installing the Reusing an old seal could result in prema-
seal.
ture failure.
To ease installation of the seal, lubricate the shaft
sleeve O-ring and the external stationary seat O-
ring with a very small amount of light lubricating oil.
See Figure 6 for seal part identification.

RETAINER SEAL PLATE

SPRING
O-RINGS
IMPELLER
SEAL
SLEEVE
O-RING
BELLOWS
IMPELLER
SHAFT SEAL
ROTATING STATIONARY SLEEVE
ELEMENT ELEMENT
SHEAR
RING
(SHEARED)

IMPELLER SHIMS
STATIONARY
DRIVE BAND SEAT

Figure 6. 46513---154 Cartridge Seal Assembly

To prevent damaging the shaft sleeve O-ring (27)
on the shaft threads, stretch the O-ring over a piece
of tubing that the I.D is a little larger than the shaft
O.D. Slide the tube over the shaft threads, then
slide the O-ring off the tube and onto the shaft. Re-
This seal is not designed for operation at
move the tube, and continue to slide the O-ring
temperatures above 160_F (71_C). Do not
down the shaft until it seats against the shaft shoul-
use at higher operating temperatures. der.

If the seal plate was removed, install the seal plate When installing a new cartridge seal assembly,
gasket (4). Position the seal plate over the shaft remove the seal from the container, and remove
and secure it to the bearing housing with the hard- the mylar storage tabs from between the seal
ware (6 and 7). faces.

MAINTENANCE & REPAIR PAGE E -- 11

OM -- 01824 U SERIES

STATIONARY SEAT
FULLY SEATED IN
SEAL PLATE BORE

New cartridge seal assemblies are

equipped with mylar storage tabs between
the seal faces. These storage tabs must be
removed before installing the seal.
Lubricate the external stationary seat O-ring with
light oil. Slide the seal assembly onto the shaft until
the external stationary seat O-ring engages the
SHEAR RING
bore in the seal plate. (SHEARED)

Clean and inspect the impeller as described in Im-

peller Installation and Adjustment. Install the full Figure 8. Seal Fully Installed
set of impeller shims (26) provided with the seal, Measure the impeller-to-seal plate clearance, and
and screw the impeller onto the shaft until it is remove impeller adjusting shims to obtain the
seated against the seal (see Figure 7). proper clearance as described in Impeller Instal-
lation and Adjustment.
O-RING ENGAGED
WITH SEAL PLATE
BORE 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 should be installed

any time the old seal is removed from the
SHEAR RING
(UNSHEARED) pump. Wear patterns on the finished faces
cannot be realigned during reassembly.
Figure 7. Seal Partially Installed Reusing an old seal could result in prema-
ture failure.
Continue to screw the impeller onto the shaft. This
Handle the seal parts with extreme care to prevent
will press the stationary seat into the seal plate
damage. Be careful not to contaminate precision
bore.
finished faces; even fingerprints on the faces can
NOTE shorten seal life. If necessary, clean the faces with a
non-oil based solvent and a clean, lint-free tissue.
A firm resistance will be felt as the impeller presses
Wipe lightly in a concentric pattern to avoid
the stationary seat into the seal plate bore.
scratching the faces.

Carefully wash all metallic parts in fresh cleaning

As the stationary seat becomes fully seated, the
solvent and allow to dry thoroughly.
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 shaft until the impeller, shims, and sleeve are
fully seated against the shaft shoulder (see Figure Do not attempt to separate the rotating
8). portion of the seal from the shaft sleeve
PAGE E -- 12 MAINTENANCE & REPAIR
U SERIES OM -- 01824

when reusing an old seal. The rubber bel- rection of the impeller when checking this clear-
lows will adhere to the sleeve during use, ance.
and attempting to separate them could
damage the bellows. NOTE
If the rotating assembly has been installed in the
Inspect the seal components for wear, scoring, pump casing, this clearance may be measured by
grooves, and other damage that might cause leak- reaching through the priming port with a feeler
age. Inspect the integral shaft sleeve for nicks or gauge.
cuts on either end. If any components are worn, or
the sleeve is damaged, replace the complete seal; Coat the threads of the impeller capscrew (29) with
never mix old and new seal parts. ‘Never---Seez’ or equivalent compound and install
the impeller washer (28) and capscrew; torque the
Install the stationary seal element in the stationary capscrew to 90 ft. lbs. (1080 in. lbs. or 12,44 m.
seat. Press this stationary subassembly into the kg.).
seal plate bore until it seats squarely against the
bore shoulder. A push tube made from a piece of
Rotating Assembly Installation
plastic pipe would aid this installation. The I.D. of
the tube should be slightly larger than the O.D. of (Figure 1)
the shaft sleeve.

Slide the rotating portion of the seal (consisting of

the integral shaft sleeve, spring centering washer,
spring, bellows and retainer, and rotating element) A repair rotating assembly is shipped dry
onto the shaft until the seal faces contact.
of lubricant. Refer to lubrication at the end
Proceed with Impeller Installation and Adjust- of this section before installing a repair ro-
ment. tating assembly.
Install the seal plate O-ring (29), and lubricate it
Impeller Installation And Adjustment and the rotating assembly O-ring (27) with light
grease. Ease the rotating assembly into the pump
(Figure 2) casing using the installation tool. Be careful not to
damage the O-rings.
Inspect the impeller, and replace it if cracked or
badly worn. Inspect the impeller and shaft threads Install the casing ring (12) and secure with the in-
for dirt or damage, and clean or dress the threads ner hardware (15 and 16).
as required.
NOTE
The inner capscrews are 1/4 inch (3,2 mm) shorter
Install the same thickness of impeller adjusting
than the outer capscrews.
shims (26) as previously removed, and screw the
impeller onto the shaft until tight.
Install an equal thickness of rotating assembly
NOTE shims (11) under the casing ring, and secure the
At the slightest sign of binding, immediately back ring to the pump casing with the outer hardware
the impeller off, and check the threads for dirt. Do (13 and 14).
not try to force the impeller onto the shaft.
A clearance of .003 to .005 inch (0,08 to 0,13 mm)
between the impeller and the wear plate is also rec-
A clearance of .015 to .030 inch (0,38 to 0,76 mm) ommended for maximum pump efficiency. This
between the impeller and the seal plate is recom- clearance can be obtained by removing an equal
mended for maximum pump efficiency. Measure amount of shims from each rotating assembly
this clearance, and add or remove impeller adjust- shim set until the impeller binds against the wear
ing shims as required. Preload the shaft in the di- plate when the shaft is turned. Preload the shaft

MAINTENANCE & REPAIR PAGE E -- 13

OM -- 01824 U SERIES

in the direction of the impeller when checking (8 and 53). Apply ‘Permatex Aviation No. 3 Form-A-
this clearance. After the impeller binds, add .003 Gasket’ or equivalent to the mating surfaces, and
inch (0,08 mm) of shims to each shim set. secure the flanges to the pump casing (1) with the
attaching hardware (4, 5, 47 and 48).
NOTE
An alternate method of adjusting this clearance is NOTE
to reach through the priming port with a feeler There is a threaded passage through the interior
gauge and measure the gap. Add or subtract rotat- wall of the pump casing just in front of the blind
ing assembly shims accordingly. flange assembly. This passage is designed to
equalize pressure in the casing when the pump is
in operation, and must be kept clear.
After the face clearance has been set, tighten the
hardware securing the rotating assembly to the
pump casing. Secure the extension pipe assembly (41) to the
back suction cover (36) using the coupling (40).

Back Suction Cover Installation Install the shaft key (17, Figure 2) and reconnect
the power source. Be sure to install any guards
(Figure 1)
used over the rotating parts.
If the wear plate assembly (30) was removed for re-
Install the suction and discharge lines and open all
placement, carefully center it on the back cover
valve. Make certain that all piping connections are
(36) and secure it with the hardware (32 and 33).
tight, properly supported and secure.
The wear plate must be concentric to prevent bind-
ing when the back cover is installed. Be sure the pump and power source have been
properly lubricated, see LUBRICATION.
Replace the back suction cover O-ring (34), and lu-
bricate it with a generous amount of No. 2 grease. Fill the pump casing with clean liquid. Install the
Clean any scale or debris from the contacting sur- cover plate assembly (17). Refer to OPERATION,
faces in the pump casing that might interfere or Section C, before putting the pump back into ser-
prevent a good seal with the back cover. Slide the vice.
back suction cover into the pump casing. Be sure
the wear plate does not bind against the impeller.
PRESSURE RELIEF VALVE
NOTE MAINTENANCE
To ease future disassembly, apply a film of grease
or ‘Never-Seez’ on the back cover shoulder, or any (Figure 1)
surface which contacts the pump casing. This ac-
tion will reduce rust and scale build-up. The back suction cover is equipped with a pres-
sure relief valve (45) to provide additional safety for
the pump and operator (refer to Liquid Tempera-
Secure the back suction cover (36) by tightening
ture And Overheating in OPERATION).
the hardware (38 and 39) evenly. Do not over-
tighten the hardware; they should be just tight It is recommended that the pressure relief valve as-
enough to ensure a good seal at the back cover sembly be replaced at each overhaul, or any time
shoulder. Be sure the wear plate does not bind the pump overheats and activates the valve. Never
against the casing. replace this valve with a substitute which has not
been specified or provided by the Gorman-Rupp
Final Pump Assembly Company.

(Figure 1) Periodically, the valve should be removed for in-

spection and cleaning. When reinstalling the relief
If the discharge flange (7) or blind flange assembly valve, apply ‘Loctite Pipe Sealant With Teflon No.
(49) were removed, replace the respective gaskets 592’, or equivalent compound, on the relief valve

PAGE E -- 14 MAINTENANCE & REPAIR

U SERIES OM -- 01824

threads. Position the valve as shown in Figure 1, Over-lubrication can cause the bearings to over-
with the discharge port pointing down. heat, resulting in premature bearing failure.

NOTE
LUBRICATION The white reflector in the sight gauge must be
positioned horizontally to provide proper drain-
age.

Under normal conditions, drain the bearing hous-

A repair rotating assembly is shipped dry ing once each year and refill with approximately 32
of lubricant. Refer to the following informa- ounces (0,95 liters) of clean oil. Change the oil
tion for lubrication specifications. more frequently if the pump is operated continu-
ously or installed in an environment with rapid tem-
Seal Assembly perature change.

(Figure 2)

Before starting the pump, remove the vented plug

(10) and fill the seal cavity with approximately 90
ounces (2,7 liters) of SAE No. 30 non-detergent oil Monitor the condition of the bearing lubri-
(so it is above the level of the internal casting). cant regularly for evidence of rust or mois-
Clean and reinstall the vented plug. Maintain the oil ture condensation. This is especially im-
at this level. portant in areas where variable hot and
cold temperatures are common.
Bearings For cold weather operation, consult the factory or a
lubricant supplier for the recommended grade of
(Figure 2)
oil.
The bearing housing was fully lubricated when
shipped from the factory. Check the oil level regu- Power Source
larly through the sight gauge (20) and maintain it at
the middle of the gauge. When lubrication is re- Consult the literature supplied with the power
quired, add SAE No. 30 non-detergent oil through source, or contact your local power source repre-
the hole for the air vent (11). Do not over-lubricate. sentative.

MAINTENANCE & REPAIR PAGE E -- 15

 July 18, 1979

WARRANTY

Pumping units manufactured by The Gorman-Rupp Company,

Mansfield, Ohio are guaranteed to be free from defects in mate-
rial and workmanship for one year from date of shipment from
factory in Mansfield, Ohio. The obligation under this Warranty,
statutory or otherwise, is limited to replacement or repair at
Mansfield, Ohio factory or at a point designated by Gorman-
Rupp, of such part as shall appear to us upon inspection at such
point, to have been defective in material or workmanship.

This Warranty does not obligate The Gorman-Rupp Company to

bear the cost of labor or transportation charges in connection
with replacement or repair of defective parts; nor shall it apply to
a pump upon which repairs or alterations have been made un-
less authorized by Gorman-Rupp.

No warranty is made in respect to engines, motors, or trade ac-

cessories, such being subject to warranties of their respective
manufacturers.

In Submersible Pumps, pump and motor are integral and Sub-

mersibles are warranted as a unit. Since motor is subject to an
important degree upon quality and performance of electrical
controls, unit warranty is valid only when controls have been
specified and provided by Gorman-Rupp.

No express implied or statutory warranty, other than herein set

forth is made or authorized to be made by Gorman-Rupp.

In no event shall The Gorman-Rupp Company be liable for con-

sequential damages or contingent liabilities arising out of the fail-
ure of any Gorman-Rupp pump or parts thereof to operate prop-
erly.

THE GORMAN-RUPP COMPANY

Mansfield, Ohio

NOTE: In Canada, all above references to “The Gorman-Rupp

Company, Mansfield, Ohio” is understood to mean “Gorman-
Rupp of Canada Limited, St. Thomas, Ontario.”

THE GORMAN-RUPP COMPANY F MANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

ECopyright by the Gorman-Rupp Company