GORMAN-RUPP U4B60-B Installation, Operation And Maintenance Manual

C
OM-01863-OB02
November 7, 1986
Rev.D
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
U SERIES PUMP
MODEL
U4B60---B
INCLUDING: /F, /FM
THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA
ECopyright by the Gorman-Rupp Company
Printed in U.S.A.
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE I --- 1
SAFETY --- SECTION A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE A --- 1
INSTALLATION --- SECTION B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE B --- 1
Pump Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREINSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POSITIONING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUCTION AND DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections to Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUCTION LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Lines In Sumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Line Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Siphoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC AIR RELEASE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Release Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupled Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-Belt Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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PAGE B --- 9
OPERATION --- SECTION C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE C --- 1
PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lines With a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lines Without a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Temperature And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strainer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEARING TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE C --- 1
PAGE C --- 1
PAGE C --- 2
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS LISTS:
Pump Model U4B60---B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44163---041 Repair Rotating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
Back Cover And Wear Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Check Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft and Bearing Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft and Bearing Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE RELIEF VALVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE E --- 1
ii
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U SERIES
OM -- 01863-- 02
INTRODUCTION
valve. The pump is designed for high-efficiency,
self-priming service, and is capable of handling
most non-volatile , non-corrosive liquids containing specified entrained solids. The basic material
of construction for wetted parts is cast iron, with
ductile iron impeller and alloy steel impeller shaft.
This Installation, Operation, and Maintenance
manual is designed to help you achieve the best
performance and longest life from your GormanRupp pump.
This pump is a U Series, semi-open impeller, selfpriming centrifugal model with a suction check
If there are any questions regarding the pump or its application which are not covered in this manual or in
other literature accompanying this unit, please contact your Gorman-Rupp distributor, or write:
The Gorman-Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-- 1217
or
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
For information or technical assistance on the power source, contact the power source manufacturer’s local
dealer or representative.
The following are used to alert maintenance personnel to procedures which require special attention, to
those which could damage equipment, and to those which could be dangerous to personnel:
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure required and the injury which will result
from failure to follow the procedure.
Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.
INTRODUCTION
Hazards or unsafe practices which COULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possible damage which could result from failure
to follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
PAGE I -- 1
U SERIES
OM -- 01863-- 02
SAFETY --- SECTION A
This information applies to U Series basic pumps. Gorman-Rupp has no control over or particular knowledge of the
power source which will be used. Refer
to the manual accompanying the power
source before attempting to begin
operation.
Before attempting to open or service the
pump:
1. Familiarize yourself with this manual.
2. Disconnect or lock out the power
source to ensure that the pump will
remain inoperative.
3. Allow the pump to cool if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.
This pump is designed to handle most
non-volatile, non-corrosive liquids containing specified entrained solids. Do
not attempt to pump volatile, corrosive,
or flammable materials which may damage the pump or endanger personnel as
a result of pump failure.
SAFETY
After the pump has been positioned,
make certain that the pump and all piping connections are tight, properly supported and secure before operation.
Do not operate the pump without the
guards in place over the rotating parts.
Exposed rotating parts can catch clothing, fingers, or tools, causing severe injury to personnel.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an overheated pump. Vapor pressure within the
pump can cause parts being disengaged to be ejected with great force. Allow the pump to cool before servicing.
Do not operate the pump against a
closed discharge valve for long periods
of time. If operated against a closed discharge valve, pump components will
deteriorate, and the liquid could come
to a boil, build pressure, and cause the
pump casing to rupture or explode.
PAGE A -- 1
OM -- 01863-- 02
Never run this pump backwards. Be certain that rotation is correct before fully
engaging the pump.
PAGE A -- 2
U SERIES
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or damage to equipment. Suction and discharge hoses and piping must be removed from the pump before lifting.
SAFETY
U SERIES
OM -- 01863-- 02
INSTALLATION --- SECTION B
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this
section offers only general recommendations and
practices required to inspect, position, and arrange the pump and piping.
Most of the information pertains to a standard
static lift application where the pump is positioned above the free level of liquid to be pumped.
If installed in a flooded suction application where
the liquid is supplied to the pump under pressure,
some of the information such as mounting, line
configuration, and priming must be tailored to the
specific application. Since the pressure supplied
to the pump is critical to performance and safety,
be sure to limit the incoming pressure to 50% of
the maximum permissible operating pressure as
shown on the pump performance curve.
For further assistance, contact your Gorman-Rupp
distributor or the Gorman-Rupp Company.
Pump Dimensions
See Figure 1 for the approximate physical dimensions of this pump.
OUTLINE DRAWING
NOTE: OPTIONAL ASA OR DIN STANDARD SUCTION & DISCHARGE SPOOL FLANGES AVAILABLE
Figure 1. Pump Model U4B60-B
INSTALLATION
PAGE B -- 1
OM -- 01863-- 02
U SERIES
PREINSTALLATION INSPECTION
POSITIONING PUMP
The pump assembly was inspected and tested before shipment from the factory. Before installation,
inspect the pump for damage which may have occurred during shipment. Check as follows:
Lifting
a. Inspect the pump for cracks, dents, damaged
threads, and other obvious damage.
b. Check for and tighten loose attaching hardware. Since gaskets tend to shrink after drying, check for loose hardware at mating surfaces.
c. Carefully read all warnings and cautions contained in this manual or affixed to the pump,
and perform all duties indicated. Note the direction of rotation indicated on the pump.
Check that the pump shaft rotates clockwise
when facing the pump drive shaft.
Use lifting equipment with a capacity of at least
3,000 pounds (1361 kg). This pump weighs approximately 600 pounds (272 kg), not including
the weight of accessories and base. Customer installed equipment such as suction and discharge
piping must be removed before attempting to lift.
The pump assembly can be seriously
damaged if the cables or chains used to lift
and move the unit are improperly wrapped
around the pump.
Mounting
Locate the pump in an accessible place as close as
practical to the liquid being pumped. Level mounting is essential for proper operation.
Only operate this pump in the direction indicated by the arrow on the pump body
and on the accompanying decal. Refer to
ROTATION in OPERATION, Section C.
d. Check levels and lubricate as necessary. Refer to LUBRICATION in the MAINTENANCE
AND REPAIR section of this manual and perform duties as instructed.
The pump may have to be supported or shimmed
to provide for level operation or to eliminate vibration.
The complete rotating assembly may be removed
through the cover plate opening, or from the opposite side after disconnecting the power source to
provide necessary clearance.
Clearance
e. If the pump and power source have been
stored for more than 12 months, some of the
components or lubricants may have exceeded their maximum shelf life. These must
be inspected or replaced to ensure maximum pump service.
A minimum clearance of 18 inches (457 mm) in
front of the back cover is required to permit removal of the cover and easy access to the pump
interior.
SUCTION AND DISCHARGE PIPING
If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Gorman-Rupp distributor or the factory to determine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.
PAGE B -- 2
Pump performance is adversely effected by increased suction lift, discharge elevation, and friction losses. See the performance curve and operating range shown on Page E-1 to be sure your
INSTALLATION
U SERIES
overall application allows pump to operate within
the safe operation range.
Materials
Either pipe or hose maybe used for suction and
discharge lines; however, the materials must be
compatible with the liquid being pumped. If hose is
used in suction lines, it must be the rigid-wall, reinforced type to prevent collapse under suction. Using piping couplings in suction lines is not recommended.
Line Configuration
Keep suction and discharge lines as straight as
possible to minimize friction losses. Make minimum use of elbows and fittings, which substantially increase friction loss. If elbows are necessary,
use the long-radius type to minimize friction loss.
Connections to Pump
Before tightening a connecting flange, align it exactly with the pump port. Never pull a pipe line into
place by tightening the flange bolts and/or couplings.
Lines near the pump must be independently supported to avoid strain on the pump which could
cause excessive vibration, decreased bearing life,
and increased shaft and seal wear. If hose-type
lines are used, they should have adequate support
to secure them when filled with liquid and under
pressure.
OM -- 01863-- 02
SUCTION LINES
To avoid air pockets which could affect pump priming, the suction line must be as short and direct as
possible. When operation involves a suction lift, the
line must always slope upward to the pump from
the source of the liquid being pumped; if the line
slopes down to the pump at any point along the
suction run, air pockets will be created.
Fittings
Suction lines should be the same size as the pump
inlet. If reducers are used in suction lines, they
should be the eccentric type, and should be installed with the flat part of the reducers uppermost
to avoid creating air pockets. Valves are not normally used in suction lines, but if a valve is used,
install it with the stem horizontal to avoid air pockets.
Strainers
If a strainer is furnished with the pump, be certain
to use it; any spherical solids which pass through a
strainer furnished with the pump will also pass
through the pump itself.
If a strainer is not furnished with the pump, but is
installed by the pump user, make certain that the
total area of the openings in the strainer is at least
three or four times the cross section of the suction
line, and that the openings will not permit passage
of solids larger than the solids handling capability
of the pump.
This pump is designed to handle up to 1-1/8 inch
(28,6 mm) diameter spherical solids.
Gauges
Sealing
Most pumps are drilled and tapped for installing
discharge pressure and vacuum suction gauges.
If these gauges are desired for pumps that are not
tapped, drill and tap the suction and discharge
lines not less than 18 inches (457,2 mm) from the
suction and discharge ports and install the lines.
Installation closer to the pump may result in erratic
readings.
Since even a slight leak will affect priming, head,
and capacity, especially when operating with a
high suction lift, all connections in the suction line
should be sealed with pipe dope to ensure an airtight seal. Follow the sealant manufacturer’s recommendations when selecting and applying the
pipe dope. The pipe dope should be compatible
with the liquid being pumped.
INSTALLATION
PAGE B -- 3
OM -- 01863-- 02
Suction Lines In Sumps
If a single suction line is installed in a sump, it
should be positioned away from the wall of the
sump at a distance equal to 1 1/2 times the diameter 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 suction inlet because the inflow will carry air down into
the sump, and air entering the suction line will reduce pump efficiency.
If it is necessary to position inflow close to the suction inlet, install a baffle between the inflow and the
suction inlet at a distance 1 1/2 times the diameter
of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into
the suction inlet.
If two suction lines are installed in a single sump,
the flow paths may interact, reducing the efficiency
U SERIES
of one or both pumps. To avoid this, position the
suction inlets so that they are separated by a distance equal to at least 3 times the diameter of the
suction pipe.
Suction Line Positioning
The depth of submergence of the suction line is
critical to efficient pump operation. Figure 2 shows
recommended minimum submergence vs. velocity.
NOTE
The pipe submergence required may be reduced
by installing a standard pipe increaser fitting at the
end of the suction line. The larger opening size will
reduce the inlet velocity. Calculate the required
submergence using the following formula based
on the increased opening size (area or diameter).
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
PAGE B -- 4
INSTALLATION
U SERIES
DISCHARGE LINES
Siphoning
Do not terminate the discharge line at a level lower
than that of the liquid being pumped unless a siphon breaker is used in the line. Otherwise, a siphoning action causing damage to the pump
could result.
Valves
A check valve in the discharge line is normally recommended, but it is not necessary in low discharge head applications.
If a throttling valve is desired in the discharge line,
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 installed in the discharge line to protect the pump
from excessive shock pressure and reverse rotation when it is stopped.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
Bypass Lines
Self-priming pumps are not air compressors. During the priming cycle, air from the suction line must
be vented to atmosphere on the discharge side. If
the discharge line is open, this air will be vented
through the discharge. However, if a check valve
has been installed in the discharge line, the discharge side of the pump must be opened to atmospheric pressure through a bypass line installed between the pump discharge and the check valve. A
self-priming centrifugal pump will not prime if
there is sufficient static liquid head to hold the discharge check valve closed.
INSTALLATION
OM -- 01863-- 02
NOTE
The bypass line should be sized so that it does not
affect pump discharge capacity; however, the bypass line should be at least 1 inch in diameter to
minimize the chance of plugging.
In low discharge head applications (less than 30
feet or 9 meters), it is recommended that the bypass line be run back to the wet well, and located 6
inches below the water level or cut-off point of the
low level pump. In some installations, this bypass
line may be terminated with a six-to-eight foot
length of 1 1/4 inch I.D. smooth-bore hose; air and
liquid vented during the priming process will then
agitate the hose and break up any solids, grease,
or other substances likely to cause clogging.
A bypass line that is returned to a wet well
must be secured against being drawn into
the pump suction inlet.
It is also recommended that pipe unions be installed 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 bypassed and forced back to the wet well under the
full working pressure of the pump; this will reduce
overall pumping efficiency. Therefore, it is recommended that a Gorman-Rupp Automatic Air Release Valve be installed in the bypass line.
Gorman-Rupp Automatic Air Release Valves are
reliable, and require minimum maintenance. See
AUTOMATIC AIR RELEASE VALVE in this section
for installation and theory of operation of the Automatic Air Release Valve. Consult your GormanRupp distributor, or contact the Gorman-Rupp
Company for selection of an Automatic Air Release
Valve to fit your application.
If the installation involves a flooded suction such as
a below-ground lift station. A pipe union and manual shut-off valve may be installed in the bleed line to
allow service of the valve without shutting down the
station, and to eliminate the possibility of flooding.
If a manual shut-off valve is installed anywhere in
the air release piping, it must be a full-opening ball
type valve to prevent plugging by solids.
PAGE B -- 5
OM -- 01863-- 02
If a manual shut-off valve is installed in
a bypass line, it must not be left closed
during operation. A closed manual shutoff valve may cause a pump which has
lost prime to continue to operate without reaching prime, causing dangerous
overheating and possible explosive
rupture of the pump casing. Personnel
could be severely injured.
Allow an over-heated pump to cool before servicing. Do not remove plates,
covers, gauges, or fittings from an overheated pump. Liquid within the pump
can reach boiling temperatures, and vapor 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 removing the casing drain plug. Use caution when removing the plug to prevent
injury to personnel from hot liquid.
U SERIES
Figure 3. Valve in Open Position
During the priming cycle, air from the pump casing
flows through the bypass line, and passes through
the Air Release Valve to the wet well (Figure 3).
Figure 4. Valve in Closed Position
When the pump is fully primed, pressure resulting
from flow against the valve diaphragm compresses the spring and closes the valve (Figure 4).
The valve will remain closed, reducing the bypass
of liquid to 1 to 5 gallons (4 to 19 liters) per minute,
until the pump loses its prime or stops.
AUTOMATIC AIR RELEASE VALVE
When properly installed and correctly adjusted to
the specific hydraulic operating conditions of the
application, the Gorman-Rupp Automatic Air Release Valve will permit air to escape through the bypass line, and then close automatically when the
pump is fully primed and pumping at full capacity.
Theory of Operation
Figures 3 and 4 show a cross-sectional view of the
Automatic Air Release Valve, and a corresponding
description of operation.
PAGE B -- 6
Some leakage (1 to 5 gallons [4 to 19 liters] per minute) will occur when the
valve is fully closed. Be sure the bypass
line is directed back to the wet well or
tank to prevent hazardous spills.
When the pump shuts down, the spring returns the
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
INSTALLATION
U SERIES
OM -- 01863-- 02
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 closing pressure can be further adjusted to the exact
system requirements by moving the spring retaining pin up or down the plunger rod to increase or
decrease tension on the spring. Contact your Gorman-Rupp distributor or the Gorman-Rupp Company for information about an Automatic Air Release Valve for your specific application.
Air Release Valve Installation
The Automatic Air Release Valve must be independently mounted in a horizontal position and
connected to the discharge line of the self-priming
centrifugal pump (see Figure 5).
NOTE
If the Air Release Valve is to be installed on a staged
pump application, contact the factory for specific
installation instructions.
DISCHARGE PIPE
CLEAN-OUT
COVER
INSTALL AIR RELEASE VALVE
IN HORIZONTAL POSITION
90_ LONG
RADIUS
ELBOW
SUPPORT
BRACKET
BLEED LINE 1”
(25,4 MM) DIA. MIN.
(CUSTOMER
FURNISHED)
EXTEND 6”
(152,4 MM)
BELOW LIQUID
LEVEL SURFACE
DISCHARGE
CHECK VALVE
PUMP DISCHARGE
SELF-PRIMING
CENTRIFUGAL
PUMP
SUCTION
LINE
WET WELL
OR SUMP
Figure 5. Typical Automatic Air Release Valve Installation
The valve inlet line must be installed between the
pump discharge port and the non-pressurized side
of the discharge check valve. The valve inlet is at
the large end of the valve body, and is provided
with standard 1-inch NPT pipe threads.
The valve outlet is located at the opposite end of
the valve, and is also equipped with standard
1-inch NPT pipe threads. The outlet should be connected to a bleed line which slopes back to the wet
well or sump. The bleed line must be the same size
as the inlet piping, or larger. If piping is used for the
INSTALLATION
bleed line, avoid the use of elbows whenever possible.
NOTE
It is recommended that each Air Release Valve be
fitted with an independent bleeder line directed
back to the wet well. However, if multiple Air Release Valves are installed in a system, the bleeder
lines may be directed to a common manifold pipe.
Contact your Gorman-Rupp distributor or the Gorman-Rupp Company for information about installation of an Automatic Air Release Valve for your spePAGE B -- 7
OM -- 01863-- 02
U SERIES
cific application.
Most couplings require a specific gap or clearance
between the driving and the driven shafts. Refer to
the coupling manufacturer’s service literature.
ALIGNMENT
The alignment of the pump and its power source is
critical for trouble-free mechanical operation. In
either a flexible coupling or V-belt driven system,
the driver and pump 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 operation.
Align spider insert type couplings by using calipers
to measure the dimensions on the circumference
of the outer ends of the coupling hub every 90 degrees. The coupling is in alignment when the hub
ends are the same distance apart at all points (see
Figure 6A).
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. Misalignment 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.
When checking alignment, disconnect
the power source to ensure that the
pump will remain inoperative.
Adjusting the alignment in one direction
may alter the alignment in another direction. check each procedure after altering
alignment.
Coupled Drives
When using couplings, the axis of the power
source must be aligned to the axis of the pump
shaft in both the horizontal and vertical planes.
PAGE B -- 8
Figure 6A. Aligning Spider-Type Couplings
Figure 6B. Aligning Non-Spider
Type Couplings
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
when the hubs are the same distance apart at all
points (see Figure 6B).
Check parallel adjustment by laying a straightedge
across both coupling rims at the top, bottom, and
side. When the straightedge rests evenly on both
halves of the coupling, the coupling is in horizontal
parallel alignment. If the coupling is misaligned,
use a feeler gauge between the coupling and the
straightedge to measure the amount of misalignment.
INSTALLATION
U SERIES
OM -- 01863-- 02
V-Belt Drives
When using V-belt drives, the power source and
the pump must be parallel. Use a straightedge
along the sides of the pulleys to ensure that the pulleys are properly aligned (see Figure 6C). In drive
systems using two or more belts, make certain that
the belts are a matched set; unmatched sets will
cause accelerated belt wear.
MISALIGNED:
SHAFTS
NOT PARALLEL
MISALIGNED:
SHAFTS
NOT IN LINE
Do not operate the pump without the
guards in place over the rotating parts.
Exposed rotating parts can catch clothing, fingers, or tools, causing severe injury to personnel.
ALIGNED: SHAFTS
PARALLEL AND
SHEAVES IN LINE
Figure 6C. Alignment of V-Belt Driven Pumps
Tighten the belts in accordance with the belt manufacturer’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 ratio; overspeeding the pump may damage both
pump and power source.
INSTALLATION
PAGE B -- 9
OM -- 01863-- 02
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OPERATION --- SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and decals attached to the pump.
This pump is designed to handle most
non-volatile, non-corrosive liquids containing specified entrained solids. Do
not attempt to pump volatile, corrosive,
or flammable materials which may damage the pump or endanger personnel as
a result of pump failure.
Pump speed and operating conditions
must be within the performance range
shown on page E-1.
PRIMING
Install the pump and piping as described in INSTALLATION. Make sure that the piping connections are tight, and that the pump is securely
mounted. Check that the pump is properly lubricated (see LUBRICATION in MAINTENANCE
AND REPAIR).
This pump is self-priming, but the pump should
never be operated unless there is liquid in the
pump casing.
not prime when dry. extended operation of
a dry pump will destroy the seal assembly.
Add liquid to the pump casing when:
1. The pump is being put into service for the
first time.
2. The pump has not been used for a considerable length of time.
3. The liquid in the pump casing has evaporated.
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 connecting piping is securely installed. Otherwise, liquid in the pump forced out
under pressure could cause injury to
personnel.
To fill the pump, remove the pump casing fill cover
or fill plug in the top of the casing, and add clean
liquid until the casing is filled. Replace the fill cover
or fill plug before operating the pump.
NOTE
The threaded passage through the interior wall of
the pump casing just in front of the check valve is
closed by a pipe plug, and must remain closed to
maintain prime in the pump.
STARTING
Consult the operations manual furnished with the
power source.
Never operate this pump unless there is
liquid in the pump casing. The pump will
OPERATION
Starting procedures will vary slightly depending on
the pump application, type of priming device, and
type of drive.
PAGE C -- 1
OM -- 01863-- 02
Rotation
The correct direction of pump rotation is clockwise
when facing the pump drive shaft. The pump could
be damaged and performance adversely affected
by incorrect rotation. If pump performance is not
within the specified limits (see the curve on page
E-1), check the direction of power source rotation
before further troubleshooting.
If an electric motor is used to drive the pump, remove V-belts, couplings, or otherwise disconnect
the pump from the motor before checking motor
rotation. Operate the motor independently while
observing the direction of the motor shaft, or cooling fan.
If rotation is incorrect on a three-phase motor, have
a qualified electrician interchange any two of the
three phase wires to change direction. If rotation is
incorrect on a single-phase motor, consult the literature supplied with the motor for specific instructions.
OPERATION
Lines With a Bypass
If a Gorman-Rupp Automatic Air Release Valve has
been installed, the valve will automatically open to
allow the pump to prime, and automatically close
after priming is complete (see INSTALLATION for
Air Release Valve operation).
If the bypass line is open, air from the suction line
will be discharged through the bypass line back to
the wet well during the priming cycle. Liquid will
then continue to circulate through the bypass line
while the pump is in operation.
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
quieter operation. The pump may not prime immediately because the suction line must first fill with
liquid. If the pump fails to prime within five minutes,
stop it and check the suction line for leaks.
PAGE C -- 2
U SERIES
After the pump has been primed, partially close the
discharge line throttling valve in order to fill the line
slowly and guard against excessive shock pressure which could damage pipe ends, gaskets,
sprinkler heads, and any other fixtures connected
to the line. When the discharge line is completely
filled, adjust the throttling valve to the required 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 surfaces, or at pump connections or fittings. Keep all
line connections and fittings tight to maintain maximum pump efficiency.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
160_ F (71_ C). Do not apply it at a higher operating temperature.
Overheating can occur if operated with the valves
in the suction or discharge lines closed. Operating
against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to rupture or explode. If overheating occurs, stop the
pump and allow it to cool before servicing it. Refill
the pump casing with cool liquid.
Allow an over-heated pump to cool before servicing. Do not remove plates,
OPERATION
OM -- 01863-- 02
U SERIES
covers, gauges, or fittings from an overheated pump. Liquid within the pump
can reach boiling temperatures, and vapor 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 removing the casing drain plug. Use caution when removing the plug to prevent
injury to personnel from hot liquid.
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 overheated pump cautiously. It is recommended that
the pressure relief valve assembly be replaced at
each overhaul, or any time the pump casing overheats and activates the valve. Never replace this
valve with a substitute which has not been specified or provided by the Gorman-Rupp Company.
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 discharge valve.
Open the suction line, and read the vacuum gauge
with the pump primed and at operation speed.
Shut off the pump. The vacuum gauge reading will
immediately drop proportionate to static suction
lift, and should then stabilize. If the vacuum reading
falls off rapidly after stabilization, an 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.
On engine driven pumps, reduce the throttle
speed slowly and allow the engine to idle briefly before stopping.
Strainer Check
If a suction strainer has been shipped with the
pump or installed by the user, check the strainer
regularly, and clean it as necessary. The strainer
should also be checked if pump flow rate begins to
drop. If a vacuum suction gauge has been installed, monitor and record the readings regularly
to detect strainer blockage.
Never introduce air or steam pressure into the
pump casing or piping to remove a blockage. This
could result in personal injury or damage to the
equipment. If backflushing is absolutely necessary, liquid pressure must be limited to 50% of the
maximum permissible operating pressure shown
on the pump performance curve.
Pump Vacuum Check
With the pump inoperative, install a vacuum gauge
in the system, using pipe dope on the threads.
Block the suction line and start the pump. At operOPERATION
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
After stopping the pump, lock out or disconnect
the power source to ensure that the pump will remain inoperative.
Cold Weather Preservation
In below freezing conditions, drain the pump to
prevent damage from freezing. Also, clean out any
solids by flushing with a hose. Operate the pump
for approximately one minute; this will remove any
remaining liquid that could freeze the pump rotating parts. If the pump will be idle for more than a
few hours, or if it has been pumping liquids containing a large amount of solids, drain the pump,
and flush it thoroughly with clean water. To prevent
large solids from clogging the drain port and preventing the pump from completely draining, insert
a rod or stiff wire in the drain port, and agitate the
PAGE C -- 3
OM -- 01863-- 02
liquid during the draining process. Clean out any
remaining solids by flushing with a hose.
BEARING TEMPERATURE CHECK
Bearings normally run at higher than ambient temperatures because of heat generated by friction.
Temperatures up to 160_F (71_ C) are considered
normal for bearings, and they can operate safely to
at least 180_F (82_ C).
Checking bearing temperatures by hand is inaccurate. Bearing temperatures can be measured accurately by placing a contact-type thermometer
PAGE C -- 4
U SERIES
against the housing. Record this temperature for
future reference.
A sudden increase in bearing 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 correct level (see LUBRICATION in MAINTENANCE
AND REPAIR). Bearing overheating can also be
caused by shaft misalignment and/or excessive vibration.
When pumps are first started, the bearings may
seem to run at temperatures above normal. Continued operation should bring the temperatures
down to normal levels.
OPERATION
U SERIES
OM -- 01863-- 02
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 cool if overheated.
4. Check the temperature before opening any covers, plates, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.
TROUBLE
POSSIBLE CAUSE
PROBABLE REMEDY
PUMP FAILS
TO
PRIME
Not enough liquid in casing.
Add liquid to casing. See PRIMING.
Suction check valve contaminated or
damaged.
Clean or replace check valve.
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 install bypass line if needed. See
INSTALLATION.
Strainer clogged.
Check strainer and clean if necessary.
Plug in threaded passage through interior wall of pump casing loose or
missing.
Tighten or install plug.
TROUBLESHOOTING
PAGE D -- 1
OM -- 01863-- 02
U SERIES
TROUBLE
POSSIBLE CAUSE
PROBABLE REMEDY
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
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.
Strainer clogged.
Check strainer and clean if necessary.
Suction intake not submerged at
proper level or sump too small.
Check installation and correct submergence as needed.
Impeller or other wearing parts worn
or damaged.
Replace worn or damaged parts.
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. Reduce lift and/or friction losses in
suction line.
Pump speed too high.
Check driver output; check that
sheaves or couplings are correctly sized.
Discharge head too low.
Adjust discharge valve.
Liquid solution too thick.
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 increase flow rate, and run power
source at maximum governed
speed.
Suction check valve or foot valve
clogged or binding.
Clean valve.
PUMP REQUIRES
TOO MUCH
POWER
PUMP CLOGS
FREQUENTLY
PAGE D -- 2
TROUBLESHOOTING
U SERIES
OM -- 01863-- 02
TROUBLE
POSSIBLE CAUSE
PROBABLE REMEDY
EXCESSIVE NOISE
Cavitation in pump.
Reduce suction lift and/or friction
losses in suction line. Record vacuum 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 damaged parts.
Bearing temperature is high, but
within limits.
Check bearing temperature regularly to monitor any increase.
Low or incorrect lubricant.
Check for proper type and level of
lubricant.
Suction and discharge lines not
properly supported.
Check piping installation for
proper support.
Drive misaligned.
Align drive properly.
BEARINGS RUN
TOO HOT
PREVENTIVE MAINTENANCE
Since pump applications are seldom identical, and
pump wear is directly affected by such things as
the abrasive qualities, pressure and temperature
of the liquid being pumped, this section is intended
only to provide general recommendations and
practices for preventive maintenance. Regardless
of the application however, following a routine preventive maintenance schedule will help assure
trouble-free performance and long life from your
Gorman-Rupp pump. For specific questions concerning your application, contact your GormanRupp distributor or the Gorman-Rupp Company.
Record keeping is an essential component of a
good preventive maintenance program. Changes
in suction and discharge gauge readings (if so
TROUBLESHOOTING
equipped) between regularly scheduled inspections can indicate problems that can be corrected
before system damage or catastrophic failure occurs. The appearance of wearing parts should also
be documented at each inspection for comparison
as well. Also, if records indicate that a certain part
(such as the seal) fails at approximately the same
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 inspections should be performed at the intervals shown
on the chart below. Critical applications should be
inspected more frequently.
PAGE D -- 3
OM -- 01863-- 02
U SERIES
Preventive Maintenance Schedule
Item
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.)
Pump Performance (Gauges, Speed, Flow)
Bearing Lubrication
Seal Lubrication (And Packing Adjustment,
If So Equipped)
V-Belts (If So Equipped)
Air Release Valve Plunger Rod (If So Equipped)
Front Impeller Clearance (Wear Plate)
Rear Impeller Clearance (Seal Plate)
Check Valve
Pressure Relief Valve (If So Equipped)
Pump and Driver Alignment
Shaft Deflection
Bearings
Bearing Housing
Piping
Driver Lubrication --- See Mfgr’s Literature
Service Interval*
Daily
I
I
Weekly
Monthly
Semi- Annually
Annually
I
I
R
I
I
R
C
I
I
I
C
I
I
I
I
I
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
OM -- 01863-- 02
U SERIES
PUMP MAINTENANCE AND REPAIR --- SECTION E
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE.
STANDARD PERFORMANCE FOR PUMP MODEL U4B60-B
Based on 70_ F (21_ C) clear water at sea level
with minimum suction lift. Since pump installations
are seldom identical, your performance may be difference 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.
MAINTENANCE & REPAIR
Contact the Gorman-Rupp Company to verify performance or part numbers.
Pump speed and operating condition
points must be within the continuous performance range shown on the curve.
PAGE E -- 1
OM -- 01863-- 02
U SERIES
SECTION DRAWING
TOP VIEW
38
39
40
3
4
5
6
7, 8
9
41
10
37
36
1
35
44
45
46
47
43
34
33
11
12
32
31
27 30
29
28
13
26
2
25
14
15
16
24 23, 22
21
20
19
18
17
Figure 1. Pump Model U4B60---B
PAGE E -- 2
MAINTENANCE & REPAIR
OM -- 01863-- 02
U SERIES
PARTS LIST
Pump Model U4B60---B
(From S/N 860554 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
NO.
PART
NUMBER
MAT’L
CODE
QTY
ITEM PART NAME
NO.
PART
NUMBER
1
PUMP CASING
38222--- 508
2
3
4
REPAIR ROTATING ASSY 44163--- 041
SUCTION FLANGE
11389
CHECK VALVE PIN
11557
10010
1
--- --- --10010
17010
1
1
1
11389G
P04
B1007
J10
1756
19370
15079
15991
15991
10010
1
1
8
8
1
DISCH FLANGE GSKT
NAME PLATE
DRIVE SCREW
1676G
38818--- 026
BM#04--- 03
19370
13990
15990
1
1
4
37
38
39
40
41
43
44
45
46
47
J10
15991
P04
15079
38111--- 004 11010
A1014
15991
31912--- 009 15000
42111--- 344 --- --- --NOT AVAILABLE
38816--- 097 13990
BM#04--- 03 17000
50G
19210
8
1
1
2
1
1
1
1
2
1
5
6
7
8
9
SUCTION FLANGE GSKT
PIPE PLUG
HEX HD CAPSCREW
LOCKWASHER
DISCHARGE FLANGE
10
11
12
13
14
15
16
ROTATING ASSY O-RING
ROTATION DECAL
HEX HD CAPSCREW
LOCKWASHER
25152--- 277
2613M
B0806
J08
--- --- ----- --- --15991
15991
REF
1
4
4
17
18
ROT ASSY SHIM SET
CASING DRAIN PLUG
13130
P16
17000
10009
REF
2
11421
6588AG
6588BJ
6588AH
38816--- 096
--- --- ----- --- ----- --- ----- --- ----- --- ---
1
1
1
1
1
19
SEAL PLATE O-RING
25152--- 276
--- --- ---
REF
20
WEAR PLATE ASSY
46451--- 710
--- --- ---
1
12859
24000
1
21
22
23
WEAR PLATE O-RING
HEX NUT
LOCKWASHER
25152--- 258
D06
J06
--- --- --15991
15991
1
2
2
12066
12066A
10010
10010
1
1
24
25
26
27
28
29
30
BACK COVER O-RING
STUD
HAND NUT
BACK CVR PLATE ASSY
--- WARNING PLATE
--- DRIVE SCREW
--- BACK COVER PLATE
25152--- 277 --- --- --C1010
15991
10701
15040
42111--- 940 --- --- --2613EV
13990
BM#04--- 03 17000
NOT AVAILABLE
1
2
2
1
1
4
1
38642--- 210
38642--- 211
10000
10000
1
1
CD4 SST WEAR PLATE
46451--- 738
BUNA-N CHECK VLV ASSY46411--- 104
--- --- ----- --- ---
1
1
31
32
--- PRESS RELIEF VALVE
--- CAUTION DECAL
26662--- 006
2613FG
--- --- ----- --- ---
1
1
PRESS RELIEF VALVE:
--- SEWAGE TYPE
--- --- ---
1
33
34
35
36
CHECK VALVE ASSY
PIPE PLUG
PIPE PLUG
HEX HD CAPSCREW
46411--- 062
P04
P04
B1008
--- --- --15079
15079
15991
1
1
1
8
--- 10# COMP SPRING
GRP33--- 07A --- --- ---
1
--- 25# COMP SPRING
--- 80# COMP SPRING
GRP33--- 07 --- --- --GRP33--- 07B --- --- ---
1
1
LOCKWASHER
PIPE PLUG
CLAMP BAR
MACHINE BOLT
CLAMP BAR SCREW
FILL COVER ASSY
--- FILL COVER PLATE
--- WARNING PLATE
--- DRIVE SCREW
--- FILL COVER GASKET
NOT SHOWN:
LUB DECAL
SUCTION STICKER
DISCHARGE STICKER
PRIMING STICKER
WARNING DECAL
OPTIONAL:
DISASSEMBLY TOOL
/F FLANGES:
--- SUCTION
--- DISCHARGE
/FM METRIC FLANGES:
--- SUCTION
--- DISCHARGE
MAT’L
CODE
46431--- 628
QTY
AIR RELEASE VALVES:
INDICATES PARTS RECOMMENDED FOR STOCK
Above Serial Numbers Do Not Apply To Pumps Made In Canada.
CANADIAN SERIAL NO. ..............................
MAINTENANCE & REPAIR
AND UP
PAGE E -- 3
OM -- 01863-- 02
U SERIES
SECTION DRAWING
DRIVE END VIEW
29
30
3
SEAL AREA DETAIL
25
28
26
1
2
4
5
6, 31
7, 32
27
8
9
10
11
12
24
23
13
14
22
21 20,19
18
17
34
16, 15
33
Figure 2. 44163---041 Repair Rotating Assembly
PAGE E -- 4
MAINTENANCE & REPAIR
OM -- 01863-- 02
U SERIES
PARTS LIST
44163---041 Repair Rotating Assembly
ITEM
PART NAME
NO.
1
IMPELLER
2
SEAL PLATE O-RING
3
SEAL ASSEMBLY
4
INBOARD BALL BEARING
5
BEARING HOUSING
6
VENTED PLUG
7
AIR VENT
8
REDUCING PIPE BUSHING
9
OUTBOARD BALL BEARING
10
BEARING CAP
11
IMPELLER SHAFT
12
SHAFT KEY
13
BEARING CAP OIL SEAL
14
BEARING RETAINING RING
15
HEX HD CAPSCREW
16
LOCKWASHER
17
BEARING CAP GASKET
18
INBOARD OIL SEAL
19
HEX HD CAPSCREW
20
LOCKWASHER
21
SEAL PLATE GASKET
22
SEAL PLATE
23
IMPELLER WASHER
24
SOCKET HD CAPSCREW
25
PIPE PLUG
26
BEARING HOUSING DRAIN PLUG
27
SEAL CAVITY DRAIN PLUG
28
SIGHT GAUGE
29
IMPELLER ADJ SHIM SET
30
SEAL SLEEVE O-RING
31
SHIPPING PLUG
32
SHIPPING PLUG
33
ROTATING ASSY ADJ SHIM SET
34
ROTATING ASSY O-RING
OPTIONAL:
CD4 SST IMPELLER
CD4 SST SEAL PLATE
SST IMPELLER WASHER
SST IMPELLER CAPSCREW
[
PERMALON COATED MECH SEAL ASSY
[
STD MECHANICAL SEAL ASSEMBLY
[
MECH SEAL SHAFT SLEEVE
NOT SHOWN:
ROTATION DECAL
[
PART
NUMBER
38619---011
25152---276
46513---151
23276---009
38251---508
4823A
S1530
AP0802
S1040
38322---215
10529
N0608
S1352
S244
B0605
J06
38683---248
S1352
B0805 1/2
J08
10959G
38272---233
10278
DM1004S
P12
P08
P08
S1471
37J
S2088
11495B
11495B
13130
25152---277
MAT’L
CODE
11000
--- --- ----- --- ----- --- --10010
15079
--- --- --15079
--- --- --10010
16040
15990
--- --- ----- --- --15991
15991
18000
--- --- --15991
15991
20000
10010
15030
15991
15079
15079
15079
--- --- --17090
--- --- --15079
15079
17000
--- --- ---
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
4
4
1
1
1
1
1
1
1
1
REF
REF
1
1
4
1
38619---011
38272---233
10278
DM1004S
46512---150
46512---047
11876A
1718H
1718H
17090
17090
--- --- ----- --- --16000
1
1
1
1
1
1
1
2613M
--- --- ---
1
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MECHANICAL SEAL SHAFT SLEEVE MUST BE USED WITH OPTIONAL MECHANICAL SEAL(S).
MAINTENANCE & REPAIR
PAGE E -- 5
OM -- 01863-- 02
PUMP AND SEAL DISASSEMBLY
AND REASSEMBLY
U SERIES
6. Vent the pump slowly and cautiously.
7. Drain the pump.
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and decals
attached to the pump.
This pump requires little service due to its rugged,
minimum-maintenance design. However, if it becomes necessary to inspect or replace the wearing
parts, follow these instructions which are keyed to
the sectional views (see Figures 1 and 2) and the
accompanying parts lists.
Many service functions may be performed by
draining the pump and removing the back cover
assembly. If major repair is required, the piping
and/or power source must be disconnected. The
following instructions assume complete disassembly is required.
Before attempting to service the pump, disconnect
or lock out the power source and take precautions
to ensure that it will remain inoperative. Close all
valves in the suction and discharge lines.
For power source disassembly and repair, consult
the literature supplied with the power source, or
contact your local power source representative.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or damage to equipment.
Back Cover And Wear Plate Removal
(Figure 1)
The wear plate (20) is easily accessible and may be
serviced by removing the back cover assembly
(27). Before attempting to service the pump, remove the pump casing drain plugs (18) and drain
the pump. Clean and reinstall the drain plugs.
Remove the hand nuts (26) and pull the back cover
and assembled wear plate from the pump casing
(1). Inspect the wear plate, and replace it if badly
scored or worn. To remove the wear plate, disengage the hardware (22 and 23).
Inspect the wear plate and back cover O-rings (21
and 24) and replace them if damaged or worn.
Suction Check Valve Removal
(Figure 1)
Before attempting to open or service the
pump:
1. Familiarize yourself with this manual.
2. Disconnect or lock out the power
source to ensure that the pump will
remain inoperative.
3. Allow the pump to cool if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
PAGE E -- 6
If the check valve assembly (33) is to be serviced,
remove the check valve pin (4), reach through the
back cover opening and pull the complete assembly from the suction flange (3).
NOTE
Further disassembly of the check valve is not required since it must be replaced as a complete unit.
Individual parts are not sold separately.
Rotating Assembly Removal
(Figure 2)
The rotating assembly may be serviced without
disconnecting the suction or discharge piping;
MAINTENANCE & REPAIR
U SERIES
OM -- 01863-- 02
however, the power source must be removed to
provide clearance.
The impeller (1) should be loosened while the rotating assembly is still secured to the pump casing.
Before loosening the impeller, remove the seal cavity drain plug (27) and drain the seal lubricant. This
will prevent the oil in the seal cavity from escaping
when the impeller is loosened. Clean and reinstall
the seal cavity drain plug.
Immobilize the impeller by wedging a block wood
between the vanes and the pump casing, and remove the impeller capscrew and washer (23 and
24).
If removed, install the shaft key (12). Install a lathe
dog on the drive end of the shaft (11) with the “V”
notch positioned over the shaft key.
(Figure 1)
Remove the hardware (15 and 16) securing the rotating assembly to the pump casing. Separate the
rotating assembly by pulling straight away from the
pump casing.
NOTE
An optional disassembly tool is available from the
factory. If the tool is used, follow the instructions
packed with it. A similar tool may be assembled using 1/2-inch pipe (schedule 80 steel or malleable
iron) and a standard tee (see Figure 4). All threads
are 1/2-inch NPT. Do not pre-assemble the tool.
TEE
With the impeller rotation still blocked, see Figure 3
and use a long piece of heavy bar stock to pry
against the arm of the lathe dog in a counterclockwise direction (when facing the drive end of the
shaft). Use caution not to damage the shaft or keyway. When the impeller breaks loose, remove the
lathe dog, key and wood block.
NOTE
Do not remove the impeller until the rotating assembly has been removed from the pump casing.
Turn
Counterclockwise
Lathe Dog Arm
Heavy
Bar Stock
“V” Notch
APPROX. 6 IN.
(152 MM) LONG
APPROX. 14 IN.
(356 MM) LONG
Figure 4. Rotating Assembly Tool
To install the tool, remove the air vent (7, Figure 2)
from the bearing housing, and screw the longest
length of pipe into the vent hole until fully engaged.
Install the tee, and screw the handles into the tee.
Use caution when lifting the rotating assembly to
avoid injury to personnel or damage to the assembly.
Remove the bearing housing and seal plate Orings (13 and 19). Remove the rotating assembly
shim sets (17); tie and tag the shim sets, or measure and record their thickness for ease of reassembly.
Shaft Key
Impeller Shaft
Impeller Removal
Lathe Dog
(Figure 2)
Setscrew
Figure 3. Loosening Impeller
MAINTENANCE & REPAIR
With the rotating assembly removed from the
pump casing, unscrew the impeller from the shaft.
Use caution when unscrewing the impeller; tenPAGE E -- 7
OM -- 01863-- 02
sion on the shaft seal spring will be released as the
impeller is removed. Inspect the impeller and replace if cracked or badly worn.
Remove the impeller adjusting shims (29); tie and
tag the shims, or measure and record their thickness for ease of reassembly.
Seal Removal
(Figure 2)
U SERIES
Disengage the hardware (15 and16) and slide the
bearing cap (10) and oil seal (13) off the shaft.Remove the bearing cap gasket (17), and press the oil
seal from the bearing cap.
Place a block of wood against the impeller end of
the shaft and tap the shaft and assembled bearings (4 and 9) from the bearing housing.
After removing the shaft and bearings, clean and
inspect the bearings in place as follows.
Slide the integral shaft sleeve and rotating portion
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 (19
and 20) and separate the seal plate (22) and gasket (21) from the bearing housing (5). Position the
seal plate on a flat surface with the impeller side
down. Use a wooden dowel or other suitable tool to
press on the back side of the stationary seat until
the seat, O-rings, and stationary element can be
removed.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and bearings are removed.
Clean the bearing housing, shaft and all component parts (except the bearings) with a soft cloth
soaked in cleaning solvent. Inspect the parts for
wear or damage and replace as necessary.
Remove the shaft sleeve O-ring (30).
If no further disassembly is required, refer to Seal
Installation.
Shaft and Bearing Removal and Disassembly
(Figure 2)
When the pump is properly operated and maintained, the bearing housing should not require disassembly. Disassemble the shaft and bearings
only when there is evidence of wear or damage.
Shaft and bearing disassembly in the field
is not recommended. These operations
should be performed only in a properlyequipped shop by qualified personnel.
Remove the bearing housing drain plug (26) and
drain the lubricant. Clean and reinstall the drain
plug.
PAGE E -- 8
Most cleaning solvents are toxic and
flammable. Use them only in a well-ventilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent containers.
Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.
Bearings must be kept free of all dirt and
foreign material. Failure to do so will greatly shorten bearing life. DO NOT spin dry
bearings. This may scratch the balls or
races and cause premature bearing failure.
Rotate the bearings by hand to check for roughness or binding and inspect the bearing balls. If roMAINTENANCE & REPAIR
U SERIES
tation is rough or the bearing balls are discolored,
replace the bearings.
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 outboard bearing retaining ring (14), and use a bearing puller to remove the bearings from the shaft.
Press the inboard oil seal (18) from the bearing
housing.
Shaft and Bearing Reassembly and Installation
(Figure 2)
Clean the bearing housing, shaft and all component 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-ventilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent containers.
Inspect the shaft for distortion, nicks or scratches,
or for thread damage on the impeller end. Dress
small nicks and burrs with a fine file or emery cloth.
Replace the shaft if defective.
Position the inboard oil seal (18) in the bearing
housing bore with the lip positioned as shown in
Figure 2. Press the oil seal into the housing until the
face is just flush with the machined surface on the
housing.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
MAINTENANCE & REPAIR
OM -- 01863-- 02
be replaced any time the shaft and bearings are removed.
NOTE
Position the inboard bearing (4) on the shaft with
the shielded side toward the impeller end of the
shaft. Position the outboard bearing (9) on the shaft
with the integral retaining ring on the bearing O.D.
toward the drive end of the shaft.
The bearings may be heated to ease installation.
An induction heater, hot oil bath, electric oven, or
hot plate may be used to heat the bearings. Bearings should never be heated with a direct flame or
directly on a hot plate.
NOTE
If a hot oil bath is used to heat the bearings, both the
oil and the container must be absolutely clean. If
the oil has been previously used, it must be thoroughly filtered.
Heat the bearings to a uniform temperature no
higher than 250_F (120_C), and slide the bearings
onto the shaft, one at a time, until they are fully
seated. This should be done quickly, in one continuous motion, to prevent the bearings from cooling and sticking on the shaft.
After the bearings have been installed and allowed
to cool, check to ensure that they have not moved
away from the shaft shoulders in shrinking. If
movement has occurred, use a suitable sized
sleeve and a press to reposition the bearings
against the shaft shoulders.
If heating the bearings is not practical, use a suitable sized sleeve, and an arbor (or hydraulic) press
to install the bearings on the shaft.
When installing the bearings onto the
shaft, never press or hit against the outer
race, balls, or ball cage. Press only on the
inner race.
Secure the outboard bearing on the shaft with the
bearing retaining ring (14).
PAGE E -- 9
OM -- 01863-- 02
Slide the shaft and assembled bearings into the
bearing housing until the retaining ring on the outboard bearing seats against the bearing housing.
When installing the shaft and bearings into
the bearing bore, push against the outer
race. Never hit the balls or ball cage.
Press the outboard oil seal (13) into the bearing
cap (10) with the lip positioned as shown in Figure
2. Replace the bearing cap gasket (17), and secure
the bearing cap with the hardware (15 and 16). Be
careful not to damage the oil seal lip on the shaft
keyway.
Lubricate the bearing housing as indicated in LUBRICATION.
Seal Installation
(Figures 2, 5, 6 and 7)
U SERIES
Most cleaning solvents are toxic and
flammable. Use them only in a well --ventilated area free from excessive
heat, sparks, and flame. Read and follow all precautions printed on solvent
containers.
Clean the seal cavity and shaft with a cloth soaked
in fresh cleaning solvent. Inspect the stationary
seat bore in the seal plate for dirt, nicks and burrs,
and remove any that exist. The stationary seat bore
must be completely clean before installing the
seal.
A new seal assembly should be installed
any time the old seal is removed from the
pump. Wear patterns on the finished faces
cannot be realigned during reassembly.
Reusing an old seal could result in premature failure.
To ease installation of the seal, lubricate the shaft
sleeve O-ring and the external stationary seat Oring with a very small amount of light lubricating oil.
See Figure 5 for seal part identification.
PAGE E -- 10
MAINTENANCE & REPAIR
U SERIES
OM -- 01863-- 02
RETAINER
SEAL PLATE
SPRING
O-RINGS
IMPELLER
SLEEVE
O-RING
IMPELLER
SHIMS
IMPELLER
SHAFT
ROTATING ELEMENT
BELLOWS
STATIONARY ELEMENT
INTEGRAL
SHAFT
SLEEVE
SHEAR
RING
(SHEARED)
SPRING
CENTERING WASHER
STATIONARY SEAT
DRIVE BAND
Figure 5. 46513-- 151 Cartridge Seal Assembly
When installing a new cartridge seal assembly,
remove the seal from the container, and remove
the mylar storage tabs from between the seal
faces.
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 (21). Position the seal plate over the shaft
and secure it to the bearing housing with the hardware (19 and 20).
New cartridge seal assemblies are
equipped with mylar storage tabs between
the seal faces. These storage tabs must be
removed before installing the seal.
To prevent damaging the shaft sleeve O-ring (30)
on the shaft threads, stretch the O-ring over a piece
of tubing 1-1/4 I.D. x 1-1/2 O.D. x 2-inches long (32
mm x 38 mm x 51 mm). Slide the tube over the shaft
threads, then slide the O-ring off the tube and onto
the shaft. Remove the tube, and continue to slide
the O-ring down the shaft until it seats against the
shaft shoulder.
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
bore in the seal plate.
MAINTENANCE & REPAIR
Clean and inspect the impeller as described in Impeller Installation and Adjustment. Install the full
set of impeller shims (29) provided with the seal,
PAGE E -- 11
OM -- 01863-- 02
U SERIES
and screw the impeller onto the shaft until it is
seated against the seal (see Figure 6).
O-RING ENGAGED
WITH SEAL PLATE
BORE
SHEAR RING
(UNSHEARED)
Figure 6. Seal Partially Installed
Continue to screw the impeller onto the shaft. This
will press the stationary seat into the seal plate
bore.
NOTE
A firm resistance will be felt as the impeller presses
the stationary seat into the seal plate bore.
As the stationary seat becomes fully seated, the
seal spring compresses, and the shaft sleeve will
break the nylon shear ring. This allows the sleeve
to slide down the shaft until seated against the
shaft shoulder. Continue to screw the impeller onto
the shaft until the impeller, shims, and sleeve are
fully seated against the shaft shoulder (see Figure
7).
STATIONARY SEAT
FULLY SEATED IN
SEAL PLATE BORE
Measure the impeller-to-seal plate clearance, and
remove impeller adjusting shims to obtain the
proper clearance as described in Impeller Installation and Adjustment.
If necessary to reuse an old seal in an emergency, carefully separate the rotating and stationary seal faces from the bellows retainer and stationary seat.
A new seal assembly should be installed
any time the old seal is removed from the
pump. Wear patterns on the finished faces
cannot be realigned during reassembly.
Reusing an old seal could result in premature failure.
Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate precision
finished faces; even fingerprints on the faces can
shorten seal life. If necessary, clean the faces with a
non-oil based solvent and a clean, lint-free tissue.
Wipe lightly in a concentric pattern to avoid
scratching the faces.
Carefully wash all metallic parts in fresh cleaning
solvent and allow to dry thoroughly.
Do not attempt to separate the rotating
portion of the seal from the shaft sleeve
when reusing an old seal. The rubber bellows will adhere to the sleeve during use,
and attempting to separate them could
damage the bellows.
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leakage. Inspect the integral shaft sleeve for nicks or
cuts on either end. If any components are worn, or
the sleeve is damaged, replace the complete seal;
never mix old and new seal parts.
SHEAR RING
(SHEARED)
Figure 7. Seal Fully Installed
PAGE E -- 12
Install the stationary seal element in the stationary
seat. Press this stationary subassembly into the
seal plate bore until it seats squarely against the
bore shoulder. A push tube made from a piece of
plastic pipe would aid this installation. The I.D. of
MAINTENANCE & REPAIR
U SERIES
OM -- 01863-- 02
the pipe should be slightly larger than the O.D. of
the shaft sleeve.
Slide the rotating portion of the seal (consisting of
the integral shaft sleeve, spring centering washer,
spring, bellows and retainer, and rotating element)
onto the shaft until the seal faces contact.
Proceed with Impeller Installation and Adjustment.
Impeller Installation
(Figure 2)
Inspect the impeller, and replace it if cracked or
badly worn. Inspect the impeller and shaft threads
for dirt or damage, and clean or dress the threads
as required.
pump casing, this clearance may be measured by
reaching through the priming port with a feeler
gauge.
NOTE
Proceed with Rotating Assembly Installation before installing the impeller capscrew and washer
(23 and 24). The rotating assembly must be installed in the pump casing in order to torque the impeller capscrew.
After the rotating assembly is installed in the pump
casing, coat the threads of the impeller capscrew
(24) with ‘Never-Seez’ or equivalent compound,
and install the impeller washer (23) and capscrew;
torque the capscrew to 90 ft. lbs. (1080 in. lbs. or
12,4 m. kg.).
Rotating Assembly Installation
The shaft and impeller threads must be
completely clean before reinstalling the impeller. Even the slightest amount of dirt on
the threads can cause the impeller to seize
to the shaft, making future removal difficult
or impossible without damage to the impeller or shaft.
Install the same thickness of impeller adjusting
shims (29) as previously removed. Apply ‘NeverSeez’ or equivalent to the shaft threads and screw
the impeller onto the shaft until tight. Be sure the
seal spring seats squarely over the shoulder on the
back side of the impeller.
NOTE
At the slightest sign of binding, immediately back
the impeller off, and check the threads for dirt. Do
not try to force the impeller onto the shaft.
A clearance of .025 to .040 inch (0,64 to 1,02 mm)
between the impeller and the seal plate is recommended for maximum pump efficiency. Preload
the shaft in the direction of the impeller. Measure
this clearance, and add or remove impeller adjusting shims as required.
NOTE
If the rotating assembly has been installed in the
MAINTENANCE & REPAIR
(Figure 1)
NOTE
If the pump has been completely disassembled, it
is recommended that the suction check valve and
back cover assembly be reinstalled at this point.
The back cover assembly must be in place to adjust
the impeller face clearance.
Install the bearing housing and seal plate O-rings
(13 and 19) and lubricate them with light grease.
Ease the rotating assembly into the pump casing
using the installation tool. Be careful not to damage the O-rings.
Install the four sets of rotating assembly adjusting
shims (17) using the same thickness as previously
removed. Secure the rotating assembly to the
pump casing with the hardware (15 and 16). Do
not fully tighten the capscrews until the back cover
has been reinstalled and the impeller face clearance has been set.
A clearance of .003 to .005 inch (0,08 to 0,13 mm)
between the impeller and the wear plate is also recommended for maximum pump efficiency. This
clearance can be obtained by removing an equal
amount of shims from each rotating assembly
shim set until the impeller scrapes against the wear
plate when the shaft is turned. Preload the shaft in
PAGE E -- 13
OM -- 01863-- 02
U SERIES
the direction of the impeller when checking this
clearance. After the impeller scrapes, add approximately .003 inch (0,08 mm) of shims to each shim
set.
the pump casing with the attaching hardware.
Back Cover Installation
(Figure 1)
NOTE
An alternate method of adjusting this clearance is to
reach through the suction port with a feeler gauge
and measure the gap. Add or subtract rotating assembly shims accordingly.
After the face clearance has been set, tighten the
hardware securing the rotating assembly to the
pump casing.
Suction Check Valve Installation
If the wear plate (20) was removed for replacement, install the wear plate O-ring (21). Carefully
center the wear plate on the back cover and secure
it with the hardware (22 and 23). The wear plate
must be concentric to prevent binding when the
back cover is installed.
Replace the back cover O-ring (24), and lubricate it
with a generous amount of No. 2 grease. Clean any
scale or debris from the contacting surfaces in the
pump casing that might interfere or prevent a good
seal with the back cover. Slide the back cover assembly into the pump casing. Be sure the wear
plate does not bind against the impeller.
(Figure 1)
NOTE
NOTE
Check the pipe plug (35) in the interior wall of the
pump casing to be sure it is tightly installed.
Inspect the check valve assembly (33), and replace it if badly worn.
NOTE
The check valve assembly must be replaced as a
complete unit. Individual parts are not sold separately.
Reach through the back cover opening with the
check valve (33), and position the check valve
adaptor in the mounting slot in the suction flange
(3). Align the adaptor with the flange hole, and secure the assembly with the check valve pin (4).
NOTE
If the suction or discharge flanges were removed,
replace the respective gaskets, apply ‘Permatex
Aviation No. 3 Form-A-Gasket’ or equivalent compound to the mating surfaces, and secure them to
PAGE E -- 14
To ease future disassembly, apply a film of grease
or ‘Never-Seez’ on the back cover shoulder, or any
surface which contacts the pump casing. This action will reduce rust and scale build-up.
Secure the back cover assembly by tightening the
hand nuts (26) evenly. Do not over-tighten the
hand nuts; they should be just tight enough to ensure a good seal at the back cover shoulder. Be
sure the wear plate does not bind against the casing.
PRESSURE RELIEF VALVE
MAINTENANCE
(Figure 1)
The back cover is equipped with a pressure relief
valve (31) to provide additional safety for the pump
and operator (refer to Liquid Temperature And
Overheating in OPERATION).
It is recommended that the pressure relief valve assembly be replaced at each overhaul, or any time
the pump overheats and activates the valve. Never
replace this valve with a substitute which has not
been specified or provided by the Gorman-Rupp
Company.
MAINTENANCE & REPAIR
U SERIES
OM -- 01863-- 02
Periodically, the valve should be removed for inspection and cleaning. When reinstalling the relief
valve, apply ‘Loctite Pipe Sealant With Teflon No.
592’, or equivalent compound, on the relief valve
threads. Position the valve as shown in Figure 1
with the discharge port pointing down.
Clean and reinstall the vented plug. Maintain the oil
at this level.
Final Pump Assembly
The bearing housing was fully lubricated when
shipped from the factory. Check the oil level regularly through the sight gauge (28) and maintain it at
the middle of the gauge. When lubrication is required, add SAE No. 30 non-detergent oil through
the hole for the air vent (7). Do not over-lubricate.
Over-lubrication can cause the bearings to overheat, resulting in premature bearing failure.
(Figure 1)
Install the shaft key (12, Figure 2) and reconnect
the power source. Be sure to install any guards
used over the rotating members.
Bearings
(Figure 2)
NOTE
Do not operate the pump without the
guards in place over the rotating parts.
Exposed rotating parts can catch clothing, fingers, or tools, causing severe injury to personnel.
Install the suction and discharge lines and open all
valves. Make certain that all piping connections are
tight, properly supported and secure.
The white reflector in the sight gauge must be positioned horizontally to provide proper drainage.
Under normal conditions, drain the bearing housing once each year and refill with approximately 32
ounces (1 liter) clean oil. Change the oil more frequently if the pump is operated continuously or installed in an environment with rapid temperature
change.
Be sure the pump and power source have been
properly lubricated, see LUBRICATION.
Remove the fill cover assembly (43) and fill the
pump casing with clean liquid. Reinstall the fill
cover and tighten it. Refer to OPERATION, Section
C, before putting the pump back into service.
LUBRICATION
Seal Assembly
(Figure 2)
Before starting the pump, remove the vented plug
(6) and fill the seal cavity with approximately 20
ounces (0,6 liters) of SAE No. 30 non-detergent oil,
or to a level just below the tapped vented plug hole.
MAINTENANCE & REPAIR
Monitor the condition of the bearing lubricant regularly for evidence of rust or moisture condensation. This is especially important in areas where variable hot and
cold temperatures are common.
For cold weather operation, consult the factory or a
lubricant supplier for the recommended grade of
oil.
Power Source
Consult the literature supplied with the power
source, or contact your local power source representative.
PAGE E -- 15
For U.S. and International Warranty Information,
Please Visit www.grpumps.com/warranty
or call:
U.S.: 419−755−1280
International: +1−419−755−1352
For Canadian Warranty Information,
Please Visit www.grcanada.com/warranty
or call:
519−631−2870
THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA