Installation, Operation, and Maintenance Manual: Ultra V Pump

CDS OM-06014-02
November 10, 2006

Rev. D 12‐14‐12
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
ULTRA V PUMP
MODEL
VS6A60‐B
INCLUDING: /WW
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO

www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
2006 The Gorman‐Rupp Company
Register your new
Gorman‐Rupp pump online at
www.grpumps.com
Valid serial number and e‐mail address required.
RECORD YOUR PUMP MODEL AND SERIAL NUMBER
Please record your pump model and serial number in the

spaces provided below. Your Gorman‐Rupp distributor
needs this information when you require parts or service.
Pump Model:
Serial Number:
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 - 1
POSITIONING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 1
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
SUCTION AND DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
Line Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
Connections to Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
SUCTION LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 2
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 3
Suction Lines In Sumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 3
Suction Line Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 3
DISCHARGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 4
Siphoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 4
Bypass Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 4
AUTOMATIC AIR RELEASE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 5
Air Release Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 6
DRIVE ARRANGEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 7
Dual Motor Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 7
Single Motor Belt Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 7
Single Motor Combination Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 8
HIGH PUMP TEMPERATURE SHUTDOWN FOR STAGED APPLICATIONS . . . . . . . . PAGE B - 9
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 9
Coupled Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 9
Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 10
DRIVE BELT TENSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 10
General Rules of Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 10
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
i
TABLE OF CONTENTS
(continued)
Pump Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C - 3

STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C - 3
Cold Weather Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C - 3
BEARING TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C - 3
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:
VS6A60-B And VS6A60-B /WW Pump Models . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 3
Pump Models 46167-041 And 46146-042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 5
46146-001 Ultra Mate Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 7
Repair Rotating Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 9
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 10
Support Plare Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 11
Back Cover And Wear Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 11
Rotating Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 11
Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 12
Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 12
Shaft and Bearing Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 12
Pump Casing and Transition Chamber Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 13
Pump Casing and Transition Chamber Installation . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 14
Shaft and Bearing Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 14
Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 15
Impeller Installation And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 18
Rotating Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 18
Back Cover Installation And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 18
PRESSURE RELIEF VALVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 19
Final Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 20
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 20
Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 20
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 20
Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 20
ii
ULTRA V SERIES OM-06014
INTRODUCTION
Thank You for purchasing a Gorman‐Rupp pump. The following are used to alert maintenance per
Read this manual carefully to learn how to safely sonnel to procedures which require special atten
install and operate your pump. Failure to do so tion, to those which could damage equipment, and
could result in personal injury or damage to the to those which could be dangerous to personnel:
pump.
Ultra V Series pumps are designed for handling liq

uids containing large entrained solids and slurries.
The basic material of construction for Ultra V Series
pumps is cast iron, with ductile iron impeller and
steel wearing parts. Immediate hazards which WILL result in
This manual will alert personnel to known proce severe personal injury or death. These
dures which require special attention, to those instructions describe the procedure re
which could damage equipment, and to those quired and the injury which will result
which could be dangerous to personnel. However, from failure to follow the procedure.
this manual cannot possibly anticipate and provide
detailed precautions for every situation that might
occur during maintenance of the unit. Therefore, it
is the responsibility of the owner/maintenance per
sonnel to ensure that only safe, established main Hazards or unsafe practices which
tenance procedures are used, and that any proce COULD result in severe personal injury
dures not addressed in this manual are performed or death. These instructions describe
only after establishing that neither personal safety the procedure required and the injury
nor pump integrity are compromised by such prac which could result from failure to follow
tices. the procedure.
For information or technical assistance on the
power source, contact the power source manufac
turer's local dealer or representative.
Hazards or unsafe practices which COULD
If there are any questions regarding the pump or
its application which are not covered in this man
result in minor personal injury or product
ual or in other literature accompanying this unit, or property damage. These instructions
please contact your Gorman‐Rupp distributor, or: describe the requirements and the possi
ble damage which could result from failure
The Gorman‐Rupp Company to follow the procedure.
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: (419) 755-1011
NOTE
or: Instructions to aid in installation, operation, and
Gorman‐Rupp of Canada Limited maintenance or which clarify a procedure.
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-2870
INTRODUCTION PAGE I - 1
SAFETY - SECTION A
This information applies toUltra V Se containing large entrained solids or

ries pumps. Gorman‐Rupp has no con slurries. Do not attempt to pump vola
trol over or particular knowledge of the tile, corrosive, or flammable materials
power source which will be used. Refer which may damage the pump or endan
to the manual accompanying the power ger personnel as a result of pump fail
source before attempting to begin ure.
operation.
Because pump installations are seldom

identical, this manual cannot possibly
provide detailed instructions and pre After the pump has been positioned,
cautions for each specific application. make certain that the pump and all pip
Therefore, it is the owner/installer's re ing connections are tight, properly sup
sponsibility to ensure that applications ported 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
jury to personnel.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Disconnect or lock out the power Do not remove plates, covers, gauges,
source to ensure that the pump will pipe plugs, or fittings from an over
remain inoperative. heated pump. Vapor pressure within the
3. Allow the pump to completely cool pump can cause parts being disen
if overheated. gaged to be ejected with great force. Al
4. Check the temperature before low the pump to completely cool before
opening any covers, plates, or servicing.
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau
tiously.
Do not operate the pump against a
7. Drain the pump.
closed discharge valve for long periods
of time. If operated against a closed dis
charge valve, pump components will
deteriorate, and the liquid could come
to a boil, build pressure, and cause the
This pump is designed to handle liquids pump casing to rupture or explode.
SAFETY PAGE A - 1
OM-06014 ULTRA V SERIES
Use lifting and moving equipment in Do not attempt to disengage any part of
good repair and with adequate capacity an overheated pump unit. Vapor pres
to prevent injuries to personnel or dam sure within the pump casing can eject
age to equipment. Suction and dis these parts with great force when they
charge hoses and piping must be re are disengaged. Allow the pump to
moved from the pump before lifting. completely cool before servicing it.
Do not install a suction check valve in Pumps and related equipment must be in
the first stage of the VS Series pump stalled and operated according to all na
model. Installing a suction check valve tional, local and industry standards.
in the first stage of the VS Series pump
model can cause over‐pressurization of
the first stage pump casing, resulting in
possible explosion of the pump and se
rious injury or death to presonnel.
PAGE A - 2 SAFETY
INSTALLATION - SECTION B
Review all SAFETY information in Section A. Check that the pump shaft rotates counter
clockwise when facing the impeller.
Since pump installations are seldom identical, this
section offers only general recommendations and
practices required to inspect, position, and ar
range the pump and piping.
Most of the information pertains to a standard stat Only operate this pump in the direction in
ic lift application where the pump is positioned dicated by the arrow on the pump body
above the free level of liquid to be pumped. and on the accompanying decal. Refer to
ROTATION in OPERATION, Section C.
If installed in a flooded suction application where d. Check levels and lubricate as necessary.
the liquid is supplied to the pump under pressure, Refer to LUBRICATION in the MAINTEN
some of the information such as mounting, line ANCE AND REPAIR section of this manual
configuration, and priming must be tailored to the and perform duties as instructed.
specific application. Since the pressure supplied
to the pump is critical to performance and safety, e. If the pump and power source have been
be sure to limit the incoming pressure to 50% of stored for more than 12 months, some of the
the maximum permissible operating pressure as components or lubricants may have ex
shown on the pump performance curve. ceeded their maximum shelf life. These must
be inspected or replaced to ensure maxim
For further assistance, contact your Gorman‐Rupp um pump service.
distributor or the Gorman‐Rupp Company.
If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Pump Dimensions Gorman‐Rupp distributor or the factory to determ
ine the repair or updating policy. Do not put the
Consult the pump Specification Data Sheet or con pump into service until appropriate action has
sult the factory for the approximate physical dimen been taken.
sions of your pump.
POSITIONING PUMP
PREINSTALLATION INSPECTION
Lifting
The pump assembly was inspected and tested be
fore shipment from the factory. Before installation, Pump unit weights will vary depending on the
inspect the pump for damage which may have oc mounting and drive provided. Check the shipping
curred during shipment. Check as follows: tag on the unit packaging for the actual weight, and
use lifting equipment with appropriate capacity.
a. Inspect the pump for cracks, dents, damaged
Drain the pump and remove all customer‐installed
threads, and other obvious damage.
equipment such as suction and discharge hoses
b. Check for and tighten loose attaching hard or piping before attempting to lift existing, installed
ware. Since gaskets tend to shrink after dry units.
ing, check for loose hardware at mating sur
faces.
c. Carefully read all warnings and cautions con
tained in this manual or affixed to the pump,
and perform all duties indicated. Note the dir The pump assembly can be seriously
ection of rotation indicated on the pump. damaged if the cables or chains used to lift
INSTALLATION PAGE B - 1
and move the unit are improperly wrapped increase friction loss. If elbows are necessary, use
around the pump. the long‐radius type to minimize friction loss.
Connections to Pump
Mounting
Before tightening a connecting flange, align it ex
Locate the pump in an accessible place as close as actly with the pump port. Never pull a pipe line into
practical to the liquid being pumped. Level mount place by tightening the flange bolts and/or coup
ing is essential for proper operation. lings.
The pump may have to be supported or shimmed Lines near the pump must be independently sup
to provide for level operation or to eliminate vibra ported to avoid strain on the pump which could
tion. 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
Clearance
pressure.
It is recommended that 24 inches (609.6 mm) of Gauges

clearance be provided in front of the back cover to
permit removal of the cover and easy access to the Most pumps are drilled and tapped for installing
pump interior. A minimum clearance of 14 inches discharge pressure and vacuum suction gauges. If
(355.2 mm) must be maintained to permit removal these gauges are desired for pumps that are not
of the cover. 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.
SUCTION AND DISCHARGE PIPING
Installation closer to the pump may result in erratic
readings.
Pump performance is adversely effected by in SUCTION LINES

creased suction lift, discharge elevation, and fric
tion losses. See the performance curve and oper To avoid air pockets which could affect pump prim
ating range shown on Page E‐1 to be sure your ing, the suction line must be as short and direct as
overall application allows pump to operate within possible. When operation involves a suction lift, the
the safe operation range. 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.
Materials
Fittings
Either pipe or hose maybe used for suction and
Suction lines should be the same size as the pump
discharge lines; however, the materials must be
inlet. If reducers are used in suction lines, they
compatible with the liquid being pumped. If hose is
should be the eccentric type, and should be in
used in suction lines, it must be the rigid‐wall, rein
stalled with the flat part of the reducers uppermost
forced type to prevent collapse under suction. Us
to avoid creating air pockets. Valves are not nor
ing piping couplings in suction lines is not recom
mally used in suction lines, but if a valve is used,
mended.
install it with the stem horizontal to avoid air pock
ets.
Line Configuration
Strainers
Keep suction and discharge lines as straight as
possible to minimize friction losses. Make minim If a strainer is furnished with the pump, be certain
um use of elbows and fittings, which substantially to use it; any spherical solids which pass through a
PAGE B - 2 INSTALLATION
strainer furnished with the pump will also pass tion inlet because the inflow will carry air down into
through the pump itself. the sump, and air entering the suction line will re
duce pump efficiency.
If a strainer is not furnished with the pump, but is
installed by the pump user, make certain that the If it is necessary to position inflow close to the suc
total area of the openings in the strainer is at least tion inlet, install a baffle between the inflow and the
three or four times the cross section of the suction suction inlet at a distance 1 1/2 times the diameter
line, and that the openings will not permit passage of the suction pipe. The baffle will allow entrained
of solids larger than the solids handling capability air to escape from the liquid before it is drawn into
of the pump. the suction inlet.
This pump is designed to handle up to 3 inch (76,2

If two suction lines are installed in a single sump,
mm) diameter spherical solids.
the flow paths may interact, reducing the efficiency
of one or both pumps. To avoid this, position the
Sealing suction inlets so that they are separated by a dis
tance equal to at least 3 times the diameter of the
Since even a slight leak will affect priming, head, suction pipe.
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 air Suction Line Positioning
tight seal. Follow the sealant manufacturer's re
commendations when selecting and applying the The depth of submergence of the suction line is
pipe dope. The pipe dope should be compatible critical to efficient pump operation. Figure 1 shows
with the liquid being pumped. recommended minimum submergence vs. velo
city.
Suction Lines In Sumps

NOTE
If a single suction line is installed in a sump, it The pipe submergence required may be reduced
should be positioned away from the wall of the by installing a standard pipe increaser fitting at the
sump at a distance equal to 1 1/2 times the diamet end of the suction line. The larger opening size will
er of the suction line. reduce the inlet velocity. Calculate the required
submergence using the following formula based
If there is a liquid flow from an open pipe into the on the increased opening size (area or diameter).
sump, the flow should be kept away from the suc
Figure 1. Recommended Minimum Suction Line Submergence vs. Velocity

DISCHARGE LINES 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
Siphoning suction line.
Do not terminate the discharge line at a level lower With high discharge heads, it is recommended that
than that of the liquid being pumped unless a si a throttling valve and a system check valve be in
phon breaker is used in the line. Otherwise, a si stalled in the discharge line to protect the pump
phoning action causing damage to the pump from excessive shock pressure and reverse rota
could result. tion when it is stopped.
Valves Bypass Lines
Self‐priming pumps are not air compressors. Dur

ing the priming cycle, air from the suction line must
be vented to atmosphere on the discharge side. If
the discharge line is open, this air will be vented
If the application involves a high discharge through the discharge. However, if a check valve
head, the discharge throttling valve should has been installed in the discharge line, the dis
close gradually before the pump is charge side of the pump must be opened to atmo
stopped. spheric pressure through a bypass line installed
between the pump discharge and the check valve.
Due to the high discharge head potential A self‐priming centrifugal pump will not prime if
for Ultra V Series pumps, an electronically there is sufficient static liquid head to hold the dis
controlled or automatic slow‐closing dis charge check valve closed.
charge throttling valve may be required.
Consult the factory for additional informa NOTE
tion on high discharge head applications. The bypass line should be sized so that it does not
affect pump discharge capacity; however, the by

pass line should be at least 1 inch in diameter to
minimize the chance of plugging.
If a manual shut‐off valve is installed in

In low discharge head applications (less than 30 a bypass line, it must not be left closed
feet or 9 meters), it is recommended that the by during operation. A closed manual
pass line be run back to the wet well, and located 6 shut‐off valve may cause a pump which
inches below the water level or cut‐off point of the has lost prime to continue to operate
low level pump. In some installations, this bypass without reaching prime, causing dan
line may be terminated with a six‐to‐eight foot
gerous overheating and possible ex
length of 1-1/4 inch I.D. smooth‐bore hose; air
plosive rupture of the pump casing. Per
and liquid vented during the priming process will
sonnel could be severely injured.
then agitate the hose and break up any solids,
grease, or other substances likely to cause clog
ging. Allow an over‐heated pump to com
pletely cool before servicing. Do not re
move plates, covers, gauges, or fittings
from an over‐heated pump. Liquid with
in the pump can reach boiling temperat
A bypass line that is returned to a wet well ures, and vapor pressure within the
must be secured against being drawn into pump can cause parts being disen
the pump suction inlet.
gaged to be ejected with great force.
It is also recommended that pipe unions be in After the pump completely cools, drain
stalled at each 90 elbow in a bypass line to ease the liquid from the pump by removing
disassembly and maintenance.
the casing drain plug. Use caution when
In high discharge head applications (more than removing the plug to prevent injury to
30 feet), an excessive amount of liquid may be by personnel from hot liquid.
passed and forced back to the wet well under the
full working pressure of the pump; this will reduce
overall pumping efficiency. Therefore, it is recom AUTOMATIC AIR RELEASE VALVE
mended that a Gorman‐Rupp Automatic Air Re
lease Valve be installed in the bypass line. When properly installed, a Gorman‐Rupp Auto
matic Air Release Valve will permit air to escape
Gorman‐Rupp Automatic Air Release Valves are through the bypass line and then close automatic
reliable, and require minimum maintenance. See ally when the pump is fully primed and pumping at
AUTOMATIC AIR RELEASE VALVE in this section full capacity.
for information about Gorman‐Rupp Automatic Air
Release Valves. Consult your Gorman‐Rupp dis
tributor, or contact the Gorman‐Rupp Company for
selection of an Automatic Air Release Valve to fit
your application.
Some leakage (1 to 5 gallons [3.8 to 19
If the installation involves a flooded suction such as liters] per minute) will occur when the
a below‐ground lift station, a pipe union and manu valve is fully closed. Be sure the bypass
al shut‐off valve may be installed in the bleed line to line is directed back to the wet well or
allow service of the valve without shutting down the tank to prevent hazardous spills.
station, and to eliminate the possibility of flooding.
If a manual shut‐off valve is installed anywhere in Consult the manual accompanying the Air Release
the air release piping, it must be a full‐opening ball Valve for additional information on valve installation
type valve to prevent plugging by solids. and performance.
Air Release Valve Installation lowing any entrained air in the system to escape
through the Air Release Valve. When air in the sys
Staged pump applications generate much higher tem is purged, pressure opens the second dis
operating pressures within the pump casings than charge check valve for full operation.
non‐staged pump applications. This high pressure
When the liquid level in the sump lowers enough to
could cause a suction check valve to fail, resulting
de‐activate the automatic liquid level device and
in loss of prime. Therefore, any pump used in a
stop the pumps, the first discharge check valve
staged application, whether in the lower or up
closes and creates an air‐tight seal, thus maintain
per position, must have the suction check valve
ing liquid in the pump casing and suction line to al
removed. The lower stage of the VS Series pump
low the pump to re‐prime when the liquid level in
is designed without a suction check valve, so re
the sump rises and again activates the automatic
moval of the check valve is not required.
liquid level device.
In order to maintain the suction leg and facilitate ini The second discharge check valve in the staged
tial priming (or re‐priming if the suction leg is lost) application acts as a “shock absorber” to prevent
without a suction check valve, it is recommended destructive “water hammer” when the pump shuts
that staged pump applications be installed using down.
two discharge check valves, with an automatic Air
Release Valve installed between the two discharge The Automatic Air Release Valve must be inde
check valves (see Figure 3). In this manner, when pendently mounted in a horizontal position
the liquid level in the sump activates the automatic between the discharge check valves. (see Figure
liquid level device and starts the pumps, discharge 2). The inlet opening in the Air Release Valve is
pressure opens the first discharge check valve, al equipped with standard 1‐inch NPT pipe threads.
DISCHARGE
PIPE AIR RELEASE
VALVE
DISCHARGE
DISCHARGE CHECK
CHECK VALVE
VALVE
VS SERIES PUMP
Figure 2. Typical Automatic Air Release Valve Installation
NOTE close as possible to the primary discharge check

When installing the Air Release Valve on a staged valve. Six‐inch and larger discharge check valves
pump application, position the Air Release Valve as are available drilled and tapped to receive a stand
ard 1‐inch NPT fitting, or the Air Release Valve may then the first stage pump motor “ramping down”
be installed in a spool flange between the two dis and shutting off. This “ramp up” and “ramp down”
charge check valves. configuration helps reduce inrush current on star
tup and destructive “water hammer” on both star
tup and shut down.
Connect the valve outlet to a bleed line which
slopes back to the wet well or sump. The bleed line
must be the same size as the outlet opening or lar
ger, depending on which Air Release Valve is being
used. If piping is used for the bleed line, avoid the
use of elbows whenever possible.
NOTE
For multiple pump installations, it is recommended
that each Air Release Valve be fitted with an inde
pendent bleeder line directed back to the wet well.
If multiple Air Release Valves are installed in a sys
tem, do not direct bleeder lines to a common mani
fold pipe. Contact your Gorman‐Rupp distributor or
the Gorman‐Rupp Company for information about
installation of an Automatic Air Release Valve for
your specific application.
Figure 3. Recommended Dual Motor Direct

Drive Arrangement
DRIVE ARRANGEMENTS
Special consideration must be given to drive ar

rangements for staged pumping applications.
Since pump installations are seldom identical, this
section provides some general recommendations
for selecting drive arrangements for staged
pumps. Consult the factory for information regard
ing your specific application.
Dual Motor Drives
It is recommended that each pump be directly driv

en by its own electric motor, either through coup
lings (see Figure 3) or a belt arrangement (see Fig
ure 4).
Each motor should be independently operated

through a reduced voltage solid state (RVSS) Figure 4. Recommended Dual Motor Belt
starter, a variable frequency drive (VFD) or an ad Drive Arrangement
justable speed drive (ASD). In this arrangement,
the motor powering the lower stage pump should Single Motor Belt Drives
be programmed to start first and “ramp up” to full
condition speed, then the second stage pump mo In staged applications where both pumps are belt
tor should start and “ramp up” to full condition driven by a single motor (either through a syn
speed. Pump motor shutdown should be pro cronous [cog] or V‐belt configuration) certain ar
grammed in reverse order, with the second stage rangements must be used in order to ensure prop
pump motor “ramping down” before shutting off, er operation.
Figure 5 shows a recommended alternate single

motor belt drive arrangement where the both
pump shafts are driven by separate drive belts con
nected to one motor. In this arrangement, shaft
and/or bearing loads are evenly divided between
the two pumps.
Figure 6. Alternate Single Motor Combination

Drive Arrangement
Figures 7 and 8 show single motor belt drive ar

rangements that are not recommended because
they can cause an overload condition on the shaft
and/or bearings, resulting in premature failure.
Figure 5. Alternate Single Motor Belt Drive

Arrangement
Single Motor Combination Drives
In staged applications where both pumps are driv

en by a single motor in a combination belt and
coupling drive configuration, certain arrange
ments must be used in order to ensure proper op
eration.
Figure 6 shows a recommended alternate single

motor combination drive arrangement, where
the first stage pump shaft is direct‐coupled to the
motor and the second stage pump shaft is driven
by belts and an idler located between the two
shafts. In this arrangement, shaft and/or bearing Figure 7. Improper Single Motor Belt Drive
loads are shared between the two pumps. Arrangement (Dual Belts)
either a flexible coupling or 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 opera
tion.
NOTE
Check Rotation, Section C, before final alignment
of the pump.
When mounted at the Gorman‐Rupp factory, driver

and pump are aligned before shipment. Misalign
ment will occur in transit and handling. Pumps
must be checked and realigned before operation.
Before checking alignment, tighten the foundation
Figure 8. Improper Single Motor Belt Drive bolts. The pump casing feet and/or pedestal feet,
Arrangement (Single Belt Set) and the driver mounting bolts should also be tightly
secured.
HIGH PUMP TEMPERATURE SHUT
DOWN FOR DUAL‐MOTOR DRIVE
APPLICATIONS
When checking alignment, disconnect
NOTE the power source to ensure that the
In dual‐motor drive arrangements, the starters for pump will remain inoperative.
both motors must be interlocked at the control pan
el to ensure that both motors shut down if overheat
ing of either pump should occur.
In a dual‐motor drive arrangement where each Adjusting the alignment in one direction
pump is directly driven by its own electric motor, it may alter the alignment in another direc
is recommended that each pump be equipped tion. check each procedure after altering
with a high temperature shutdown sensor and that alignment.
these sensors be connected in parallel to the pump
control panel(s) so that if either sensor is activated, Coupled Drives
both motors shut down (if powered independent
ly). When using couplings, the axis of the power
source must be aligned to the axis of the pump
It is also recommended that the pump control pan
shaft in both the horizontal and vertical planes.
el(s) be configured with an alarm system and
Most couplings require a specific gap or clearance
manual reset for the high pump temperature shut
between the driving and the driven shafts. Refer to
down circuit. In this manner, the cause of overheat
the coupling manufacturer's service literature.
ing must be investigated and corrected before the
pumping system can be put back into service.
Align spider insert type couplings by using calipers
to measure the dimensions on the circumference
ALIGNMENT of the outer ends of the coupling hub every 90.
The coupling is in alignment when the hub ends
The alignment of the pump and its power source is are the same distance apart at all points (see Fig
critical for trouble‐free mechanical operation. In ure 9).
Figure 9. Aligning Spider‐Type Couplings
MISALIGNED: MISALIGNED: ALIGNED: SHAFTS

SHAFTS SHAFTS PARALLEL AND
NOT PARALLEL NOT IN LINE SHEAVES IN LINE
Figure 11. Alignment of V‐Belt Driven Pumps
Tighten the belts in accordance with the belt manu

facturer's instructions. If the belts are too loose,
they will slip; if the belts are too tight, there will be
excessive power loss and possible bearing failure.
Select pulleys that will match the proper speed ra
tio; overspeeding the pump may damage both
pump and power source.
Figure 10. Aligning Non‐Spider Type Couplings
Align non‐spider type couplings by using a feeler

gauge or taper gauge between the coupling halves Do not operate the pump without the
every 90. The coupling is in alignment when the guard in place over the rotating parts.
hubs are the same distance apart at all points (see exposed rotating parts can catch cloth
Figure 10). ing, fingers, or tools, causing severe in
jury to personnel.
Check parallel adjustment by laying a straightedge
across both coupling rims at the top, bottom, and DRIVE BELT TENSIONING
side. When the straightedge rests evenly on both
halves of the coupling, the coupling is in horizontal General Rules of Tensioning
parallel alignment. If the coupling is misaligned,
use a feeler gauge between the coupling and the
For new drive belts, check the tension after 5, 20
straightedge to measure the amount of misalign
and 50 hours of operation and re‐tension as re
ment.
quired (see the following procedure for measuring
belt tension). Thereafter, check and re‐tension if re
quired monthly or at 500 hour intervals, whichever
Drive Belts
comes first.
When using drive belts, the power source and the Ideal drive belt tension is the lowest tension at
pump must be parallel. Use a straightedge along which the belt will not slip under peak load condi
the sides of the pulleys to ensure that the pulleys tions. Do not over‐tension drive belts. Over‐ten
are properly aligned (see Figure 11). In drive sys sioning will shorten both drive belt and bearing life.
tems using two or more belts, make certain that the Under‐tensioning will cause belt slippage. Always
belts are a matched set; unmatched sets will cause keep belts free from dirt, grease, oil and other for
accelerated belt wear. eign material which may cause slippage.
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 casing has been filled, the pump
This pump is designed to handle liquids will prime and reprime as necessary.
containing large entrained solids and
slurries. Do not attempt to pump vola
tile, corrosive, or flammable liquids
which may damage the pump or endan
ger personnel as a result of pump fail After filling the pump casing, reinstall
ure. and tighten the fill plug. Do not attempt
to operate the pump unless all connect
ing piping is securely installed. Other
wise, liquid in the pump forced out
under pressure could cause injury to
personnel.
Pump speed and operating conditions
must be within the performance range To fill the pump, remove the pump casing fill cover
or fill plug in the top of the casing, and add clean
shown on pages E‐1.
liquid until the casing is filled. Replace the fill cover
or fill plug before operating the pump.
PRIMING
STARTING
Install the pump and piping as described in IN
Consult the operations manual furnished with the
STALLATION. Make sure that the piping connec
power source.
tions are tight, and that the pump is securely
mounted. Check that the pump is properly lubri
cated (see LUBRICATION in MAINTENANCE Rotation
AND REPAIR).
The correct direction of pump rotation is counter
clockwise when facing the impeller. The pump
This pump is self‐priming, but the pump should
could be damaged and performance adversely af
never be operated unless there is liquid in the
fected by incorrect rotation. If pump performance
pump casing.
is not within the specified limits (see the curve on
pages E‐1), check the direction of power source ro
tation before further troubleshooting.
If an electric motor is used to drive the pump, re

move drive belts, couplings, or otherwise discon
Never operate this pump unless there is nect the pump from the motor before checking mo
liquid in the pump casing. The pump will tor rotation. Operate the motor independently
not prime when dry. extended operation of while observing the direction of the motor shaft, or
a dry pump will destroy the seal assembly. cooling fan.
OPERATION PAGE C - 1
If rotation is incorrect on a three‐phase motor, have pump components will deteriorate, and
a qualified electrician interchange any two of the the liquid could come to a boil, build
three phase wires to change direction. If rotation is pressure, and cause the pump casing to
incorrect on a single‐phase motor, consult the liter rupture or explode.
ature supplied with the motor for specific instruc
tions.
Leakage
OPERATION
No leakage should be visible at pump mating sur
faces, or at pump connections or fittings. Keep all
Lines With a Bypass line connections and fittings tight to maintain maxi
mum pump efficiency.
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 Liquid Temperature And Overheating
after priming is complete (see INSTALLATION for
Air Release Valve operation).
The maximum liquid temperature for this pump is
If the bypass line is open, air from the suction line 160F (71C). Do not apply it at a higher operating
will be discharged through the bypass line back to temperature.
the wet well during the priming cycle. Liquid will
Overheating can occur if operated with the valves
then continue to circulate through the bypass line
in the suction or discharge lines closed. Operating
while the pump is in operation.
against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to rup
ture or explode. If overheating occurs, stop the
Lines Without a Bypass
pump and allow it to cool before servicing it. Refill
the pump casing with cool liquid.
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 imme
diately because the suction line must first fill with Allow an over‐heated pump to com
liquid. If the pump fails to prime within five minutes, pletely cool before servicing. Do not re
stop it and check the suction line for leaks. move plates, covers, gauges, or fittings
from an over‐heated pump. Liquid with
After the pump has been primed, partially close the
in the pump can reach boiling tempera
discharge line throttling valve in order to fill the line
slowly and guard against excessive shock pres
tures, and vapor pressure within the
sure which could damage pipe ends, gaskets, pump can cause parts being disen
sprinkler heads, and any other fixtures connected gaged to be ejected with great force. Af
to the line. When the discharge line is completely ter the pump completely cools, drain
filled, adjust the throttling valve to the required flow the liquid from the pump by removing
rate. 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
Do not operate the pump against a valve which will open if vapor pressure within the
closed discharge throttling valve for pump casing reaches a critical point. If overheating
long periods of time. If operated against does occur, stop the pump immediately and allow
a closed discharge throttling valve, it to cool before servicing it. Approach any over
PAGE C - 2 OPERATION
heated pump cautiously. It is recommended that shock waves can be transmitted to the pump and
the pressure relief valve assembly be replaced at piping system. Close all connecting valves slowly.
each overhaul, or any time the pump casing over
heats and activates the valve. Never replace this
valve with a substitute which has not been speci
fied or provided by the Gorman‐Rupp Company.
If the application involves a high discharge
head, gradually close the discharge
Strainer Check
throttling valve before stopping the pump.
After stopping the pump, lock out or disconnect
If a suction strainer has been shipped with the the power source to ensure that the pump will re
pump or installed by the user, check the strainer main inoperative.
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 in
stalled, monitor and record the readings regularly
to detect strainer blockage. Do not operate the pump against a
closed discharge throttling valve for
Never introduce air or steam pressure into the
pump casing or piping to remove a blockage. This
long periods of time. If operated against
could result in personal injury or damage to the
a closed discharge throttling valve,
equipment. If backflushing is absolutely neces pump components will deteriorate, and
sary, liquid pressure must be limited to 50% of the the liquid could come to a boil, build
maximum permissible operating pressure shown pressure, and cause the pump casing to
on the pump performance curve. rupture or explode.
Cold Weather Preservation

Pump Vacuum Check
In below freezing conditions, drain the pump to

With the pump inoperative, install a vacuum gauge prevent damage from freezing. Also, clean out any
in the system, using pipe dope on the threads. solids by flushing with a hose. Operate the pump
Block the suction line and start the pump. At oper for approximately one minute; this will remove any
ating speed the pump should pull a vacuum of 20 remaining liquid that could freeze the pump rotat
inches (508,0 mm) or more of mercury. If it does ing parts. If the pump will be idle for more than a
not, check for air leaks in the seal, gasket, or dis few hours, or if it has been pumping liquids con
charge valve. taining a large amount of solids, drain the pump,
and flush it thoroughly with clean water. To prevent
Open the suction line, and read the vacuum gauge large solids from clogging the drain port and pre
with the pump primed and at operation speed. venting the pump from completely draining, insert
Shut off the pump. The vacuum gauge reading will a rod or stiff wire in the drain port, and agitate the
immediately drop proportionate to static suction liquid during the draining process. Clean out any
lift, and should then stabilize. If the vacuum reading remaining solids by flushing with a hose.
falls off rapidly after stabilization, an air leak exists.
Before checking for the source of the leak, check
BEARING TEMPERATURE CHECK
the point of installation of the vacuum gauge.
Bearings normally run at higher than ambient tem

STOPPING peratures because of heat generated by friction.
Temperatures up to 160F (71C) are considered
Never halt the flow of liquid suddenly. If the liquid normal for bearings, and they can operate safely to
being pumped is stopped abruptly, damaging at least 180F (82C).
OPERATION PAGE C - 3
Checking bearing temperatures by hand is inaccu rect level (see LUBRICATION in MAINTENANCE
rate. Bearing temperatures can be measured ac AND REPAIR). Bearing overheating can also be
curately by placing a contact‐type thermometer caused by shaft misalignment and/or excessive vi
against the housing. Record this temperature for bration.
future reference.
A sudden increase in bearing temperature is a When pumps are first started, the bearings may
warning that the bearings are at the point of failing seem to run at temperatures above normal. Con
to operate properly. Make certain that the bearing tinued operation should bring the temperatures
lubricant is of the proper viscosity and at the cor down to normal levels.
PAGE C - 4 OPERATION
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.

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.
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.
TROUBLESHOOTING PAGE D - 1
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP STOPS OR Strainer clogged. Check strainer and clean if neces

FAILS TO DELIVER sary.
RATED FLOW OR
PRESSURE Suction intake not submerged at Check installation and correct sub
proper level or sump too small. mergence as needed.
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 POWER sheaves or couplings are cor
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
PREVENTIVE MAINTENANCE in suction and discharge gauge readings (if so

equipped) between regularly scheduled inspec
tions can indicate problems that can be corrected
Routine preventive maintenance of the pump will
before system damage or catastrophic failure oc
maintain peak operating performance. Since
curs. The appearance of wearing parts should also
pump applications are seldom identical, and pump
be documented at each inspection for comparison
wear is directly affected by such things as the abra
as well. Also, if records indicate that a certain part
sive qualities, pressure and temperature of the liq
(such as the seal) fails at approximately the same
uid being pumped, this section is intended only to
duty cycle, the part can be checked and replaced
provide general recommendations and practices
before failure occurs, reducing unscheduled down
for preventive maintenance. Regardless of the ap
time.
plication however, following a routine preventive
maintenance schedule will help assure trouble‐ For new applications, a first inspection of wearing
free performance and long life from your Gorman‐ parts at 250 hours will give insight into the wear rate
Rupp pump. for your particular application. Subsequent inspec
tions should be performed at the intervals shown
Record keeping is an essential component of a on the chart below. Critical applications should be
good preventive maintenance program. Changes inspected more frequently.
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.
TROUBLESHOOTING PAGE D - 3
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 VS6A60‐B, Including /WW
Based on 70F (21C) clear water at sea level with

minimum suction lift. Since pump installations are
seldom identical, your performance may be differ
ent due to such factors as viscosity, specific gravity,
elevation, temperature, and impeller trim. Pump speed and operating condition
points must be within the continuous per
If your pump serial number is followed by an “N”, formance range shown on the curves.
your pump is NOT a standard production model.
Contact the Gorman‐Rupp Company to verify per NOTE
formance or part numbers. The horsepower shown in the above curve is total
combined horsepower for both the first and second
stage of the VS Model.
MAINTENANCE & REPAIR PAGE E - 1

PARTS PAGE
SECTION DRAWING
Figure 1. Pump Model VS6A60-B (Including /WW)

PAGE E - 2 MAINTENANCE & REPAIR
PARTS LIST
Pump Model VS6A60-B (Including /WW)
(From S/N 1352521 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 MAT'L

NO. PART NAME NUMBER CODE QTY
1 PUMP ASSEMBLY
VS6A60-B 46146-041 --- 1
VS6A60-B /WW 46146-042 --- 1
2 DISCHARGE GASKET 38687-062 19000 1
3 LOCK WASHER J12 15991 8
4 HEX HD CAPSCREW B1209 15991 8
5 ULTRA MATE PUMP ASSY 46146-067 --- 1
7 SUPPORT PLATE 34455-011 15080 1
8 DRIVE SCREW BM#04-03 17000 4
9 NAME PLATE 38818-149 13000 1
NOT SHOWN:
LUBRICATION DECAL 38817-084 --- 2
G‐R DECAL GR-03 --- 1
“ULTRA V” DECAL 38816-342 --- 1
ROTATION DECAL 2613M --- 1
INSTRUCTION TAG 38817-023 --- 1
WARNING DECAL 2613FE --- 1
DISCHARGE STICKER 6588BJ --- 1
SUCTION STICKER 6588AG --- 1
PRIMING STICKER 6588AH --- 1
INSTRUCTION TAG 38817-011 --- 1
SMART SCROLL DECAL 38816-251 --- 1
OPTIONAL:
STAGED FLANGE KITS:
-NPT 48213-131 --- 1
-ASA SPOOL 48213-132 --- 1
-METRIC SPOOL 48213-133 --- 1
HI TEMP SHUT-DOWN KITS:
-145F 48313-186 --- 1
-130F 48313-256 --- 1
-120F 48313-257 --- 1
HIGH TEMP SHUT‐DOWN
THERMOSTAT KIT 145F 48313-172 --- 1
AIR RELEASE VALVES:
-10# COMP SPRING GRP33-07A --- 1
-25# COMP SPRING GRP33-07 --- 1
-80# COMP SPRING GRP33-07B --- 1
INDICATES PARTS RECOMMENDED FOR STOCK

SECTION DRAWING
Figure 2. Pump Assemblies 46146-041 and 46146-042

PARTS LIST
Pump Assemblies 46146-041 and 46146-042
ITEM PART NAME PART MAT'L QTY ITEM PART NAME PART MAT'L QTY
NO. NUMBER CODE NO. NUMBER CODE
1 PUMP CASING 38224-612 10000 1 -STUD C1221 15991 8
2 REPAIR ROTATING ASSY -HEX NUT D12 15991 8
VS6A60-B 44163-453 --- 1 -LOCK WASHER J12 15991 8
VS6A60-B /WW 44163-454 --- 1 SUCTION STICKER 6588AG --- 1
3 STUD C1213 15991 4 ROTATION DECAL 2613M --- 1
4 PIPE PLUG P20 10009 1 LUBRICATION DECAL 38817-084 --- 1
5 WEAR PLATE ASSY 46451-759 24150 1 “ULTRA V” DECAL 38816-342 --- 1
6 O‐RING 25152-453 --- 1 WARNING DECAL 2613FE --- 1
7 LOCK WASHER J06 15991 12 DISCHARGE STICKER 6588BJ --- 1
8 HEX NUT D06 15991 4 G‐R DECAL GR-03 --- 1
9 LOCK COLLAR 38115-551 23030 4 PRIMING STICKER 6588AH --- 1
10 COVER PLATE ASSY 42111-832 --- 1 INSTRUCTION TAG 38817-023 --- 1
-WARNING PLATE 2613EV 13990 1 OPTIONAL:
-DRIVE SCREW BM#04-03 17000 4 DISASSEMBLY TOOL 48711-020 --- 1
FLANGE KITS:
-PRESS RELIEF VALVE 26662-007 --- 1
8” X 6” NPT SUCTION/DISCHARGE
-WARNING DECAL 38816-302 --- 1
FLANGE KIT 48213-118 --- 1
-8” NPT SUCTION
12 ADJUSTING SCREW 31871-070 1500G 4 FLANGE KIT 48213-154 --- 1
13 HEX HD CAPSCREW B0804 15991 4 -6” NPT DISCHARGE
14 BACK COVER NUT 31871-073 15000 4 FLANGE KIT 48213-155 --- 1
15 HEX HD CAPSCREW B0605 15991 2 8” X 6” ASA SUCTION/DISCHARGE
16 HANDLE 12354 13010 1 SPOOL KIT 48213-151 --- 1
17 O‐RING S1676 --- 2 -8” ASA SUCTION
18 FLAT HD CAPSCREW F0604 17000 2 SPOOL KIT 48213-150 --- 1
19 PIPE PLUG P04 15079 2 -6” ASA DISCHARGE
20 NPT SUCT FLG/VLV SEAT 38641-533 10000 1 SPOOL KIT 48213-116 --- 1
21 GASKET 38683-659 19370 1 8” X 6” METRIC SUCTION/DISCHARGE
22 FLAP VALVE PLUG 38349-414 19020 1 SPOOL KIT 48213-117 --- 1
23 FLAP VALVE COVER 38346-620 17040 1 -8” METRIC SUCTION
24 HEX HD CAPSCREW B0604 15991 6 SPOOL KIT 48213-152 --- 1
25 SQUARE HD BOLT A1014 15991 2 -6” METRIC DISCHARGE
26 FILL PORT COVER ASSY 42111-437 --- 1 SPOOL KIT 48213-153 --- 1
-FILL PORT GASKET 50G 19210 1 G‐R HARD IRON PARTS:
-WARNING PLATE 38816-097 13990 1 -WEAR PLATE ASSY 46451-759 24160 1
-DRIVE SCREW BM#04-03 17000 2 SST PARTS:
27 HEX HD CAPSCREW B1010S 15991 1 -WEAR PLATE ASSY 46451-759 24170 1
28 CLAMP BAR 38111-004 11010 1 HI TEMP SHUT-DOWN KITS:
29 HEX HD CAPSCREW B0806 15991 4 -145F 48313-186 --- 1
30 SPACER 33221-022 17040 4 -130F 48313-256 --- 1
31 O‐RING 25152-381 --- 1 -120F 48313-257 --- 1
32 PIPE PLUG P08 15079 2 HIGH TEMP SHUT‐DOWN
NOT SHOWN: THERMOSTAT KIT 145F 48313-172 --- 1
SUCTION SPOOL PARTS (VS6A60-B /WW ONLY) AIR RELEASE VALVES:
-SPOOL FLANGE 12799 10010 1 -10# COMP SPRING GRP33-07A --- 1
-FLANGE GASKET 25113-038 --- 1 -25# COMP SPRING GRP33-07 --- 1
-FLANGE PIPE PLUG P20 10009 1 -80# COMP SPRING GRP33-07B --- 1

SECTION DRAWING
Figure 3. 46146-067 Ultra Mate Pump Assembly

PARTS LIST
46146-067 Ultra Mate Pump Assembly
ITEM PART MAT'L

1 PUMP CASING 38219-501 10000 1

2 REPAIR ROTATING ASSY
VS6A60-B 44163-453 --- 1
VS6A60-B /WW 44163-454 --- 1
3 PIPE PLUG P08 15079 4
4 PIPE PLUG P12 15079 3
5 TRANSITION CHAMBER 38644-813 11010 1
6 PIPE PLUG P04 15079 1
7 COVER PLATE ASSY 42111-832 --- 1
-WARNING PLATE 2613EV 13990 1
-DRIVE SCREW BM#04-03 17000 4
-PRESS RELIEF VALVE 26662-007 --- 1
-WARNING DECAL 38816-302 --- 1
8 LOCK COLLAR 38115-551 23030 4
13 HANDLE 12354 13010 1
14 BACK COVER NUT 31871-073 15000 4
15 ADJUSTING SCREW 31871-070 1500G 4
16 O‐RING S1676 --- 2
17 HEX NUT D06 15991 4
18 O‐RING 25152-453 --- 1
19 WEAR PLATE ASSY 46451-759 24150 1
20 STUD C1213 15991 4
22 O‐RING 25152-280 --- 1
23 O‐RING 25152-381 --- 1
24 SPACER 33221-022 17040 4
OPTIONAL:
DISASSEMBLY TOOL 48711-020 --- 1
G‐R HARD IRON PARTS:
-WEAR PLATE ASSY 46451-759 24160 1
SST PARTS:
-WEAR PLATE ASSY 46451-759 24170 1
HI TEMP SHUT-DOWN KITS:
-145F 48313-186 --- 1
-130F 48313-256 --- 1
-120F 48313-257 --- 1
HIGH TEMP SHUT‐DOWN
THERMOSTAT KIT 145F 48313-172 --- 1
AIR RELEASE VALVES:
-10# COMP SPRING GRP33-07A --- 1
-25# COMP SPRING GRP33-07 --- 1
-80# COMP SPRING GRP33-07B --- 1

SECTION DRAWING
Figure 4. Repair Rotating Assemblies

PARTS LIST
Repair Rotating Assemblies
Note: Order the complete Repair Rotating Assembly from the Pump Model Assembly Parts Lists on pages
E-2 or E-3. Rotating Assemblies for /WW models also include all standard parts listed below.
ITEM PART MAT'L

1 IMPELLER 38615-102 11010 1
2 IMP ADJ SHIM SET 48261-057 --- 1
3 CARTRIDGE SEAL ASSY 46513-155 --- 1
4 SEAL PLATE 38272-262 10000 1
5 GASKET 38687-059 20000 1
6 OIL SEAL 25227-771 --- 2
9 BEARING HOUSING 38251-521 10000 1
10 SOC HD PIPE PLUG PC20 10009 1
11 VENTED PIPE PLUG 4823A 15079 1
12 RED PIPE BUSING AP0802 15079 1
13 AIR VENT S1530 --- 1
14 PIPE PLUG P12 15079 2
15 SIGHT GAUGE S1471 --- 2
16 PIPE PLUG P04 15079 2
19 OIL SEAL S1907 --- 1
20 BEARING CAP 38322-230 10000 1
21 GASKET 38683-474 18000 1
22 RETAINING RING S720 --- 1
23 THRUST WASHER 31133-268 15000 1
24 BALL BEARING 23422-414 --- 1
25 SHAFT KEY N0812 15990 1
26 IMPELLER SHAFT 38514-826 16000 1
27 O‐RING 25154-131 --- REF
28 BALL BEARING 23422-019 --- 1
29 IMPELLER CAPSCREW DM1004S 15991 1
30 IMPELLER WASHER 31514-015 17000 1
31 DRIVE SCREW BM#04-03 17000 2
32 S/N PLATE 2613GG 13990 1
33 O‐RING 25152-381 --- 1
34 O‐RING S1676 --- 1
35 SPACER 33221-022 17040 4
36 SHIPPING PLUG 11495B 15079 2
NOT SHOWN:
SOC HD PIPE PLUG PC20 10009 1
INSTRUCTION TAG 6588U --- 1
ROTATION DECAL 2613M --- 1
OPTIONAL:
G‐R HARD IRON PARTS:
-IMPELLER 38615-102 1102H 1
-SEAL PLATE 38272-262 1102H 1
SST PARTS:
-IMPELLER 38615-102 17070 1
-SEAL PLATE 38272-262 17070 1
-IMPELLER SHAFT 38514-826 1706H 1
-IMP CAPSCREW DM1004S 17090 1
-CART SEAL ASSY 46513-158 --- 1

PUMP AND SEAL DISASSEMBLY

AND REASSEMBLY

Review all SAFETY information in Section A.
pump:
1. Familiarize yourself with this man
Follow the instructions on all tags, label and decals ual.
attached to the pump. 2. Disconnect or lock out the power
source to ensure that the pump will
remain inoperative.
This pump requires little service due to its rugged, 3. Allow the pump to completely cool
minimum‐maintenance design. However, if it be if overheated.
comes necessary to inspect or replace the wearing 4. Check the temperature before
parts, follow these instructions which are keyed to opening any covers, plates, or
the sectional views (see Figures 1, 2, 3 and 4) and plugs.
the accompanying parts lists.
valves.
This manual will alert personnel to known proce 6. Vent the pump slowly and cau
dures which require special attention, to those tiously.
which could damage equipment, and to those 7. Drain the pump.
which could be dangerous to personnel. However,
this manual cannot possibly anticipate and provide
detailed precautions for every situation that might
occur during maintenance of the unit. Therefore, it
is the responsibility of the owner/maintenance per
sonnel to ensure that only safe, established main Use lifting and moving equipment in
tenance procedures are used, and that any proce good repair and with adequate capacity
dures not addressed in this manual are performed to prevent injuries to personnel or dam
only after establishing that neither personal safety age to equipment.
nor pump integrity are compromised by such prac
tices.
Many service functions may be performed by

draining the pump and removing the back cover Do not install a suction check valve in
assembly. If major repair is required, the piping the first stage of the VS Series pump
and/or power source must be disconnected. The
model. Installing a suction check valve
following instructions assume complete disassem
in the first stage of the VS Series pump
bly is required.
model can cause over‐pressurization of
the first stage pump casing, resulting in
Before attempting to service the pump, disconnect
possible explosion of the pump and se
or lock out the power source and take precautions
rious injury or death to personnel.
to ensure that it will remain inoperative. Close all
valves in the suction and discharge lines. NOTE
The back cover and rotating assemblies are identi
cal for both the first stage pump and the Ultra Mate
For power source disassembly and repair, consult second stage, therefore the service instructions are
the literature supplied with the power source, or the same. Because of these similarities, most of the
contact your local power source representative. following instructions reference the first stage

pump model drawing (Figure 2). Instructions spe The impeller (1) should be loosened while the rotat
cific to the Ultra Mate second stage will reference ing assembly is still secured to the pump casing.
Figures 1 and/or 3 and will denote “Ultra Mate Sec Before loosening the impeller, remove the seal cav
ond Stage Only”. ity drain plug and drain the seal lubricant. This will
prevent the oil in the seal cavity from escaping
when the impeller is loosened. Clean and reinstall
Support Plate Removal the seal cavity drain plug.
(Figure 1) Immobilize the impeller by wedging a block wood

between the vanes and the pump casing. Remove
Disassembly of the first or second stage pump the impeller capscrew and washer (29 and 30).
model requires removal of the support plate (9).
Disengage the hardware (8) and remove the plate. If removed, install the shaft key (25). Install a lathe
dog on the drive end of the shaft (26) with the “V”
notch positioned over the shaft key.
Back Cover And Wear Plate Removal
With the impeller rotation still blocked, see Figure 5
(Figure 2)
and use a long piece of heavy bar stock to pry
The wear plate (5) is easily accessible and may be against the arm of the lathe dog in a counterclock
serviced by removing the back cover assembly wise direction (when facing the drive end of the
(10). Before attempting to service the pump, re shaft). Use caution not to damage the shaft or key
move the pump casing drain plug (6) and drain the way. When the impeller breaks loose, remove the
pump. Clean and reinstall the drain plug. lathe dog, key and wood block.
Remove the back cover nuts (14) and pry the back NOTE
cover and assembled wear plate from the pump Do not remove the impeller until the rotating assem
casing (1). bly has been removed from the pump casing.
NOTE
An alternate method of removing the back cover Turn
from the pump casing is to remove the back cover Counterclockwise
nuts (14) and two diagonally opposing locking col
lars (9). Install two 1/2-13 UNC x 2 inch long
screws in the tapped holes in the back cover and
use them to press the back cover out of the pump
casing. Lathe Dog Arm
Inspect the wear plate, and replace it if badly “V” Notch

scored or worn. To remove the wear plate, disen Heavy
Bar Stock Shaft Key
gage the hardware (7 and 8).
Impeller
Inspect the back cover O‐rings (6 and 17) and re Shaft
Lathe Dog
place it if damaged or worn.
Setscrew
Rotating Assembly Removal Figure 5. Loosening Impeller
(Figure 4) (Figure 2)
The rotating assembly may be serviced without Disengage the hardware (11 and 29) securing the
disconnecting the suction or discharge piping; rotating assembly to the pump casing and remove
however, the power source must be removed to the spacers (30). Separate the rotating assembly
provide clearance. by pulling straight away from the pump casing.

NOTE Seal Removal

An optional disassembly tool is available from the (Figure 4)
factory. If the tool is used, follow the instructions
packed with it. A similar tool may be assembled us Slide the shaft sleeve and rotating portion of the
ing 1/2‐inch pipe (schedule 80 steel or malleable seal off the shaft as a unit.
iron) and a standard tee (see Figure 6). All threads
are 1/2‐inch NPT. Do not pre‐assemble the tool. Use a pair of stiff wires with hooked ends to remove
the stationary element and seat.
An alternate method of removing the stationary

seal components is to remove the hardware (7 and
8) and separate the seal plate (4) and gasket (5)
from the bearing housing (9). Position the seal
TEE plate on a flat surface with the impeller side down.
APPROX. 6 IN.
(152 MM) LONG Use a wooden dowel or other suitable tool to press
on the back side of the stationary seat until the
seat, O‐rings, and stationary element can be re
moved.
Remove the shaft sleeve O‐ring (27).

APPROX. 14 IN.
(356 MM) LONG If no further disassembly is required, refer to Seal
Installation.
Figure 6. Rotating Assembly Tool Shaft and Bearing Removal and Disassembly
(Figure 4)
To install the tool, remove the vented plug (11, Fig
When the pump is properly operated and main
ure 4) from the bearing housing, and screw the
tained, the bearing housing should not require dis
longest length of pipe into the vent hole until fully
assembly. Disassemble the shaft and bearings
engaged. Install the tee, and screw the handles into
only when there is evidence of wear or damage.
the tee. Use caution when lifting the rotating assem
bly to avoid injury to personnel or damage to the as
sembly.
Remove the O‐rings (19 and 33). Shaft and bearing disassembly in the field
is not recommended. These operations
should be performed only in a properly‐
Impeller Removal equipped shop by qualified personnel.
Remove the bearing housing drain plug and drain
(Figure 4)
the lubricant. Clean and reinstall the drain plug.
With the rotating assembly removed from the Disengage the hardware (17 and 18) and slide the
pump casing, unscrew the impeller from the shaft. bearing cap (20) and oil seal (19) off the shaft. Re
Use caution when unscrewing the impeller; ten move the bearing cap gasket (21) and press the oil
sion on the shaft seal spring will be released as the seal from the bearing cap.
impeller is removed. Inspect the impeller and re
Place a block of wood against the impeller end of
place if cracked or badly worn.
the shaft (26) and tap the shaft and assembled
bearings (24 and 28) from the bearing housing.
Remove the impeller adjusting shims (2); tie and
tag the shims, or measure and record their thick Pry or press the oil seals (6) from the bearing hous
ness for ease of reassembly. ing.

After removing the shaft and bearings, clean and If bearing replacement is required, remove the out
inspect the bearings in place as follows. board bearing retaining ring (22) and thrust wash
er (23). Use a bearing puller to remove the bear
ings from the shaft.
Pump Casing and Transition Chamber Removal

(Ultra Mate Second Stage Model Only)
To prevent damage during removal from
the shaft, it is recommended that bearings (Figure 3)
be cleaned and inspected in place. It is The removal method for the Ultra Mate pump cas
strongly recommended that the bearings ing (1) depends on the configuration of the casing
be replaced any time the shaft and bear discharge port. If the discharge port is in a vertical
ings are removed. position, install two eye hooks in opposing holes in
the discharge flange. Use a suitable sling and hoist
Clean the bearing housing, shaft and all compo
to remove the casing.
nent parts (except the bearings) with a soft cloth
soaked in cleaning solvent. Inspect the parts for If the discharge port is in a horizontal position, fab
wear or damage and replace as necessary. ricate a lifting device as shown in Figure 7 and
screw it into the hole for the pipe plug (4). Make
certain that the threaded end of the tool fully en
gages the threads in the casing. Use a suitable
sling and hoist to remove the casing.
Most cleaning solvents are toxic and
flammable. Use them only in a well ven
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain STANDARD
5/8‐11 UNC
ers.
LIFTING EYE
Clean the bearings thoroughly in fresh cleaning 1” DIA. COLD
ROLLED STEEL
solvent. Dry the bearings with filtered compressed
ROD DRILLED
air and coat with light oil. AND TAPPED
5/8‐11 UNC
3/4-14 NPT
Bearings must be kept free of all dirt and Figure 7. Casing Removal Tool
foreign material. Failure to do so will great
ly shorten bearing life. Do not spin dry
bearings. This may scratch the balls or
races and cause premature bearing fail
ure. Do not attempt to lift the complete pump
unit using the lifting device. It is de
Rotate the bearings by hand to check for rough signed to facilitate removal or installa
ness or binding and inspect the bearing balls. If ro
tion of individual components only. Ad
tation is rough or the bearing balls are discolored,
ditional weight may result in damage to
replace the bearings.
the pump or failure of the lifting device.
The bearing tolerances provide a tight press fit Remove the hardware (9 and 21) securing the
onto the shaft and a snug slip fit into the bearing pump casing to the transition chamber. Separate
housing. Replace the bearings, shaft, or bearing the pump casing and O‐ring (22) from the transi
housing if the proper bearing fit is not achieved. tion chamber.

If the transition chamber requires removal from the soaked in cleaning solvent. Inspect the parts for
Ultra V first stage pump, support the chamber us wear or damage as necessary.
ing a suitable hoist and sling. See Figure 1 and re
move the external mounting hardware (3 and 4).
Reach through the back cover opening and re
move the socket head capscrews (6) and lock
washers (5). Use the hoist and sling to remove the Most cleaning solvents are toxic and
transition chamber and remove the gasket (2). flammable. Use them only in a well ven
tilated area free from excessive heat,
Pump Casing and Transition Chamber Installa sparks, and flame. Read and follow all
tion (Ultra Mate Second Stage Model Only) precautions printed on solvent contain
ers.
(Figure 1)
Inspect the shaft for distortion, nicks or scratches,
Apply `Permatex Aviation No. 3 Form‐A‐Gasket' to or for thread damage on the impeller end. Dress
the mating surfaces and install a new gasket (2). small nicks and burrs with a fine file or emery cloth.
Using the hoist and sling, position the transition Replace the shaft if defective.
chamber on top of the Ultra V pump casing. Reach
through back cover opening and install the socket Position the inboard oil seal (6) in the bearing hous
head capscrews (6) and lock washers (5). Finish ing bore with the lip positioned as shown in Figure
securing the transition chamber by installing the 4, Detail B. Press the oil seal into the housing until
remaining hardware (3 and 4). Remove the sling the face is just flush with the counterbored surface
from the transition chamber. toward the inside of the housing.
(Figure 3)
Lubricate a new O‐ring (22) with a generous

amount of grease and install it over the shoulder on
the transition chamber (5). Using the same lifting To prevent damage during removal from
method as used for disassembly, position the the shaft, it is recommended that bearings
pump casing (1) over the transition chamber be cleaned and inspected in place. It is
shoulder and secure it with the previously removed strongly recommended that the bearings
hardware (9 and 21). Remove the sling and, if be replaced any time the shaft and bear
used, the lifting device from the pump casing and ings are removed.
reinstall the pipe plug (4).
NOTE
The inboard bearing (3) comes from the manufac
turer with a retaining ring installed on the bearing
O.D. This retaining ring must be removed prior to
installation.
Do not attempt to lift the complete pump
unit using the lifting device. It is de The bearings may be heated to ease installation.
signed to facilitate removal or installa An induction heater, hot oil bath, electric oven, or
tion of individual components only. Ad hot plate may be used to heat the bearings. Bear
ditional weight may result in damage to ings should never be heated with a direct flame or
the pump or failure of the lifting device. directly on a hot plate.
Shaft and Bearing Reassembly and Installation

NOTE
If a hot oil bath is used to heat the bearings, both the
(Figure 4) oil and the container must be absolutely clean. If
the oil has been previously used, it must be thor
Clean the bearing housing, shaft and all compo oughly filtered.
nent parts (except the bearings) with a soft cloth

Heat the bearings to a uniform temperature no Position the outboard oil seal (6) in the bearing
higher than 250F (120C), and slide the bearings housing bore with the lip positioned as shown in
onto the shaft, one at a time, until they are fully Figure 4, Detail B. Press the oil seal into the hous
seated. This should be done quickly, in one con ing until the face is just flush with the machined
tinuous motion, to prevent the bearings from cool surface on the housing.
ing and sticking on the shaft.
Press the oil seal (19) into the bearing cap (20) with
After the bearings have been installed and allowed the lip positioned as shown in Figure 2, Detail C.
to cool, check to ensure that they have not moved Replace the bearing cap gasket (21) and secure
away from the shaft shoulders in shrinking. If the bearing cap with the hardware (17 and 18). Be
movement has occurred, use a suitably sized careful not to damage the oil seal lip on the shaft
sleeve and a press to reposition the bearings keyway.
against the shaft shoulders.
Lubricate the bearing housing as indicated in LU
If heating the bearings is not practical, use a suit BRICATION.
ably sized sleeve, and an arbor (or hydraulic) press
to install the bearings on the shaft. Seal Installation
(Figures 4 and 8)
When installing the bearings onto the

shaft, never press or hit against the outer Most cleaning solvents are toxic and
race, balls, or ball cage. Press only on the flammable. Use them only in a well ven
inner race. tilated area free from excessive heat,
Install the thrust washer (23) and secure the out
sparks, and flame. Read and follow all
board bearing (24) to the shaft with the snap ring precautions printed on solvent contain
(22). ers.
Clean the seal cavity and shaft with a cloth soaked
It is recommended that a sleeve be positioned in fresh cleaning solvent. Inspect the stationary
against the inboard oil seal (6) to prevent the lip of seat bore in the seal plate for dirt, nicks and burrs,
the oil seal from rolling as the shaft and bearing are and remove any that exist. The stationary seat bore
installed in the bearing housing. The O.D. of the must be completely clean before installing the
sleeve should be just smaller than the bearing seal.
housing bore, while the I.D. of the sleeve should be
just larger than the O.D. of the lip seal area of the
shaft.
With the lip seal sleeve in place, lubricate the lip

seal area of the shaft, and slide the shaft and as A new seal assembly should be installed
sembled bearings into the bearing housing until any time the old seal is removed from the
the retaining ring on the outboard bearing seats pump. Wear patterns on the finished faces
against the bearing housing. Remove the lip seal cannot be realigned during reassembly.
sleeve. Reusing an old seal could result in prema
ture failure.
The seal is not normally reused because wear pat
terns on the finished faces cannot be realigned
during reassembly. This could result in premature
When installing the shaft and bearings into failure. If necessary to reuse an old seal in an emer
the bearing bore, push against the outer gency, carefully wash all metallic parts in fresh
race. Never hit the balls or ball cage. cleaning solvent and allow to dry thoroughly.

Inspect the seal components for wear, scoring, faces to ensure that they are free of any foreign
grooves, and other damage that might cause leak matter.
age. If any components are worn, replace the com
To ease installation of the seal, lubricate the shaft
plete seal; never mix old and new seal parts.
sleeve, shaft sleeve O‐ring and the external station
ary seat O‐ring with a very small amount of light lu
If a replacement seal is being used, remove it from bricating oil. See Figure 8 for seal part identifica
the container and inspect the precision finished tion.
RETAINER SEAL PLATE
SPRING
O‐RINGS
IMPELLER
SEAL SLEEVE
O‐RING
BELLOWS
ROTATING
IMPELLER INTEGRAL
ELEMENT
SHAFT SHAFT
STATIONARY
ELEMENT SLEEVE
IMPELLER
SHIMS
DRIVE BAND STATIONARY

SEAT
Figure 8. Cartridge Seal Assembly

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.
This seal is not designed for operation at
When installing a new cartridge seal assembly,
temperatures above 160F (71C). Do not
remove the seal from the container, and remove
use at higher operating temperatures. the mylar storage tabs, if so equipped, from be
tween the seal faces.
If the seal plate was removed, install the seal plate
gasket (5). Position the seal plate over the shaft
and secure it to the bearing housing with the hard
ware (7 and 8).
To prevent damaging the shaft sleeve O‐ring (27) Some cartridge seal assemblies are
on the shaft threads, stretch the O‐ring over a piece equipped with mylar storage tabs between
of plastic tubing that the I.D. is a little larger than the the seal faces. These storage tabs must be
O.D. of the shaft. Slide the tube over the shaft removed before installing the seal.
Lubricate the external stationary seat O‐ring with As the stationary seat becomes fully seated, the
light oil. Slide the seal assembly onto the shaft until seal spring compresses, and the shaft sleeve will
the external stationary seat O‐ring engages the break the nylon shear ring. This allows the sleeve
bore in the seal plate. to slide down the shaft until seated against the
shaft shoulder. Continue to screw the impeller onto
Clean and inspect the impeller as described in Im the shaft until the impeller, shims, and sleeve are
peller Installation and Adjustment. Install the full fully seated against the shaft shoulder (see Figure
set of impeller shims (2) provided with the seal, and 10).
screw the impeller onto the shaft until it is seated
against the seal (see Figure 9). Measure the impeller‐to‐seal plate clearance, and
remove impeller adjusting shims to obtain the
O‐RING ENGAGED
proper clearance as described in Impeller Instal
WITH SEAL PLATE lation and Adjustment.
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

SHEAR RING
(UNSHEARED) any time the old seal is removed from the
pump. Wear patterns on the finished faces
Figure 9. Seal Partially Installed cannot be realigned during reassembly.
Reusing an old seal could result in prema
Continue to screw the impeller onto the shaft. This ture failure.
will press the stationary seat into the seal plate
Handle the seal parts with extreme care to prevent
bore.
damage. Be careful not to contaminate precision
finished faces; even fingerprints on the faces can
NOTE shorten seal life. If necessary, clean the faces with a
A firm resistance will be felt as the impeller presses non‐oil based solvent and a clean, lint‐free tissue.
the stationary seat into the seal plate bore. Wipe lightly in a concentric pattern to avoid
scratching the faces.
Carefully wash all metallic parts in fresh cleaning

STATIONARY SEAT
FULLY SEATED IN solvent and allow to dry thoroughly.
SEAL PLATE BORE
Do not attempt to separate the rotating

portion of the seal from the shaft sleeve
when reusing an old seal. The rubber bel
lows will adhere to the sleeve during use,
and attempting to separate them could
SHEAR RING damage the bellows.
(SHEARED)
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leak
Figure 10. Seal Fully Installed age. Inspect the integral shaft sleeve for nicks or

cuts on either end. If any components are worn, or mended for maximum pump efficiency. Measure
the sleeve is damaged, replace the complete seal; this clearance, and add or remove impeller adjust
never mix old and new seal parts. ing shims as required.
Install the stationary seal element in the stationary NOTE

seat. Press this stationary subassembly into the Proceed with Rotating Assembly Installation be
seal plate bore until it seats squarely against the fore installing the impeller capscrew and washer
bore shoulder. A push tube made from a piece of (29 and 30). The rotating assembly must be in
plastic pipe would aid this installation. The I.D. of stalled in the pump casing in order to torque the im
the pipe should be slightly larger than the O.D. of peller capscrew.
the shaft sleeve.
Slide the rotating portion of the seal (consisting of After the rotating assembly is installed in the pump
the integral shaft sleeve, spring centering washer, casing, coat the threads of the impeller capscrew
spring, bellows and retainer, and rotating element) (29) with `Never‐Seez' or equivalent compound,
onto the shaft until the seal faces contact. and install the impeller washer (30) and capscrew;
torque the capscrew to 90 ft. lbs. (1080 in. lbs. or
Proceed with Impeller Installation and Adjust 12,4 m. kg.).
ment.
Rotating Assembly Installation
Impeller Installation And Adjustment
(Figure 2)
(Figure 4)
NOTE
Inspect the impeller, and replace it if cracked or There is a 1‐1/2 inch diameter socket head pipe
badly worn. Inspect the impeller and shaft threads plug located in the side of the bearing housing. This
for dirt or damage, and clean or dress the threads hole is required for manufacturing purposes only;
as required. therefore the pipe plug should never require remov
al.
Install the O‐rings (17 and 31) and lubricate them

with light grease. Ease the rotating assembly into
The shaft and impeller threads must be the pump casing using the installation tool. Be
completely clean before reinstalling the im careful not to damage the O‐ring.
peller. Even the slightest amount of dirt on
Install the rotating assembly adjusting spacers
the threads can cause the impeller to seize
(30) and secure the rotating assembly to the pump
to the shaft, making future removal difficult
casing with the hardware (11 and 29).
or impossible without damage to the im
peller or shaft. To set the impeller and wear plate clearance, refer
to the Back Cover Installation And Adjustment.
Install the same thickness of impeller adjusting
shims (2) as previously removed. Apply `Never‐
Seez' or equivalent to the shaft threads and screw Back Cover Installation And Adjustment
the impeller onto the shaft until tight. (Figures 2 and 11)
NOTE If the wear plate (5) was removed for replacement,

At the slightest sign of binding, immediately back carefully center it on the back cover and secure it
the impeller off, and check the threads for dirt. Do with the hardware (7 and 8). The wear plate must
not try to force the impeller onto the shaft. be concentric to prevent binding when the back
cover is installed.
A clearance of .025 to .040 inch (0,64 to 1,02 mm) Clearance between the impeller and wear plate is
between the impeller and the seal plate is recom adjusted using four adjusting screws and locking

collars. There are 18 detents on the I.D. of each Loosen the back cover nuts used to press the back
locking collar (9). Indexing the collars one detent cover into the pump casing one full turn.
on the adjusting screws represents approximately
Pull the collars off the adjusting screws, index them
.005 inch (0,13 mm) of wear plate clearance. The
three detents counterclockwise, and reinstall the
recommended clearance between the wear plate
collars on the adjusting screws. Use the collars to
and the impeller is .010 to .020 inch (0,25 to 0,50
turn the adjusting screws clockwise until the holes
mm).
in the locking collars realign with the tapped screw
Replace the back cover O‐rings (6 and 17) and lu holes in the back cover plate. Secure the locking
bricate them with a generous amount of No. 2 collars to the back cover plate with the hardware
grease. Clean any scale or debris from the contact (11 and 13). Install the two remaining back cover
ing surfaces in the pump casing that might inter nuts snugly against the adjusting screws.
fere or prevent a good seal with the back cover. Remove the first two back cover nuts from their
studs. Turn the adjusting screws clockwise until
USE TWO REMAINING USE TWO they engage the pump casing. Install the locking
ADJUSTING SCREWS AND OPPOSING
BACK COVER NUTS collars and hardware (11 and 13). Reinstall the
LOCKING COLLARS TO
SET FACE CLEARANCE TO PRESS back cover nuts.
BACK COVER
INTO PUMP
CASING Be sure the wear plate does not scrape against the
impeller.
INDEX COLLARS 3
DETENTS COUNTER‐
CLOCKWISE, THEN Over time it may be necessary to repeat the adjust
TURN CLOCKWISE ment process to compensate for normal wear be
UNTIL SCREW
HOLES ALIGN tween the impeller and wear plate. When all of the
adjustment has been used on the back cover side
of the pump, an additional 0.125 inch (3,2 mm) of
adjustment may be obtained by removing the ro
tating assembly spacers (30).
Allow an installed pump to completely cool before

draining liquid from the pump casing. Remove the
back cover. Remove the rotating assembly adjust
Figure 11. Installing and Adjusting Back Cover ing shims, then reinstall the hardware securing the
rotating assembly to the pump casing. Perform the
Screw the four adjusting screws (12) into the back cover adjustment procedure described
tapped holes in the back cover plate until they are above to obtain the proper face clearance.
just flush with the machined surface on the back
PRESSURE RELIEF VALVE
side of the cover plate.
MAINTENANCE
Align the back cover plate over the studs (3) and (Figure 2)
slide it into the pump casing. Use two back cover The back cover is equipped with a pressure relief
nuts (14) on diagonally opposing studs to press valve to provide additional safety for the pump and
the back cover into the pump casing until the wear operator (refer to Liquid Temperature And Over
plate just touches the impeller when the shaft is heating in OPERATION).
turned by hand. Tighten the back cover nuts
It is recommended that the pressure relief valve as
evenly to avoid binding.
sembly be replaced at each overhaul, or any time
With the wear plate just touching the impeller, turn the pump overheats and activates the valve. Never
the two free adjusting screws until they engage the replace this valve with a substitute which has not
pump casing. Position the locking collars over the been specified or provided by the Gorman‐Rupp
adjusting screws so the holes in the collars for the Company.
locking screws align approximately with the holes Periodically, the valve should be removed for in
in the cover plate. spection and cleaning. When reinstalling the relief

valve, apply `Loctite Pipe Sealant With Teflon No. Bearings

592', or equivalent compound, on the relief valve
threads. Position the valve as shown in Figure 2 (Figure 4)
with the discharge port pointing down. The bearing housing was fully lubricated when
Final Pump Assembly shipped from the factory. Check the oil level regu
larly through the bearing cavity sight gauge (15)
(Figure 2)
and maintain it at the middle of the gauge. When
Install the shaft keys (26, Figure 4) in the keyways lubrication is required, add SAE No. 30 non‐deter
of both shafts and reconnect the power source. Be gent oil through the hole for the air vent (13). Do not
sure to install any guards used over the rotating over‐lubricate. Over‐lubrication can cause the
members. bearings to over‐heat, resulting in premature bear
ing failure.
NOTE
Do not operate the pump without the The white reflector in the sight gauge must be posi
guards in place over the rotating parts. tioned horizontally to provide proper drainage.
Exposed rotating parts can catch cloth
ing, fingers, or tools, causing severe in
jury to personnel. Under normal conditions, drain the bearing hous
Install the suction and discharge lines and open all ing once each year and refill with approximately 24
valves. Make certain that all piping connections are ounces (710 ml) of clean oil. Change the oil more
tight, properly supported and secure. frequently if the pump is operated continuously or
installed in an environment with rapid temperature
Be sure the pump and power source have been change.
properly lubricated, see LUBRICATION.
Remove the fill cover assembly (26) and fill the
pump casing with clean liquid. Reinstall the fill
cover, install the clamp bar (28) and secure it with
the capscrew (27). Refer to OPERATION, Section
C, before putting the pump back into service. Monitor the condition of the bearing lubri
LUBRICATION cant regularly for evidence of rust or mois
ture condensation. This is especially im
Seal Assembly portant in areas where variable hot and
(Figure 4) cold temperatures are common.
Before starting the pump, remove the vented plug
(11) and fill the seal cavity with approximately 132 For cold weather operation, consult the factory or a
ounces (3,9 liters) of SAE No. 30 non‐detergent oil lubricant supplier for the recommended grade of
to the middle of the seal level sight gauge (15) and oil.
maintain it at the middle of the gauge. Clean and
reinstall the vented plug. Maintain the oil at this Power Source
level.
NOTE
The white reflector in the sight gauge must be posi Consult the literature supplied with the power
tioned horizontally to provide proper drainage. source, or contact your local power source repre
sentative.

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 MANSFIELD, OHIO

GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA

Installation, Operation, and Maintenance Manual: Ultra V Pump

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CDS OM-06014-02

November 10, 2006

THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

Please record your pump model and serial number in the

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

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

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

Pump Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C - 3

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

Ultra V Series pumps are designed for handling liq­

This information applies toUltra V Se­ containing large entrained solids or

Because pump installations are seldom

It is recommended that 24 inches (609.6 mm) of Gauges

Pump performance is adversely effected by in­ SUCTION LINES

This pump is designed to handle up to 3 inch (76,2

Suction Lines In Sumps

Figure 1. Recommended Minimum Suction Line Submergence vs. Velocity

Valves Bypass Lines

Self‐priming pumps are not air compressors. Dur­

affect pump discharge capacity; however, the by­

If a manual shut‐off valve is installed in

Figure 2. Typical Automatic Air Release Valve Installation

NOTE close as possible to the primary discharge check

Figure 3. Recommended Dual Motor Direct

Special consideration must be given to drive ar­

Dual Motor Drives

It is recommended that each pump be directly driv­

Each motor should be independently operated

Figure 5 shows a recommended alternate single

Figure 6. Alternate Single Motor Combination

Figures 7 and 8 show single motor belt drive ar­

Figure 5. Alternate Single Motor Belt Drive

Single Motor Combination Drives

In staged applications where both pumps are driv­

Figure 6 shows a recommended alternate single

either a flexible coupling or belt‐driven system, the

When mounted at the Gorman‐Rupp factory, driver

Figure 9. Aligning Spider‐Type Couplings

MISALIGNED: MISALIGNED: ALIGNED: SHAFTS

Figure 11. Alignment of V‐Belt Driven Pumps

Tighten the belts in accordance with the belt manu­

Figure 10. Aligning Non‐Spider Type Couplings

Align non‐spider type couplings by using a feeler

If an electric motor is used to drive the pump, re­

Cold Weather Preservation

In below freezing conditions, drain the pump to

Bearings normally run at higher than ambient tem­

Review all SAFETY information in Section A.

Before attempting to open or service the

1. Familiarize yourself with this manual.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP STOPS OR Strainer clogged. Check strainer and clean if neces­

Impeller or other wearing parts worn Replace worn or damaged parts.

Ultra V Series pumps are designed for handling liq

This information applies toUltra V Se containing large entrained solids or

Pump performance is adversely effected by in SUCTION LINES

Self‐priming pumps are not air compressors. Dur

affect pump discharge capacity; however, the by

Special consideration must be given to drive ar

It is recommended that each pump be directly driv

Figures 7 and 8 show single motor belt drive ar

In staged applications where both pumps are driv

Tighten the belts in accordance with the belt manu

If an electric motor is used to drive the pump, re

Bearings normally run at higher than ambient tem

PUMP STOPS OR Strainer clogged. Check strainer and clean if neces

Impeller clogged or damaged. Clean out debris; replace dam