GORMAN-RUPP PUMPS U Series User manual

OM-01824-OB02
October 2, 1990
Rev. C 10/11/02
C
THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
www.gormanrupp.com
eCopyright by the Gorman-Rupp Company
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
U-SERIES PUMP
MODELS
JS4D20---E9.4 230V 3P JS4D20---E9.4 230V 3P
JS4D20---E9.4 230V 3P JS4D20---E9.4 230V 3P
JS4D20---E9.4 230V 3P JS4D20---E9.4 230V 3P
MODEL
U6A60 --- B
INCLUDING: /F, /FM

TABLE OF CONTENTS
i
INTRODUCTION PAGE I --- 1...................................................
SAFETY --- SECTION A PAGE A --- 1............................................
INSTALLATION --- SE CTION B PAGE B --- 1.....................................
Pump Dimensions PAGE B --- 1........................................................
PREINSTALLATION INSPECTION PAGE B --- 2...............................................
POSITIONING PUMP PAGE B --- 2..........................................................
Lifting PAGE B --- 2....................................................................
Mounting PAGE B --- 2................................................................
Clearance PAGE B --- 2................................................................
SUCTION AND DISCHARGE PIPING PAGE B --- 2............................................
Materials PAGE B --- 3.................................................................
Line Configuration PAGE B --- 3.........................................................
Connections to Pump PAGE B --- 3.....................................................
Gauges PAGE B --- 3..................................................................
SUCTION LINES PAGE B --- 3..............................................................
Fittings PAGE B --- 3..................................................................
Strainers PAGE B --- 3.................................................................
Sealing PAGE B --- 3..................................................................
Suction Lines In Sumps PAGE B --- 3....................................................
Suction Line Positioning PAGE B --- 4...................................................
DISCHARGE LINES PAGE B --- 4...........................................................
Siphoning PAGE B --- 4................................................................
Valves PAGE B --- 4...................................................................
Bypass Lines PAGE B --- 5.............................................................
AUTOMATIC AIR RELEASE VALVE PAGE B --- 6..............................................
Theory of Operation PAGE B --- 6.......................................................
Air Release Valve Installation PAGE B --- 7...............................................
ALIGNMENT PAGE B --- 7.................................................................
Coupled Drives PAGE B --- 8...........................................................
V-Belt Drives PAGE B --- 8..............................................................
OPE RATION --- SECTION C PAGE C --- 1.......................................
PRIMING PAGE C --- 1....................................................................
STARTING PAGE C --- 1...................................................................
Rotation PAGE C --- 1.................................................................
OPERATION PAGE C --- 2.................................................................
Lines With a Bypass PAGE C --- 2.......................................................
Lines Without a Bypass PAGE C --- 2....................................................
Leakage PAGE C --- 2.................................................................
Liquid Temperature And Overheating PAGE C --- 2........................................
Strainer Check PAGE C --- 3............................................................
Pump Vacuum Check PAGE C --- 3.....................................................
STOPPING PAGE C --- 3...................................................................
Cold Weather Preservation PAGE C --- 3.................................................
BEARING TEMPERATURE CHECK PAGE C --- 3.............................................

TABLE OF CONTENTS
(continued)
ii
TROUBLESHOOTING --- SECTION D PAGE D --- 1...............................
PREVENTIVE MAINTENANCE PAGE D --- 3..................................................
PUMP MAINTENANCE AND REPAIR --- SECTION E PAGE E --- 1.................
PERFORMANCE CURVE PAGE E --- 1......................................................
PARTS LISTS:
Pump Model PAGE E --- 3.............................................................
Repair Rotating Assembly PAGE E --- 5..................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E --- 6............................
Back Suction Cover Removal PAGE E --- 6...............................................
Rotating Assembly Removal PAGE E --- 6................................................
Impeller Removal PAGE E --- 8.........................................................
Seal Removal and Disassembly PAGE E --- 8.............................................
Shaft and Bearing Removal and Disassembly PAGE E --- 8................................
Shaft and Bearing Reassembly and Installation PAGE E --- 9...............................
Seal Reassembly and Installation PAGE E --- 10..........................................
Impeller Installation And Adjustment PAGE E --- 13........................................
Rotating Assembly Installation PAGE E --- 13.............................................
Back Suction Cover Installation PAGE E --- 14............................................
Final Pump Assembly PAGE E --- 14....................................................
PRESSURE RELIEF VALVE MAINTENANCE PAGE E --- 14....................................
LUBRICATION PAGE E --- 15...............................................................
Seal Assembly PAGE E --- 15...........................................................
Bearings PAGE E --- 15................................................................
Power Source PAGE E --- 15...........................................................

USERIES OM--01824
PAGE I -- 1INTRODUCTION
INTRODUCTION
Thank You for purchasing a Gorman-Rupp pump.
Read this manual carefully to learn how to safely
install and operate your pump. Failure to do so
could result in personal injury or damage to the
pump.
This Installation, Operation, and Maintenance
manual is designed to help you achieve the best
performance and longest life from your Gorman-
Rupp pump.
This pump is a U Series, semi-open impeller, self-
priming centrifugal model with a suction check
valve. It is designed for high-efficiency distribution
of non-volatile, non-corrosive liquids containing
specified entrained solids. The basic material of
construction of wetted parts is cast iron, with duc-
tile iron impeller and alloy steel impeller shaft. The
back cover is designed for straight-in suction, and
is connected to a 6-inch extension pipe assembly
by a shoulder-type, quick-disconnect coupling.
If there are any questions regarding the pump or
its application which are not covered in this man-
ual or in other literature accompanying this unit,
please contact your Gorman-Rupp distributor, or
write:
The Gorman-Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901--1217
Phone: [phone]
or:
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: [phone]
For information or technical assistance on the
powersource, contactthe power source manufac-
turer’s local dealer or representative.
Because pump installations are seldom identical,
this manual cannot possibly provide detailed in-
structions and precautions for every aspect of
each specific application. Therefore, it is the re-
sponsibility of the owner/installer of the pump to
ensure that applications not addressed in this
manual are performed only after establishing that
neitheroperatorsafetynorpumpintegrityarecom-
promised by the installation. Pumps and related
equipment must be installed and operated ac-
cording to all national, local and industry stan-
dards.
The following are used to alert maintenance per-
sonnel to procedures which require specialatten-
tion,tothosewhichcoulddamageequipment,and
to those which could be dangerous to personnel:
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure re-
quired and the injury which will result
from failure to follow the procedure.
Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.
HazardsorunsafepracticeswhichCOULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possi-
ble damage which couldresult from failure
to follow the procedure.
NOTE
Instructions to aid in installation, operation,and
maintenance, or which clarify a procedure.

USERIES OM--01824
PAGE A -- 1SAFETY
SAFETY --- SECTION A
This information applies to U Series ba-
sic pumps. Gorman-Rupp has no con-
trol over or particular knowledge of the
power source which will be used. Refer
to the manual accompanying the power
source before attempting to begin
operation.
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and pre-
cautions for each specific application.
Therefore, it is the owner/installer’s re-
sponsibility to ensure that applications
not addressed in this manual are per-
formed only after establishing that nei-
ther operator safety nor pump integrity
are compromised by the installation.
Beforeattemptingtoopenorservicethe
pump:
1. Familiarize yourself with this man-
ual.
2. Disconnect or lock out the power
sourcetoensurethatthepumpwill
remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau-
tiously.
7. Drain the pump.
This pump is designed to handlemost
non-volatile, non-corrosive liquids con-
taining specified entrained solids. Do
not attempt to pump volatile, corrosive,
or flammable materials, or any liquids
which may damage the pump or endan-
ger personnel as a result of pump fail-
ure.
Afterthepumphasbeeninstalled,make
certainthatthepumpandall pipingcon-
nections are tight, properly supported
and secure before operation.
Do not operate the pump without the
guards in place over the rotating parts.
Exposed rotating parts can catch cloth-
ing, fingers, or tools, causing severe in-
jury to personnel.
Do not operate the pump against a
closed discharge valve for long periods
oftime.Ifoperatedagainstacloseddis-
charge valve, pump components will
deteriorate, and the liquid could come
to a boil, build pressure, and cause the
pump casing to rupture or explode.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over-
heatedpump. Vaporpressure withinthe
pump can cause parts being disen-
gaged to be ejected with great force. Al-
low the pump to completely cool before
servicing.

USERIES
OM--01824
PAGE A -- 2 SAFETY
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam-
age to equipment. The bail is intended
for use in lifting the pump assembly
only. Suction and discharge hoses and
piping must be removed from the pump
before lifting.

OM--01824USERIES
PAGE B -- 1INSTALLATION
INSTALLATION --- SECTION B
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this
section offers only general recommendations and
practices required to inspect, position, and ar-
range the pump and piping.
Most of the information pertains to a standard
static lift application where the pump is posi-
tionedabovethefreelevelofliquidtobepumped.
If installed ina flooded suction application where
the liquid is supplied to the pump under pressure,
some of the information such as mounting, line
configuration, and priming must be tailored to the
specific application. Since the pressure supplied
to the pump is critical to performance and safety,
be sure to limit the incoming pressure to 50% of
the maximum permissible operating pressure as
shown on the pump performance curve.
For furtherassistance,contact yourGorman-Rupp
distributor or the Gorman-Rupp Company.
Pump Dimensions
SeeFigure1fortheapproximatephysicaldimen-
sionsofthispump.
OUTLINE DRAWING
NOTE: OPTIONAL ASA OR DIN DISCHARGE SPOOL FLANGE AVAILABLE
Figure 1. Pump Model U6A60-B

OM--01824 USERIES
PAGE B -- 2 INSTALLATION
PREINSTALLATION INSPECTION
The pump assemblywas inspectedand tested be-
fore shipment from the factory. Before installation,
inspect the pump for damage which may haveoc-
curred during shipment. Check as follows:
a. Inspectthepumpforcracks, dents,damaged
threads, and other obvious damage.
b. Check for and tighten loose attaching hard-
ware. Since gaskets tend to shrink after dry-
ing, check for loose hardware at mating sur-
faces.
c. Carefully read allwarnings and cautions con-
tained in this manual or affixed to the pump,
and perform all duties indicated. Note the di-
rection of rotation indicated on the pump.
Check that the pump shaft rotates counter-
clockwise when facing the impeller.
Only operate this pump in the direction in-
dicated by the arrow on the pump body
and on the accompanying decal. Refer to
Rotation in Operation,SectionC.
d. Check levels and lubricate as necessary. Re-
fer to LUBRICATION in the MAINTENANCE
AND REPAIR section of this manual and per-
form duties as instructed.
e.Ifthepumpandpowersourcehavebeen
stored for more than 12 months, some of the
components or lubricants may have ex-
ceeded their maximum shelf life. These must
be inspected or replaced to ensure maxi-
mum pump service.
If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Gorman-Rupp distributor or the factory to deter-
mine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.
POSITIONING PUMP
Lifting
Use lifting equipment with a capacity of at least
5,000 pounds (2268 kg). This pump weighs ap-
proximately 1,000 pounds (453,6 kg),notinclud-
ing the weight of accessories and base. Customer
installed equipment such as suction and dis-
chargepipingmustberemovedbeforeattempting
to lift.
Thepumpassemblycanbeseriously
damagedifthecablesorchainsusedtolift
andmovetheunitareimproperlywrapped
around the pump.
Mounting
Locatethepumpinanaccessibleplaceascloseas
practical tothe liquid being pumped. Level mount-
ing is essential for proper operation.
The pump may have to be supported or shimmed
to provide for level operation or to eliminate vibra-
tion.
Clearance
The extension pipe assembly provided with this
pump is integral to pump design and must be in
placewhenthepumpispositioned.Wheninstalled
onthepump, the extensionpipeassemblywillpro-
vide an automatic clearance of 24 inches (610
mm) in front of the back cover; this will permit re-
movaloftherotatingassemblythroughthebackof
the pump.
SUCTION AND DISCHARGE PIPING
Pump performance is adversely effected by in-
creased suction lift, discharge elevation, and fric-
tion losses. See the performance curve and oper-
ating range shown on Page E-1 to be sure your
overall application allows pump to operate within
thesafeoperationrange.

OM--01824USERIES
PAGE B -- 3INSTALLATION
Materials
Either pipe or hose maybe used for suction and
discharge lines; however, the materials must be
compatiblewiththeliquidbeingpumped.Ifhoseis
used in suction lines, it must be the rigid-wall, rein-
forced type toprevent collapse under suction. Us-
ing piping couplings in suction lines is not recom-
mended.
Line Configuration
Keep suction and discharge lines as straight as
possible to minimize friction losses. Make mini-
mum use of elbows and fittings, which substan-
tiallyincreasefrictionloss.Ifelbowsarenecessary,
use the long-radius type to minimize friction loss.
Connections to Pump
Before tightening a connecting flange, align it ex-
actly with the pump port. Never pulla pipe line into
place by tightening the flange bolts and/or cou-
plings.
Lines near the pump must be independently sup-
ported to avoid strain on the pump which could
cause excessive vibration, decreased bearing life,
and increased shaft and seal wear. If hose-type
linesareused, theyshouldhaveadequatesupport
to secure them when filled with liquid and under
pressure.
Gauges
Most pumps are drilled and tapped for installing
dischargepressureandvacuumsuctiongauges.If
these gauges are desired for pumps that are not
tapped, drill and tap the suction and discharge
lines not less than 18 inches (457,2 mm) from the
suction and discharge ports and install the lines.
Installation closer tothe pump may result in erratic
readings.
SUCTION LINES
Toavoidairpocketswhichcouldaffectpumpprim-
ing, the suction line must be as short and direct as
possible.Whenoperationinvolvesasuctionlift,the
line must always slope upward to the pump from
the source of the liquid being pumped; if the line
slopes down to the pump at any point along the
suction run, air pockets will be created.
Fittings
Suction lines should bethe same sizeas thepump
inlet. If reducers are used in suction lines, they
should be the eccentric type, and should be in-
stalled withthe flatpart ofthe reducers uppermost
to avoid creating air pockets. Valves are not nor-
mally used in suction lines, but if a valve is used,
install it with the stem horizontal to avoid air pock-
ets.
Strainers
If a strainer is furnished with the pump, be certain
touseit;anysphericalsolidswhichpassthrougha
strainer furnished with the pump will also pass
through the pump itself.
If a strainer is not furnished with the pump, but is
installed by the pump user, make certain that the
total area of the openings in the strainer is at least
three or four times the cross section of the suction
line, and that the openings will not permit passage
of solids larger than the solids handling capability
of the pump.
This pump is designed to handle up to 1 1/4 inch
(31,8 mm) diameter spherical solids.
Sealing
Since even a slight leak will affect priming, head,
and capacity, especially when operating with a
high suction lift, all connections in the suction line
should be sealed with pipe dope to ensure an air-
tight seal. Follow the sealant manufacturer’s rec-
ommendations when selecting and applying the
pipe dope. The pipe dope should be compatible
with the liquid being pumped.
Suction Lines In Sumps
If a single suction line is installed in a sump, it
should be positioned away from the wall of the
sump at a distance equal to1 1/2 times the diame-
ter of the suction line.

OM--01824 USERIES
PAGE B -- 4 INSTALLATION
If there is a liquid flow from an open pipe into the
sump, the flow should be kept away from the suc-
tion inlet because the inflow willcarry air down into
the sump, and air entering the suction line will re-
duce pump efficiency.
If it is necessary to position inflow close to the suc-
tioninlet, installa baffle between the inflow and the
suction inlet at a distance 1 1/2 times the diameter
of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into
the suction inlet.
If two suction lines are installed in a single sump,
theflowpathsmayinteract,reducingtheefficiency
of one or both pumps. To avoid this, position the
suction inlets so that they are separated by a dis-
tance equal to at least 3 times the diameter of the
suction pipe.
Suction Line Positioning
The depth of submergence of the suction line is
critical to efficient pump operation. Figure 2 shows
recommended minimum submergence vs. veloc-
ity.
NOTE
The pipe submergence required may be reduced
by installing a standard pipe increaser fitting at the
end of thesuction line. The larger opening size will
reduce the inlet velocity. Calculate the required
submergence using the following formula based
on the increased opening size (area or diameter).
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
DISCHARGE LINES
Siphoning
Do not terminate the discharge line at a levellower
than that of the liquid being pumped unless a si-
phon breaker is used in the line. Otherwise, a si-
phoning action causing damage to the pump
could result.
Valves
If a throttling valve is desired in the discharge line,
useavalveaslargeasthelargestpipetominimize
friction losses. Never install a throttling valve in a
suction line.