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.

OM--01824USERIES
PAGE B -- 5INSTALLATION
Withhighdischargeheads,itisrecommendedthat
a throttling valve and a system check valve be in-
stalled in the discharge line to protect the pump
from excessive shock pressure and reverse rota-
tion when it is stopped.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
Bypass Lines
Self-priming pumps are not air compressors. 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
through the discharge. However, if a check valve
has been installed in the discharge line, the dis-
chargesideofthepumpmustbeopenedtoatmos-
phericpressurethrougha bypasslineinstalledbe-
tween the pump discharge and the check valve. A
self-priming centrifugal pump will not prime if
there is sufficient static liquid head to hold the dis-
charge check valve closed.
NOTE
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.
Inlow discharge head applications (less than 30
feet),itisrecommendedthatthebypasslineberun
back to the wet well, and located 6 inches below
the water level or cut-off point of the low level
pump. In some installations, this bypass line may
beterminatedwithasix-to-eightfootlengthof11/4
inch I.D. smooth-bore hose; air and liquid vented
during the priming process will then agitate the
hose and break up any solids, grease, or other
substances likely to cause clogging.
A bypass line that is returned to a wet well
must be secured against being drawn into
the pump suction inlet.
It is also recommended that pipe unions be in-
stalled at each 90_elbow in a bypass line to ease
disassembly and maintenance.
In high discharge head applications (more than
30 feet), an excessive amount of liquid may be by-
passed and forced back to the wet well under the
full working pressure of the pump; this will reduce
overallpumpingefficiency. Therefore,itisrecom-
mended that a Gorman-Rupp Automatic Air Re-
lease Valve be installed in the bypass line.
Gorman-Rupp Automatic Air Release Valves are
reliable, and require minimum maintenance. See
AUTOMATIC AIRRELEASE VALVEin thissection
for installation and theory of operation of the Auto-
matic Air Release Valve. Consult your Gorman-
Rupp distributor, or contact the Gorman-Rupp
CompanyforselectionofanAutomaticAirRelease
Valve to fit your application.
Iftheinstallationinvolvesafloodedsuctionsuchas
abelow-groundliftstation.Apipeunionandmanu-
alshut-off valve maybe installedinthebleed lineto
allowserviceofthevalvewithoutshuttingdownthe
station, and to eliminate the possibility of flooding.
If a manual shut-off valve is installed anywhere in
theairreleasepiping,it mustbeafull-openingball
type valve to prevent plugging by solids.
If a manual shut-off valve is installed in
a bypass line, it must not be left closed
duringoperation.Aclosedmanualshut-
off valve may cause a pump which has
lost prime to continue to operate with-
out reaching prime, causing dangerous
overheating and possible explosive
rupture of the pump casing. Personnel
could be severely injured.
Allow an over-heated pump to cool be-
fore servicing. Do not remove plates,
covers,gauges,or fittingsfrom anover-
heated pump. Liquid within the pump

OM--01824 USERIES
PAGE B -- 6 INSTALLATION
can reach boiling temperatures, andva-
porpressure within the pumpcancause
parts being disengaged to be ejected
with great force. After the pump cools,
drain the liquid from the pump by re-
moving the casing drain plug. Use cau-
tion when removing the plug to prevent
injury to personnel from hot liquid.
AUTOMATIC AIR RELEASE VALVE
When properly installed and correctly adjusted to
the specific hydraulic operating conditions of the
application, the Gorman-Rupp Automatic Air Re-
leaseValvewillpermitairtoescapethroughtheby-
pass line, and then close automatically when the
pump is fully primed and pumping at full capacity.
Theory of Operation
Figures 3 and 4 show a cross-sectional view of the
AutomaticAir Release Valve, and a corresponding
description of operation.
Figure3.ValveinOpenPosition
Duringthe primingcycle,air fromthe pump casing
flowsthroughthebypassline,andpassesthrough
theAirReleaseValvetothewetwell(Figure3).
Figure 4. Valve in Closed Position
When the pump is fully primed, pressure resulting
from flow against the valve diaphragm com-
presses the spring and closes the valve (Figure 4).
The valve will remain closed, reducing the bypass
ofliquidto1to5gallonsperminute,untilthepump
loses its prime or stops.
Some leakage (1 to 5 gallons per min-
ute) will occur when the valve is fully
closed. Be sure thebypasslineisdi-
rected back to the wet well or tank to
prevent hazardous spills.
Whenthepumpshutsdown,thespringreturnsthe
diaphragm to its original position. Any solids that
mayhave accumulated in the diaphragm chamber
settle to the bottom and are flushed out duringthe
next priming cycle.
NOTE
The valve will remain open if the pump does not
reach its designed capacity or head. Valve closing
pressureis dependentupon thedischarge head of
the pump at full capacity. The range of the valve
closing pressure is established by the tensionrate
ofthespringasorderedfromthefactory.Valveclos-
ing pressure can be further adjusted to the exact
system requirements by moving the spring retain-
ing pin up or down the plunger rod to increase or
decrease tension on the spring. Contact your Gor-
man-RuppdistributorortheGorman-RuppCompa-
ny for information about an Automatic Air Release
Valve for your specific application.

OM--01824USERIES
PAGE B -- 7INSTALLATION
Air Release Valve Installation
The Automatic Air Release Valve must be inde-
pendently mounted in a horizontal position and
connected to the discharge line of the self-priming
centrifugal pump (see Figure 5).
NOTE
IftheAirReleaseValveistobeinstalledonastaged
pump application, contact the factory for specific
installation instructions.
DISCHARGE PIPE
DISCHARGE
CHECK VALVE
PUMP DISCHARGE
SELF-PRIMING
CENTRIFUGAL
PUMP
SUCTION
LINE
SUPPORT
BRACKET
CLEAN-OUT
COVER
INSTALL AIR RELEASE VALVE
IN HORIZONTAL POSITION
90_LONG
RADIUS
ELBOW
BLEED LINE 1”
(25,4 MM) DIA. MIN.
(CUSTOMER
FURNISHED)
EXTEND 6”
(152,4 MM)
BELOW LIQUID
WET WELL
OR SUMP
LEVEL SURFACE
Figure 5. Typical Automatic Air Release Valve Installation
The valve inlet line must be installed between the
pumpdischargeportandthenon-pressurizedside
of the discharge check valve. The valve inlet is at
thelargeendofthevalvebody,andisprovided
with standard 1 inch NPT pipe threads.
The valve outlet is located at the opposite end of
the valve, and is also equipped with standard 1
inch NPT pipe threads. The outlet should be con-
nectedtoa bleedlinewhichslopesbackto thewet
well orsump. The bleed line must be the same size
astheinletpiping,orlarger.Ifpiping isusedforthe
bleed line, avoid the use of elbows whenever pos-
sible.
NOTE
It is recommended that each Air Release Valve be
fitted with an independent bleeder line directed
back to the wet well. If multiple Air Release Valves
areinstalledinasystem,theymust befitted within-
dependent bleeder lines; never use a common
manifold pipe. Contact your Gorman-Rupp distrib-
utor or the Gorman-Rupp Company for information
about installation of an Automatic Air Release Valve
for your specific application.
ALIGNMENT
The alignment ofthe pumpand its power source is
critical for trouble-free mechanical operation. In
either a flexible coupling or V-belt driven system,
thedriverandpump mustbemountedsothattheir
shaftsare alignedwith andparalleltoeach 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.

OM--01824 USERIES
PAGE B -- 8 INSTALLATION
WhenmountedattheGorman-Ruppfactory,driver
andpumparealignedbeforeshipment.Misalign-
ment will occur in transit and handling. Pumps
must be checked and realigned before operation.
Before checking alignment, tighten the foundation
bolts. The pump casing feet and/or pedestal feet,
andthedrivermountingboltsshouldalsobetightly
secured.
When checking alignment, disconnect
the power source to ensure that the
pump will remain inoperative.
Adjusting the alignment in one direction
may alter the alignment in another direc-
tion. Check each procedure after altering
alignment.
Coupled Drives
When using couplings, the axis of the power
source must be aligned to the axis of the pump
shaft in both the horizontal and vertical planes.
Mostcouplings require a specificgap or clearance
between the drivingand the driven shafts. Refer to
the coupling manufacturer’s service literature.
Alignspiderinserttypecouplingsbyusingcalipers
to measure the dimensions on the circumference
of the outer ends of the coupling hub every 90 de-
grees. The coupling is in alignment when the hub
ends are the same distance apart at all points (see
Figure 6A).
Figure 6A. Aligning Spider-Type Couplings
Figure 6B. Aligning Non-Spider
Type Couplings
Align non-spider type couplings by using a feeler
gaugeortapergaugebetweenthecouplinghalves
every 90 degrees. The coupling is in alignment
whenthehubsarethesamedistanceapartatall
points (see Figure 6B).
Checkparalleladjustmentbylayingastraightedge
across both coupling rims at the top, bottom, and
side. When the straightedge rests evenly on both
halves of the coupling, the coupling is in horizontal
parallel alignment. If the coupling is misaligned,
use a feeler gauge between the coupling and the
straightedge to measure the amount of misalign-
ment.
V-Belt Drives
When using V-belt drives, the power source and
the pump must be parallel. Use a straightedge
alongthesidesofthepulleystoensurethatthepul-

OM--01824USERIES
PAGE B -- 9INSTALLATION
leys are properly aligned (see Figure 6C). In drive
systemsusingtwoormorebelts,makecertainthat
the belts are a matched set; unmatched sets will
cause accelerated belt wear.
MISALIGNED:
SHAFTS
NOT P
A
R
A
LLEL
MISALIGNED:
SHAFTS
NOT IN LINE
ALIGNED: SHAFTS
PARALLEL AND
SHE
A
V
ES IN LINE
Figure 6C. Alignment of V-Belt Driven Pumps
Tightenthebeltsinaccordancewiththe beltmanu-
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.
Do not operate the pump without the
shield and/or guard in place over the ro-
tating parts. Exposed rotating parts can
catchclothing,fingers,ortools,causing
severe injury to personnel.

U-SERIES OM--01824
OPERATION PAGE C -- 1
OPERATION --- SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and de-
cals attached to the pump.
This pump is designed to handle most
non-volatile, non-corrosive liquids,
containing specified entrained solids.
Do not attempt to pump volatile, corro-
sive, or flammable materials, or any liq-
uidswhichmaydamagethepumporen-
danger personnel as a result of pump
failure.
Pump speed and operating conditions
must be within the performance range
shownonPageE-1.
PRIMING
Install the pump and piping as described in IN-
STALLATION. Make sure that the piping connec-
tions are tight, and that the pump is securely
mounted. Check that the pump is properly lubri-
cated (see LUBRICATION in MAINTENANCE
AND REPAIR).
This pump is self-priming, but the pump should
never be operated unless there is liquid in the
pump casing.
Never operate this pump unless there is
liquid in the pump casing. The pump will
not prime when dry. Extended operationof
a dry pump will destroy theseal assembly.
Add liquid to the pump casing when:
1. The pump is being put into service for the
first time.
2. Thepumphasnotbeenusedforaconsider-
able length of time.
3. The liquid in the pump casing has evapo-
rated.
Once the pump has been filled, the pump will
prime and reprime as necessary.
After filling the pump casing, reinstall
and tighten the fill plug. Do not attempt
to operate the pump unless allconnect-
ing piping is securely installed. Other-
wise, liquid in the pump forced out un-
der pressure could cause injury to per-
sonnel.
To fill the pump, remove the pump casing fillcover
or fill plug in the top of the casing, and add clean
liquid until the casing is filled. Replace the fill cover
or fill plug before operating the pump.
NOTE
There is a threaded passage through the interior
wall of the pump casing just in front of the blind
flange at the back of the pump. This passage is de-
signed to equalizepressurein the casing whenthe
pump is in operation, and must be kept clear.
STARTING
Consult the operations manual furnished with the
power source.
Startingprocedureswillvaryslightlydependingon
the pump application, type of priming device, and
type of drive.
Rotation
The correct direction of pump rotation is counter-
clockwise when facing the impeller. The pump

U-SERIESOM--01824
OPERATIONPAGE C -- 2
could be damaged and performance adversely af-
fected by incorrect rotation. If pump performance
is not within the specified limits (see the curve on
page E-1), check the direction of power source ro-
tation before further troubleshooting.
OPERATION
Lines With a Bypass
IfaGorman-RuppAutomaticAirReleaseValvehas
been installed, the valve will automatically open to
allow the pump to prime, and automatically close
after priming is complete (see INSTALLATION for
Air Release Valve operation).
If the bypass line is open, air from the suction line
willbe discharged through the bypass line back to
the wet well during the priming cycle. Liquid will
then continue to circulate through the bypass line
while the pump is in operation.
Lines Without a Bypass
Open all valves in the discharge line and start the
power source. Priming is indicated by a positive
reading on the discharge pressure gauge or by a
quieter operation. The pump maynot prime imme-
diately because the suction line must first fill with
liquid.If thepumpfailstoprimewithinfiveminutes,
stop it and check the suction line for leaks.
Afterthepumphasbeenprimed,partiallyclosethe
discharge line throttling valve in order to fill the line
slowly and guard against excessive shock pres-
sure which could damage pipe ends, gaskets,
sprinkler heads, and any other fixtures connected
to the line. When the discharge line is completely
filled,adjustthethrottlingvalvetothe requiredflow
rate.
Do not operate the pump against a
closed discharge throttling valve for
long periods of time.Ifoperatedagainst
a closed discharge throttling valve,
pump components will deteriorate, and
the liquid could come to a boil, build
pressure,andcausethepump casingto
rupture or explode.
Leakage
No leakage should be visible at pump mating sur-
faces, or at pump connections or fittings. Keep all
lineconnectionsandfittingstightto maintainmaxi-
mum pump efficiency.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
160_F(71_C). Donotapplyitatahigheroperat-
ing temperature.
Overheating can occur if operated with the valves
in the suction or discharge lines closed. Operating
against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to rup-
ture or explode. If overheating occurs, stop the
pump and allow it to cool before servicing it. Refill
the pump casing with cool liquid.
Allow an over-heated pump to cool be-
fore servicing. Do not remove plates,
covers,gauges,or fittingsfrom anover-
heated pump. Liquid within the pump
can reach boiling temperatures, andva-
porpressure within the pumpcancause
parts being disengaged to be ejected
with great force. After the pump cools,
drain the liquid from the pump by re-
moving the casing drain plug. Use cau-
tion when removing the plug to prevent
injury to personnel from hot liquid.
As asafeguard againstrupture orexplosion dueto
heat, this pump is equipped with a pressure relief
valve which will open if vapor pressure within the
pumpcasingreachesacriticalpoint.Ifoverheating
does occur, stop the pump immediately and allow
it to cool before servicing it. Approach any over-
heated pump cautiously. It is recommended that
the pressure relief valve assembly be replaced at
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.

U-SERIES OM--01824
OPERATION PAGE C -- 3
Strainer Check
If a suction strainer has been shipped with the
pump or installed by the user, check the strainer
regularly, and clean it as necessary. The strainer
shouldalsobecheckedifpumpflowratebeginsto
drop. If a vacuum suction gauge has been in-
stalled, monitor and record the readings regularly
to detect strainer blockage.
Never introduce air or steam pressure into the
pump casing or piping to remove a blockage. This
could result in personal injury or damage to the
equipment. If backflushing is absolutely neces-
sary, liquid pressure must be limited to 50% of the
maximum permissible operating pressure shown
on the pump performance curve.
Pump Vacuum Check
Withthepumpinoperative,installavacuumgauge
in the system, using pipe dope on the threads.
Block the suction line and start thepump. At oper-
ating speed the pump should pull a vacuum of 20
inches ((508,0 mm) or more of mercury. If it does
not, check for air leaks in the seal, gasket, or dis-
charge valve.
Openthesuctionline,andreadthe vacuumgauge
with the pump primed and at operation speed.
Shut off the pump. The vacuumgauge readingwill
immediately drop proportionate to static suction
lift,andshouldthenstabilize.Ifthevacuumreading
falls off rapidly after stabilization, an air leak exists.
Before checking for the source of the leak, check
the point of installation of the vacuum gauge.
STOPPING
Never halt the flow of liquid suddenly. If the liquid
being pumped is stopped abruptly, damaging
shock waves can be transmitted to the pump and
piping system. Close all connecting valves slowly.
On engine driven pumps, reduce the throttle
speedslowlyandallowtheenginetoidlebrieflybe-
fore stopping.
If the application involves a high discharge
head, gradually close the discharge throt-
tling valve before stopping the pump.
After stopping the pump, disconnect or lock out
the power source to ensure that the pump will re-
main inoperative.
Cold Weather Preservation
In below freezing conditions, drain the pump to
prevent damage from freezing. Also,clean out any
solids by flushing with a hose. Operate the pump
for approximately one minute; this will remove any
remaining liquid that could freeze the pump rotat-
ing parts. If the pump will be idle for more than a
few hours, or if it has been pumping liquids con-
taining a large amount of solids, drain the pump,
and flush it thoroughly with cleanwater. Toprevent
large solids from clogging the drain port and pre-
venting the pump from completely draining, insert
a rod or stiff wire in the drain port, and agitate the
liquid during the draining process. Clean out any
remaining solids by flushing with a hose.
BEARING TEMPERATURE CHECK
Bearings normallyrun at higher than ambient tem-
peratures because of heat generated by friction.
Temperatures up to 160_F(71_C) are considered
normalforbearings,andtheycanoperatesafelyto
at least 180_F(82_C).
Checkingbearingtemperatures byhandisinaccu-
rate. Bearing temperatures can be measured ac-
curately by placing a contact-type thermometer
against the housing. Record this temperature for
future reference.
A sudden increase in bearing temperature is a
warning that the bearings are at thepoint offailing
to operate properly. Make certain that the bearing
lubricant is of the proper viscosity and at the cor-
rect level (see LUBRICATION in MAINTENANCE
AND REPAIR). Bearing overheating can also be
caused by shaft misalignmentand/or excessivevi-
bration.
When pumps are first started, the bearings may
seem to run at temperatures above normal. Con-
tinued operation should bring the temperatures
down to normal levels.

USERIES OM--01824
TROUBLESHOOTING PAGE D -- 1
TROUBLESHOOTING --- SECTION D
Review all SAFETY information in Section A.
Beforeattemptingtoopen orservicethe
pump:
1. Familiarize yourselfwith thismanual.
2. Lock out or disconnect the power
source to ensure that the pump will
remain inoperative.
3. Allow the pump to completely cool if
overheated.
4. Check the temperature before open-
ing any covers, plates, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO
PRIME
Suction check valve contaminated or
damaged. Clean or replace check valve.
Air leak in suction line.
Lining of suction hose collapsed.
Correct leak.
Replace suction hose.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
leakingorwornsealorgasket.
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.
Not enough liquid in casing. Add liquid to casing. See PRIM-
ING.
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
Air leak in suction line.
Lining of suction hose collapsed.
Correct leak.
Replace suction hose.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
leakingorwornsealorgasket.
Strainer clogged. Check strainer and clean if neces-
sary.

OM--01824 USERIES
TROUBLESHOOTINGPAGE D -- 2
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE (cont.)
PUMP REQUIRES
TOO MUCH
POWER
PUMP CLOGS
FREQUENTLY
Impellerorotherwearingpartsworn
or damaged. Replace worn or damaged parts. Check that impeller is properly
centered and rotates freely.
Impeller clogged. Free impeller of debris.
Pump speed too slow. Check driver output; check belts
or couplings for slippage.
Discharge head too high. Install bypass line.
Suction lift too high. Measureliftw/vacuumgauge.Re-
duce lift and/or friction losses in
suction line.
Pump speed too high. Check driver output; check that
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).
Liquid solution too thick. Dilute if possible.
Discharge flow too slow. Open discharge valve fully to in-
crease flow rate, and run power
source at maximum governed
speed.
Suction check valve or foot valve
clogged or binding. Clean valve.
EXCESSIVE NOISE Cavitation in pump.
Impeller clogged or damaged.
Pump or drive not securelymounted.
Pumping entrained air.
Reduce suction lift and/or friction
losses in suction line. Record vac-
uum and pressure gaugereadings
and consult local representative or
factory.
Locateand eliminatesourceofair
bubble.
Secure mounting hardware.
Clean out debris; replace dam-
aged parts.
Suction intake not submerged at
proper level or sump too small. Check installation and correctsub- mergence as needed.