GORMAN-RUPP PUMPS ULTRA V Series Application guide

OM‐06295‐01
August 5, 2009
Rev. E 08‐03‐17
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
2009 The Gorman‐Rupp Company
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
ULTRA V SERIESPUMP
MODEL
V6A60‐D914L6

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:
The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects or
other reproductive harm.

TABLE OF CONTENTS
i
INTRODUCTION PAGE I - 1.................................................
SAFETY ‐ SECTION A PAGE A - 1............................................
INSTALLATION - SECTION B PAGE B - 1....................................
Pump Dimensions PAGE B - 1.....................................................
PREINSTALLATION INSPECTION PAGE B - 2............................................
Battery Specifications And Installation PAGE B - 2....................................
POSITIONING PUMP PAGE B - 2.......................................................
Lifting PAGE B - 2.................................................................
Mounting PAGE B - 3.............................................................
Clearance PAGE B - 3.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 3.........................................
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 - 4...............................................................
Strainers PAGE B - 4..............................................................
Sealing PAGE B - 4...............................................................
Suction Lines In Sumps PAGE B - 4.................................................
Suction Line Positioning PAGE B - 4................................................
FLOAT SWITCHES PAGE B - 5.........................................................
Installation PAGE B - 5............................................................
OPTIONAL SUBMERSIBLE TRANSDUCER PAGE B - 6...................................
DISCHARGE LINES PAGE B - 7........................................................
Siphoning PAGE B - 7.............................................................
Valves PAGE B - 7................................................................
Bypass Lines PAGE B - 7..........................................................
AUTOMATIC AIR RELEASE VALVE PAGE B - 8...........................................
Theory of Operation PAGE B - 8....................................................
Air Release Valve Installation PAGE B - 9............................................
ALIGNMENT PAGE B - 10..............................................................
OPERATION - SECTION C PAGE C - 1......................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 2................................................................
Manual Starting PAGE C - 2........................................................
Automatic Starting PAGE C - 2.....................................................
OPTIONAL EPS CONTROL PAGE C - 3.................................................
Features PAGE C - 3..............................................................
Functional Description PAGE C - 3..................................................
EPS Functions PAGE C - 4.........................................................
EPS Calibration PAGE C - 4........................................................
Zero Adjustment PAGE C - 4.......................................................
Span Adjustment PAGE C - 5......................................................
Level Adjustment PAGE C - 5......................................................

TABLE OF CONTENTS
(continued)
ii
Horn Delay PAGE C - 5............................................................
OPERATION PAGE C - 5..............................................................
Lines With a Bypass PAGE C - 5....................................................
Lines Without a Bypass PAGE C - 5.................................................
Leakage PAGE C - 5..............................................................
Liquid Temperature And Overheating PAGE C - 6.....................................
Strainer Check PAGE C - 6.........................................................
Pump Vacuum Check PAGE C - 6..................................................
STOPPING PAGE C - 6................................................................
Manual Stopping PAGE C - 6.......................................................
Automatic Stopping PAGE C -6....................................................
Safety Shutdown System PAGE C - 7...............................................
OPERATION IN EXTREME HEAT PAGE C - 7............................................
Cold Weather Preservation PAGE C - 7..............................................
BEARING TEMPERATURE CHECK PAGE C - 8..........................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...............................................
PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................
STANDARD PERFORMANCE CURVE PAGE E - 1........................................
PARTS LISTS:
Pump Model PAGE E - 3..........................................................
Pump Mounting Kit PAGE E - 5.....................................................
Power Unit Kit PAGE E - 7.........................................................
Pump End Assy PAGE E - 9........................................................
Repair Rotating Assy PAGE E - 11...................................................
Coupling Kit PAGE E - 12...........................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 13.........................
Suction Check Valve Removal PAGE E - 13...........................................
Back Cover And Wear Plate Removal PAGE E - 13.....................................
Separating Intermediate And Drive Assembly From Engine PAGE E - 14..................
Loosening Impeller PAGE E - 14.....................................................
Rotating Assembly Removal PAGE E - 15.............................................
Impeller Removal PAGE E - 15......................................................
Seal Removal PAGE E - 15..........................................................
Shaft and Bearing Removal and Disassembly PAGE E - 16.............................
Shaft and Bearing Reassembly and Installation PAGE E - 17............................
Seal Installation PAGE E - 18........................................................
Impeller Installation PAGE E - 21.....................................................
Rotating Assembly Installation PAGE E - 21...........................................
Back Cover Installation And Adjustment PAGE E - 21..................................
Suction Check Valve Installation PAGE E - 22.........................................
Securing Pump End To Engine PAGE E - 22..........................................
PRESSURE RELIEF VALVE MAINTENANCE PAGE E - 23..................................
Final Pump Assembly PAGE E - 24..................................................
LUBRICATION PAGE E - 24.............................................................
Seal Assembly PAGE E - 24.........................................................
Bearings PAGE E - 24..............................................................
Engine PAGE E - 24................................................................

ULTRA V SERIES OM-06295
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 pump is an Ultra V Series, semi‐open impel
ler, self‐priming centrifugal model with a suction
check valve. The pump also is designed with exter
nal shimless adjusters for setting the wear plate to
impeller clearance. The pump is close coupled to a
Deutz D914L6 diesel engine, and is designed for
handling dirty water containing specified entrained
solids and slurries. The basic material of construc
tion is gray iron, with ductile iron impeller and steel
wearing parts.
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
neither operator safety nor pump integrity are com
promised by the installation. Pumps and related
equipment must be installed and operated ac
cording to all national, local and industry stan
dards.
For information or technical assistance on the en
gine, contact the engine manufacturer's local
dealer or representative.
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]
The following are used to alert maintenance per
sonnel to procedures which require special atten
tion, to those which could damage equipment, and
to those which could be dangerous to personnel:
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure 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.
Hazards or unsafe practices which COULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possi
ble damage which could result from failure
to follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.

ULTRA V SERIES OM-06295
PAGE A - 1SAFETY
SAFETY ‐ SECTION A
This information applies to Ultra V Se
riesRengine driven pumps. Refer to the
manual accompanying the engine be
fore 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.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Switch off the engine ignition and
disconnect the positive battery
cable to ensure that the pump will
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 equipped with an automat
ic starting system, and is subject to au
tomatic restart. Keep hands and cloth
ing away from the unit to prevent injury
during automatic operation. Disconnect
the positive battery cable before per
forming any maintenance. Failure to do
so may result in serious personal injury.
This pump is designed to handle dirty
water containing specified entrained
solids. Do not attempt to pump volatile,
corrosive, or flammable liquids which
may damage the pump or endanger per
sonnel as a result of pump failure.
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.
After the unit has been installed, make
certain that the pump and all piping or
hose connections are tight, properly
supported and secure before operation.
Do not operate the pump against a
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
pump casing to rupture or explode.

ULTRA V SERIESOM-06295
PAGE A - 2 SAFETY
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over
heated pump. Vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Al
low the pump to cool before servicing.
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating internal combustion
engines in an enclosed area, make cer
tain that exhaust fumes are piped to the
outside. These fumes contain carbon
monoxide, a deadly gas that is color
less, tasteless, and odorless.
Fuel used by internal combustion en
gines presents an extreme explosion
and fire hazard. Make certain that all
fuel lines are securely connected and
free of leaks. Never refuel a hot or run
ning engine. Avoid overfilling the fuel
tank. Always use the correct type of fuel.
Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. The maximum continuous
operating speed for this pump is 1950
RPM.
Pumps and related equipment must be in
stalled and operated according to all na
tional, local and industry standards.
Do not attempt to disengage any part of
an overheated pump unit. Vapor pres
sure within the pump casing can eject
these parts with great force when they
are disengaged. Allow the pump to
completely cool before servicing it.

ULTRA V SERIES OM-06295
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 positioned
above the free level of liquid to be pumped.
If installed in a flooded suction application where
the liquid is supplied to the pump under pressure,
some of the information such as mounting, line
configuration, and priming must be tailored to the
specific application. Since the pressure supplied
to the pump is critical to performance and safety,
be sure to limit the incoming pressure to 50% of the
maximum permissible operating pressure as
shown on the pump performance curve.
For further assistance, contact your Gorman‐Rupp
distributor or the Gorman‐Rupp Company.
Pump Dimensions
See Figure 1 for the approximate physical dimen
sions of this pump.
OUTLINE DRAWING
SUCTION:
8.00 NOMINAL WITH 8 HOLES
.88/[22,4] DIA EQUALLY SPACED
ON A 11.75/[298,4] DIA B.C. DISCHARGE:
6.00 NOMINAL WITH 8 HOLES
.88/[22,4] DIA EQUALLY SPACED
ON A 9.50/[241,3] DIA B.C.
*
18.00/[457,2] RECOMMENDED FORREMOVAL OF BACK COVER PLATE
10.50/[266,7] REQUIRED FOR REMOVAL OF BACK COVER PLATE
*
.69/[17,5] DIA THRU
7 HOLES EACH SIDE
POWERED BY A DEUTZ D914L6 DIESEL ENGINE
.69/[17,5] DIA THRU
4 HOLES
51.75
[ 1314,4 ]
62.50
[ 1587,5 ]
37.81
[ 960,5 ]
52.85
[ 1342,4 ]
44.25
[ 1124,0 ]
14.75
[ 374,6 ]
29.50
[ 749,3 ]
5.50
[ 139,7 ]
22.12
[ 562,0 ]
2.75
[ 69,8 ]
25.88
[ 657,2 ]
11.93
[ 303,0 ]
12.00
[ 304,8 ]
104.00
[ 2641,6 ]
95.50
[ 2425,7 ]
25.23
[ 640,9 ]
31.94
[ 811.3 ]
2.75
[ 69,8 ] TYP
14.75
[ 374.6 ]
.75
[ 19.0 ]
8.00
[ 203,2 ]
Figure 1. Pump Model V6A60-D914L6

OM-06295 ULTRA V SERIES
PAGE B - 2 INSTALLATION
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be
fore shipment from the factory. Before installation,
inspect the pump for damage which may have oc
curred during shipment. Check as follows:
a. Inspect the pump assembly for cracks, dents,
damaged threads, and other obvious dam
age.
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 all tags, decals, and markings
on the pump assembly, and perform all duties
indicated.
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. If the pump and engine have been stored for
more than 12 months, some of the compo
nents or lubricants may have exceeded their
maximum shelf life. These must be inspected
or replaced to ensure maximum pump serv
ice.
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.
Battery Specifications And Installation
Unless otherwise specified on the pump order, the
engine battery was not included with the unit. Re
fer to the following specifications when selecting a
battery.
Table 1. Battery Specifications
Crank
@ 0F
Reserve
Capacity
(Minutes)
@ 80F
Overall
Dims.
(Inches)
850 120
10.25L
Cold
Amps
Approx.
Amp/
Hr.
Rating
75 6.75W
8.88H
x
x
Voltage
12 Volts
Refer to the information accompanying the battery
and/or electrolyte solution for activation and charg
ing instructions.
Before installing the battery, clean the positive and
negative cable connectors, and the battery termi
nals. Secure the battery by tightening the
holddown brackets. The terminals and clamps
may be coated with petroleum jelly to retard corro
sion. Connect and tighten the positive cable first,
then the negative cable.
POSITIONING PUMP
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.
Lifting
Pump unit weights will vary depending on the
mounting and drive provided. Check the shipping
tag on the unit packaging for the actual weight, and
use lifting equipment with appropriate capacity.
Drain the pump and remove all customer‐installed
equipment such as suction and discharge hoses
or piping before attempting to lift existing, installed
units.

ULTRA V SERIES OM-06295
PAGE B - 3INSTALLATION
The pump assembly can be seriously
damaged if the cables or chains used to lift
and move the unit are improperly wrapped
around the pump.
Mounting
Locate the pump in an accessible place as close as
practical to the liquid being pumped. Level 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.
If the pump has been mounted on a moveable
base, make certain the base is stationary by setting
the brake and blocking the wheels before attempt
ing to operate the pump.
To ensure sufficient lubrication and fuel supply to
the engine, do not position the pump and engine
more than 15off horizontal for continuous opera
tion. The pump and engine may be positioned up
to 30off horizontal for intermittent operation
only; however, the engine manufacturer should be
consulted for continuous operation at angles
greater than 15.
Clearance
When positioning the pump, allow a minimum
clearance of 18 inches (457,2 mm) in front of the
back cover to permit removal of the cover and easy
access to the pump interior.
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 notes
on Page E‐1 to be sure your overall application al
lows pump to operate within the safe operation
range.
Materials
Either pipe or hose maybe used for suction and
discharge lines; however, the materials must be
compatible with the liquid being pumped. If hose is
used in suction lines, it must be the rigid‐wall, rein
forced type to prevent 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
tially increase friction loss. If elbows are necessary,
use the long‐radius type to minimize friction loss.
Connections to Pump
Before tightening a connecting flange, align it ex
actly with the pump port. Never pull a 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
lines are used, they should have adequate support
to secure them when filled with liquid and under
pressure.
Gauges
Most pumps are drilled and tapped for installing
discharge pressure and vacuum suction gauges.
If these gauges are desired for pumps that are not
tapped, drill and tap the suction and discharge
lines not less than 18 inches (457,2 mm) from the
suction and discharge ports and install the lines.
Installation closer to the pump may result in erratic
readings.
SUCTION LINES
To avoid air pockets which could affect pump prim
ing, the suction line must be as short and direct as
possible. When operation involves a suction lift, the
line must always slope upward to the pump from
the source of the liquid being pumped; if the line