GORMAN-RUPP PUMPS VS4A60-B Application guide

OM-06013-02
June 17, 2008
Rev. F 03‐01‐19
GORMAN‐RUPP PUMPS
www.grpumps.com
2008 Gorman‐Rupp Pumps Printed in U.S.A.
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
ULTRA V PUMP
MODEL
VS4A60-B
INCLUDING: /WW

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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
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 - 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.........................................................

TABLE OF CONTENTS
(continued)
ii
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:
VS4A60-B And VS4A60-B /WW Pump Models PAGE E - 3...........................
Pump Assemblies 46167-039 And 46146-040 PAGE E - 5............................
46146-007 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 - 19..................................................
LUBRICATION PAGE E - 20.............................................................
Seal Assembly PAGE E - 20.........................................................
Bearings PAGE E - 20..............................................................
Power Source PAGE E - 20.........................................................

ULTRA V SERIES OM-06013
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 Mainte
nance manual is designed to help you achieve the
best performance and longest life from your Gor
man‐Rupp 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.
This manual will alert personnel to known proce
dures which require special attention, to those
which could damage equipment, and to those
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
tenance procedures are used, and that any proce
dures not addressed in this manual are performed
only after establishing that neither personal safety
nor pump integrity are compromised by such prac
tices.
For information or technical assistance on the
power source, contact the power source manufac
turer'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:
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-06013
PAGE A - 1SAFETY
SAFETY - SECTION A
This information applies toUltra V Se
ries 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.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Disconnect or lock out 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
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 handle liquids
containing large entrained solids or
slurries. Do not attempt to pump vola
tile, corrosive, or flammable materials
which may damage the pump or endan
ger personnel as a result of pump fail
ure.
After the pump has been positioned,
make certain that the pump and all pip
ing connections are tight, properly sup
ported 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 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 completely cool before
servicing.
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.
Death or serious personal injury and
damage to the pump or components

ULTRA V SERIESOM-06013
PAGE A - 2 SAFETY
can occur if proper lifting procedures
are not observed. Make certain that
hoists, chains, slings or cables are in
good working condition and of suffi
cient capacity and that they are posi
tioned so that loads will be balanced
and the pump or components will not be
damaged when lifting. Suction and dis
charge hoses and piping must be re
moved from the pump before lifting. Lift
the pump or component only as high as
necessary and keep personnel away
from suspended objects.
Do not install a suction check valve in
the first stage of the VS Series pump
model. Installing a suction check valve
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.
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.
Pumps and related equipment must be in
stalled and operated according to all na
tional, local and industry standards.

OM-06013ULTRA V SERIES
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
tioned 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
Consult the pump Specification Data Sheet or con
sult the factoryfor the approximate physical dimen
sions of your pump.
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 for cracks, 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 all warnings 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, Section C.
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 power source have been
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
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.
Death or serious personal injury and
damage to the pump or components

OM-06013 ULTRA V SERIES
PAGE B - 2 INSTALLATION
can occur if proper lifting procedures
are not observed. Make certain that
hoists, chains, slings or cables are in
good working condition and of suffi
cient capacity and that they are posi
tioned so that loads will be balanced
and the pump or components will not be
damaged when lifting. Suction and dis
charge hoses and piping must be re
moved from the pump before lifting. Lift
the pump or component only as high as
necessary and keep personnel away
from suspended objects.
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.
Clearance
It is recommended that 18 inches (457 mm) of
clearance be provided in front of the back cover to
permit removal of the cover and easy access to the
pump interior. A minimum clearance of 10-1/2 in
ches (267 mm) must be maintained to permit re
moval of the cover.
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
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
slopes down to the pump at any point along the
suction run, air pockets will be created.
Fittings
Suction lines should be the same size as the pump
inlet. If reducers are used in suction lines, they

OM-06013ULTRA V SERIES
PAGE B - 3INSTALLATION
should be the eccentric type, and should be in
stalled with the flat part of the 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
to use it; any spherical solids which pass through a
strainer furnished with the pump will also pass
through the pump itself.
If a strainer is not furnished with the pump, but is
installed by the pump user, make certain that the
total area of the openings in the strainer is at least
three or four times the cross section of the suction
line, and that the openings will not permit passage
of solids larger than the solids handling capability
of the pump.
This pump is designed to handle up to 3 inch (76,2
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 to 1 1/2 times the diame
ter of the suction line.
If there is a liquid flow from an open pipe into the
sump, the flow should be kept away from the suc
tion inlet because the inflow will carry 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
tion inlet, install a baffle between the inflow and the
suction inlet at a distance 1 1/2 times the diameter
of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into
the suction inlet.
If two suction lines are installed in a single sump,
the flow paths may interact, reducing the efficiency
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 1 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 the suction line. The larger opening size will
reduce the inlet velocity. Calculate the required
submergence using the following formula based
on the increased opening size (area or diameter).

OM-06013 ULTRA V SERIES
PAGE B - 4 INSTALLATION
Figure 1. Recommended Minimum Suction Line Submergence vs. Velocity
DISCHARGE LINES
Siphoning
Do not terminate the discharge line at a level lower
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 the application involves a high discharge
head, the discharge throttling valve should
close gradually before the pump is
stopped.
Due to the high discharge head potential
for Ultra V Series pumps, an electronically
controlled or automatic slow‐closing dis
charge throttling valve may be required.
Consult the factory for additional informa
tion on high discharge head applications.
If a throttling valve is desired in the discharge line,
use a valve as large as the largest pipe to minimize
friction losses. Never install a throttling valve in a
suction line.
With high discharge heads, it is recommended that
a throttling valve and a system check valve be in
stalled in the discharge line to protect the pump
from excessive shock pressure and reverse rota
tion when it is stopped.
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
charge side of the pump must be opened to atmos
pheric pressure through a bypass line installed be
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

OM-06013ULTRA V SERIES
PAGE B - 5INSTALLATION
affect pump discharge capacity; however, the by
pass line should be at least 1 inch in diameter to
minimize the chance of plugging.
In low discharge head applications (less than 30
feet or 9 meters), it is recommended that the by
pass line be run back to the wet well, and located 6
inches below the water level or cut‐off point of the
low level pump. In some installations, this bypass
line may be terminated with a six‐to‐eight foot
length of 1-1/4 inch I.D. smooth‐bore hose; air
and liquid vented during the priming process will
then agitate the hose and break up any solids,
grease, or other substances likely to cause clog
ging.
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
overall pumping efficiency. Therefore, it is recom
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 AIR RELEASE VALVE in this section
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.
If the installation involves a flooded suction such as
a below‐ground lift station, a pipe union and manu
al shut‐off valve may be installed in the bleed line to
allow service of the valve without shutting down the
station, and to eliminate the possibility of flooding.
If a manual shut‐off valve is installed anywhere in
the air release piping, it must be a full‐opening ball
type valve to prevent plugging by solids.
If a manual shut‐off valve is installed in
a bypass line, it must not be left closed
during operation. A closed manual shut‐
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 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 tempera
tures, and vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Af
ter the pump completely cools, drain
the liquid from the pump by removing
the casing drain plug. Use caution when
removing the plug to prevent injury to
personnel from hot liquid.
AUTOMATIC AIR RELEASE VALVE
When properly installed, a Gorman‐Rupp Auto
matic Air Release Valve will permit air to escape
through the bypass line and then close automati
cally when the pump is fully primed and pumping
at full capacity.
Some leakage (1 to 5 gallons [3.8 to 19
liters] per minute) will occur when the
valve is fully closed. Be sure the bypass
line is directed back to the wet well or
tank to prevent hazardous spills.
Consult the manual accompanying the Air Release
Valve for additional information on valve installation
and performance.

OM-06013 ULTRA V SERIES
PAGE B - 6 INSTALLATION
Air Release Valve Installation
Staged pump applications generate much higher
operating pressures within the pump casings than
non‐staged pump applications. This high pressure
could cause a suction check valve to fail, resulting
in loss of prime. Therefore, any pump used in a
staged application, whether in the lower or up
per position, must have the suction check valve
removed. The lower stage of the VS Series pump
is designed without a suction check valve, so re
moval of the check valve is not required.
In order to maintain the suction leg and facilitate ini
tial priming (or re‐priming if the suction leg is lost)
without a suction check valve, it is recommended
that staged pump applications be installed using
two discharge check valves, with an automatic Air
Release Valve installed between the two discharge
check valves (see Figure 3). In this manner, when
the liquid level in the sump activates the automatic
liquid level device and starts the pumps, discharge
pressure opens the first discharge check valve, al
lowing any entrained air in the system to escape
through the Air Release Valve. When air in the sys
tem is purged, pressure opens the second dis
charge check valve for full operation.
When the liquid level in the sump lowers enough to
de‐activate the automatic liquid level device and
stop the pumps, the first discharge check valve
closes and creates an air‐tight seal, thus maintain
ing liquid in the pump casing and suction line to al
low the pump to re‐prime when the liquid level in
the sump rises and again activates the automatic
liquid level device.
The second discharge check valve in the staged
application acts as a “shock absorber” to prevent
destructive “water hammer” when the pump shuts
down.
The Automatic Air Release Valve must be inde
pendently mounted in a horizontal position be
tween the discharge check valves. (see Figure 2).
The inlet opening in the Air Release Valve is
equipped with standard 1‐inch NPT pipe threads.
DISCHARGE
CHECK
VALVE
AIR RELEASE
VALVE
DISCHARGE
PIPE
DISCHARGE
CHECK
VALVE
VS SERIES PUMP
Figure 2. Typical Automatic Air Release Valve Installation
NOTE
When installing the Air Release Valve on a staged
pump application, position the Air Release Valve as
close as possible to the primary discharge check
valve. Six‐inch and larger discharge check valves
are available drilled and tapped to receive a stan

OM-06013ULTRA V SERIES
PAGE B - 7INSTALLATION
dard 1‐inch NPT fitting, or the Air Release Valve may
be installed in a spool flange between the two dis
charge check valves.
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
larger, depending on which Air Release Valve is be
ing 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.
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 cou
plings (see Figure 3) or a belt arrangement (see
Figure 4).
Each motor should be independently operated
through a reduced voltage solid state (RVSS) start
er, a variable frequency drive (VFD) or an adjust
able speed drive (ASD). In this arrangement, the
motor powering the lower stage pump should be
programmed to start first and “ramp up” to full con
dition speed, then the second stage pump motor
should start and “ramp up” to full condition speed.
Pump motor shutdown should be programmed in
reverse order, with the second stage pump motor
“ramping down” before shutting off, then the first
stage pump motor “ramping down” and shutting
off. This “ramp up” and “ramp down” configuration
helps reduce inrush current on startup and de
structive “water hammer” on both startup and shut
down.
Figure 3. Recommended Dual Motor Direct
Drive Arrangement
Figure 4. Recommended Dual Motor Belt
Drive Arrangement
Single Motor Belt Drives
In staged applications where both pumps are belt
driven by a single motor (either through a syn
chronous [cog] or V‐belt configuration) certain ar
rangements must be used in order to ensure prop
er operation.

OM-06013 ULTRA V SERIES
PAGE B - 8 INSTALLATION
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 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 cou
pling drive configuration, certain arrangements
must be used in order to ensure proper operation.
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
loads are shared 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 7. Improper Single Motor Belt Drive
Arrangement (Dual Belts)

OM-06013ULTRA V SERIES
PAGE B - 9INSTALLATION
Figure 8. Improper Single Motor Belt Drive
Arrangement (Single Belt Set)
HIGH PUMP TEMPERATURE SHUT
DOWN FOR DUAL‐MOTOR DRIVE
APPLICATIONS
NOTE
In dual‐motor drive arrangements, the starters for
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
pump is directly driven by its own electric motor, it
is recommended that each pump be equipped
with a high temperature shutdown sensor and that
these sensors be connected in parallel to the pump
control panel(s) so that if either sensor is activated,
both motors shut down (if powered independent
ly).
It is also recommended that the pump control pan
el(s) be configured with an alarm system and
manual reset for the high pump temperature shut
down circuit. In this manner, the cause of overheat
ing must be investigated and corrected before the
pumping system can be put back into service.
ALIGNMENT
The alignment of the pump and its power source is
critical for trouble‐free mechanical operation. In
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
bolts. The pump casing feet and/or pedestal feet,
and the driver mounting bolts should also be tightly
secured.
When checking alignment, disconnect
the power source to ensure that the
pump will remain inoperative.
Adjusting the alignment in one direction
may alter the alignment in another 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.
Most couplings require a specific gap or clearance
between the driving and the driven shafts. Refer to
the coupling manufacturer's service literature.
Align spider insert type couplings by using calipers
to measure the dimensions on the circumference
of the outer ends of the coupling hub every 90.
The coupling is in alignment when the hub ends
are the same distance apart at all points (see Fig
ure 9).

OM-06013 ULTRA V SERIES
PAGE B - 10 INSTALLATION
Figure 9. Aligning Spider‐Type Couplings
Figure 10. Aligning Non‐Spider Type Couplings
Align non‐spider type couplings by using a feeler
gauge or taper gauge between the coupling halves
every 90. The coupling is in alignment when the
hubs are the same distance apart at all points (see
Figure 10).
Check parallel adjustment by laying a straightedge
across both coupling rims at the top, bottom, and
side. When the straightedge rests evenly on both
halves of the coupling, the coupling is in horizontal
parallel alignment. If the coupling is misaligned,
use a feeler gauge between the coupling and the
straightedge to measure the amount of misalign
ment.
Drive Belts
When using drive belts, the power source and the
pump must be parallel. Use a straightedge along
the sides of the pulleys to ensure that the pulleys
are properly aligned (see Figure 11). In drive sys
tems using two or more belts, make certain that the
belts are a matched set; unmatched sets will cause
accelerated belt wear.
MISALIGNED:
SHAFTS
NOT PARALLEL
MISALIGNED:
SHAFTS
NOT IN LINE
ALIGNED: SHAFTS
PARALLEL AND
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.
Do not operate the pump without the
guard in place over the rotating parts.
exposed rotating parts can catch cloth
ing, fingers, or tools, causing severe in
jury to personnel.
DRIVE BELT TENSIONING
General Rules of Tensioning
For new drive belts, check the tension after 5, 20
and 50 hours of operation and re‐tension as re
quired (see the following procedure for measuring
belt tension). Thereafter, check and re‐tension if re
quired monthly or at 500 hour intervals, whichever
comes first.
Ideal drive belt tension is the lowest tension at
which the belt will not slip under peak load condi
tions. Do not over‐tension drive belts. Over‐ten
sioning will shorten both drive belt and bearing life.
Under‐tensioning will cause belt slippage. Always
keep belts free from dirt, grease, oil and other for
eign material which may cause slippage.

ULTRA V SERIES OM-06013
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 liquids
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
ure.
Pump speed and operating conditions
must be within the performance range
shown on pages E‐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 operation of
a dry pump will destroy the seal assembly.
Add liquid to the pump casing when:
1. The pump is being put into service for the
first time.
2. The pump has not been used for a consider
able length of time.
3. The liquid in the pump casing has evapo
rated.
Once the pump casing has been filled, the pump
will prime and reprime as necessary.
After filling the pump casing, reinstall
and tighten the fill plug. Do not attempt
to operate the pump unless all connect
ing piping is securely installed. Other
wise, liquid in the pump forced out
under pressure could cause injury to
personnel.
To fill the pump, remove the pump casing fill cover
or fill plug in the top of the casing, and add clean
liquid until the casing is filled. Replace the fill cover
or fill plug before operating the pump.
STARTING
Consult the operations manual furnished with the
power source.
Rotation
The correct direction of pump rotation is counter
clockwise when facing the impeller. The pump
could be damaged and performance adversely af
fected by incorrect rotation. If pump performance
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
nect the pump from the motor before checking mo
tor rotation. Operate the motor independently
while observing the direction of the motor shaft, or
cooling fan.

ULTRA V SERIESOM-06013
OPERATIONPAGE C - 2
If rotation is incorrect on a three‐phase motor, have
a qualified electrician interchange any two of the
three phase wires to change direction. If rotation is
incorrect on a single‐phase motor, consult the liter
ature supplied with the motor for specific instruc
tions.
OPERATION
Lines With a Bypass
If a Gorman‐Rupp Automatic Air Release Valve has
been installed, the valve will automatically open to
allow the pump to prime, and automatically close
after priming is complete (see INSTALLATION for
Air Release Valve operation).
If the bypass line is open, air from the suction line
will be discharged through the bypass line back to
the wet well during the priming cycle. Liquid will
then continue to circulate through the bypass line
while the pump is in operation.
Lines Without a Bypass
Open all valves in the discharge line and start the
power source. Priming is indicated by a positive
reading on the discharge pressure gauge or by a
quieter operation. The pump may not prime imme
diately because the suction line must first fill with
liquid. If the pump fails to prime within five minutes,
stop it and check the suction line for leaks.
After the pump has been primed, partially close the
discharge line throttling valve in order to fill the line
slowly and guard against excessive shock 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, adjust the throttling valve to the required flow
rate.
Do not operate the pump against a
closed discharge throttling valve for
long periods of time. If operated against
a closed discharge throttling valve,
pump components will deteriorate, and
the liquid could come to a boil, build
pressure, and cause the pump casing to
rupture or explode.
Leakage
No leakage should be visible at pump mating sur
faces, or at pump connections or fittings. Keep all
line connections and fittings tight to maintain maxi
mum pump efficiency.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
160F (71C). Do not apply it at a higher operating
temperature.
Overheating can occur if operated with the valves
in the suction or discharge lines closed. Operating
against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to 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 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 tempera
tures, and vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Af
ter the pump completely cools, drain
the liquid from the pump by removing
the casing drain plug. Use caution when
removing the plug to prevent injury to
personnel from hot liquid.
As a safeguard against rupture or explosion due to
heat, this pump is equipped with a pressure relief
valve which will open if vapor pressure within the
pump casing reaches a critical point. If overheating
does occur, stop the pump immediately and allow
it to cool before servicing it. Approach any over

ULTRA V SERIES OM-06013
OPERATION PAGE C - 3
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.
Strainer Check
If a suction strainer has been shipped with the
pump or installed by the user, check the strainer
regularly, and clean it as necessary. The strainer
should also be checked if pump flow rate begins to
drop. If a vacuum suction gauge has been 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
With the pump inoperative, install a vacuum gauge
in the system, using pipe dope on the threads.
Block the suction line and start the pump. At 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.
Open the suction line, and read the vacuum gauge
with the pump primed and at operation speed.
Shut off the pump. The vacuum gauge reading will
immediately drop proportionate to static suction
lift, and should then stabilize. If the vacuum reading
falls off rapidly after stabilization, an air leak exists.
Before checking for the source of the leak, check
the point of installation of the vacuum gauge.
STOPPING
Never halt the flow of liquid suddenly. If the liquid
being pumped is stopped abruptly, damaging
shock waves can be transmitted to the pump and
piping system. Close all connecting valves slowly.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
After stopping the pump, lock out or disconnect
the power source to ensure that the pump will re
main inoperative.
Do not operate the pump against a
closed discharge throttling valve for
long periods of time. If operated against
a closed discharge throttling valve,
pump components will deteriorate, and
the liquid could come to a boil, build
pressure, and cause the pump casing to
rupture or explode.
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 clean water. To prevent
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 normally run at higher than ambient tem
peratures because of heat generated by friction.
Temperatures up to 160F (71C) are considered
normal for bearings, and they can operate safely to
at least 180F (82C).