Page 1
CDSW
OM‐06013‐01
October 31, 2006
Rev. A 05‐28‐13
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
ULTRA V PUMP
MODEL
VS4A60-B
INCLUDING: /WW
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
2006 The Gorman‐Rupp Company
Page 2
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:
Page 3
TABLE OF CONTENTS
INTRODUCTION PAGE I - 1.................................................
SAFETY - SECTION A PAGE A - 1...........................................
INSTALLATION - SECTION B PAGE B - 1....................................
Pump Dimensions PAGE B - 1.....................................................
PREINSTALLATION INSPECTION PAGE B - 1............................................
POSITIONING PUMP PAGE B - 1.......................................................
Lifting PAGE B - 1.................................................................
Mounting PAGE B - 2.............................................................
Clearance PAGE B - 2.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 2.........................................
Materials PAGE B - 2..............................................................
Line Configuration PAGE B - 2......................................................
Connections to Pump PAGE B - 2..................................................
Gauges PAGE B - 2...............................................................
SUCTION LINES PAGE B - 2...........................................................
Fittings PAGE B - 2...............................................................
Strainers PAGE B - 2..............................................................
Sealing PAGE B - 3...............................................................
Suction Lines In Sumps PAGE B - 3.................................................
Suction Line Positioning PAGE B - 3................................................
DISCHARGE LINES PAGE B - 4........................................................
Siphoning PAGE B - 4.............................................................
Valves PAGE B - 4................................................................
Bypass Lines PAGE B - 4..........................................................
AUTOMATIC AIR RELEASE VALVE PAGE B - 5...........................................
Air Release Valve Installation PAGE B - 6............................................
DRIVE ARRANGEMENTS PAGE B - 7...................................................
Dual Motor Drives PAGE B - 7......................................................
Single Motor Belt Drives PAGE B - 7................................................
Single Motor Combination Drives PAGE B - 8........................................
HIGH PUMP TEMPERATURE SHUTDOWN FOR STAGED APPLICATIONS PAGE B - 9........
ALIGNMENT PAGE B - 9..............................................................
Coupled Drives PAGE B - 9........................................................
Drive Belts PAGE B - 10............................................................
DRIVE BELT TENSIONING PAGE B - 10..................................................
General Rules of Tensioning PAGE B - 10.............................................
OPERATION - SECTION C PAGE C - 1......................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 1................................................................
Rotation PAGE C - 1..............................................................
OPERATION PAGE C - 2..............................................................
Lines With a Bypass PAGE C - 2....................................................
Lines Without a Bypass PAGE C - 2.................................................
Leakage PAGE C - 2..............................................................
Liquid Temperature And Overheating PAGE C - 2.....................................
Strainer Check PAGE C - 3.........................................................
i
Page 4
TABLE OF CONTENTS
(continued)
Pump Vacuum Check PAGE C - 3..................................................
STOPPING PAGE C - 3................................................................
Cold Weather Preservation PAGE C - 3..............................................
BEARING TEMPERATURE CHECK PAGE C - 3..........................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...............................................
PUMP MAINTENANCE AND REPAIR - SECTION E PAGE E - 1................
PERFORMANCE CURVE PAGE E - 1...................................................
PARTS LISTS:
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.........................................................
ii
Page 5
ULTRA V SERIES OM-06013
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.
This Installation, Operation, and Maintenance
manual is designed to help you achieve the best
performance and longest life from your Gorman‐
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.
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: (419) 755-1011
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-2870
dures not addressed in this manual are performed
only after establishing that neither personal safety
nor pump integrity are compromised by such prac
tices.
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.
For information or technical assistance on the
power source, contact the power source manufac
turer's local dealer or representative.
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
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.
PAGE I - 1INTRODUCTION
Page 6
ULTRA V SERIES OM-06013
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:
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.
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
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.
PAGE A - 1SAFETY
Page 7
ULTRA V SERIESOM-06013
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment. Suction and dis
charge hoses and piping must be re
moved from the pump before lifting.
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.
PAGE A - 2 SAFETY
Page 8
INSTALLATION - SECTION B
OM-06013ULTRA V SERIES
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 factory for 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.
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.
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.
The pump assembly can be seriously
damaged if the cables or chains used to lift
PAGE B - 1INSTALLATION
Page 9
OM-06013 ULTRA V SERIES
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.
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
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.
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
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
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
PAGE B - 2 INSTALLATION
Page 10
OM-06013ULTRA V SERIES
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.
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.
recommended minimum submergence vs. veloc
ity.
Figure 1 shows
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
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).
PAGE B - 3INSTALLATION
Page 11
OM-06013 ULTRA V SERIES
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
PAGE B - 4 INSTALLATION
Page 12
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.
OM-06013ULTRA V SERIES
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.
PAGE B - 5INSTALLATION
Page 13
OM-06013 ULTRA V SERIES
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
PIPE
Figure 2. Typical Automatic Air Release Valve Installation
DISCHARGE
CHECK
VALVE
AIR RELEASE
VALVE
DISCHARGE
CHECK
VALVE
VS SERIES PUMP
NOTE
When installing the Air Release Valve on a staged
pump application, position the Air Release Valve as
PAGE B - 6 INSTALLATION
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
Page 14
OM-06013ULTRA V SERIES
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.
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.
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
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 syncro
nous [cog] or V‐belt configuration) certain arrange
ments must be used in order to ensure proper op
eration.
PAGE B - 7INSTALLATION
Page 15
OM-06013 ULTRA V SERIES
Figure 5 shows a recommended alternate single
motor belt drive arrangement where the both
pump shafts are driven by separate drive belts con
nected to one motor. In this arrangement, shaft
and/or bearing loads are evenly divided between
the two pumps.
Figure 6. Alternate Single Motor Combination
Drive Arrangement
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.
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)
PAGE B - 8 INSTALLATION
Page 16
Figure 8. Improper Single Motor Belt Drive
Arrangement (Single Belt Set)
OM-06013ULTRA V SERIES
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.
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
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).
PAGE B - 9INSTALLATION
Page 17
OM-06013 ULTRA V SERIES
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
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.
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.
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.
PAGE B - 10 INSTALLATION
Page 18
ULTRA V SERIES
OM-06013
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
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
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.
OPERATION PAGE C - 1
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.
Page 19
ULTRA V SERIESOM-06013
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.
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
160F (71C). 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.
Do not operate the pump against a
closed discharge throttling valve for
long periods of time. If operated against
a closed discharge throttling valve,
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
OPERATIONPAGE C - 2
Page 20
ULTRA V SERIES
OM-06013
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.
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.
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
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 160F (71C) are considered
normal for bearings, and they can operate safely to
at least 180F (82C).
OPERATION PAGE C - 3
Page 21
ULTRA V SERIESOM-06013
Checking bearing temperatures by hand is inaccu
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 the point of failing
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 misalignment and/or excessive vi
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.
OPERATIONPAGE C - 4
Page 22
ULTRA V SERIES OM-06013
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.
Before attempting to open or service the
pump:
1. Familiarize yourself with this manual.
2. Lock out or disconnect the power
source to ensure that the pump will
remain inoperative.
3. Allow the pump to completely cool if
overheated.
4. Check the temperature before open
ing any covers, plates, or plugs.
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
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
Not enough liquid in casing. Add liquid to casing. See PRIM
ING.
Suction check valve contaminated or
damaged.
Air leak in suction line.
Lining of suction hose collapsed.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
Suction lift or discharge head too high. Check piping installation and in
Strainer clogged. Check strainer and clean if neces
Air leak in suction line.
Lining of suction hose collapsed.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
Clean or replace check valve.
Correct leak.
Replace suction hose.
leaking or worn seal or gasket.
stall bypass line if needed. See
INSTALLATION.
sary.
Correct leak.
Replace suction hose.
leaking or worn seal or gasket.
TROUBLESHOOTING PAGE D - 1
Page 23
OM-06013
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
ULTRA V SERIES
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
PUMP REQUIRES
TOO MUCH POWER
Strainer clogged. Check strainer and clean if neces
sary.
Suction intake not submerged at
proper level or sump too small.
Impeller or other wearing parts worn
or damaged.
Impeller clogged. Free impeller of debris.
Pump speed too slow. Check driver output; check belts
Discharge head too high. Install bypass line.
Suction lift too high. Measure lift w/vacuum gauge. Re
Pump speed too high. Check driver output; check that
Discharge head too low. Adjust discharge valve.
Check installation and correct sub
mergence as needed.
Replace worn or damaged parts.
Check that impeller is properly
centered and rotates freely.
or couplings for slippage.
duce lift and/or friction losses in
suction line.
sheaves or couplings are cor
rectly sized.
Liquid solution too thick. Dilute if possible.
Bearing(s) frozen. Disassemble pump and check
PUMP CLOGS
FREQUENTLY
EXCESSIVE NOISE Cavitation in pump.
Liquid solution too thick. Dilute if possible.
Discharge flow too slow. Open discharge valve fully to in
Suction check valve or foot valve
clogged or binding.
Pumping entrained air.
Pump or drive not securely mounted.
bearing(s).
crease flow rate, and run power
source at maximum governed
speed.
Clean valve.
Reduce suction lift and/or friction
losses in suction line. Record vac
uum and pressure gauge readings
and consult local representative or
factory.
Locate and eliminate source of air
bubble.
Secure mounting hardware.
Impeller clogged or damaged.
Clean out debris; replace dam
aged parts.
TROUBLESHOOTINGPAGE D - 2
Page 24
ULTRA V SERIES OM-06013
PREVENTIVE MAINTENANCE
Routine preventive maintenance of the pump will
maintain peak operating performance. Since
pump applications are seldom identical, and pump
wear is directly affected by such things as the abra
sive qualities, pressure and temperature of the liq
uid being pumped, this section is intended only to
provide general recommendations and practices
for preventive maintenance. Regardless of the ap
plication however, following a routine preventive
maintenance schedule will help assure trouble‐
free performance and long life from your Gorman‐
Rupp pump.
Record keeping is an essential component of a
good preventive maintenance program. Changes
in suction and discharge gauge readings (if so
equipped) between regularly scheduled inspec
tions can indicate problems that can be corrected
before system damage or catastrophic failure oc
curs. The appearance of wearing parts should also
be documented at each inspection for comparison
as well. Also, if records indicate that a certain part
(such as the seal) fails at approximately the same
duty cycle, the part can be checked and replaced
before failure occurs, reducing unscheduled down
time.
For new applications, a first inspection of wearing
parts at 250 hours will give insight into the wear rate
for your particular application. Subsequent inspec
tions should be performed at the intervals shown
on the chart below. Critical applications should be
inspected more frequently.
Preventive Maintenance Schedule
Service Interval*
Item
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.) I
Pump Performance (Gauges, Speed, Flow) I
Bearing Lubrication I R
Seal Lubrication (And Packing Adjustment,
If So Equipped) I R
V‐Belts (If So Equipped) I
Air Release Valve Plunger Rod (If So Equipped) I C
Front Impeller Clearance (Wear Plate) I
Rear Impeller Clearance (Seal Plate) I
Check Valve I
Pressure Relief Valve (If So Equipped) C
Pump and Driver Alignment I
Shaft Deflection I
Bearings I
Bearing Housing I
Piping I
Driver Lubrication - See Mfgr's Literature
Daily Weekly Monthly Semi‐
Annually
Annually
Legend:
I = Inspect, Clean, Adjust, Repair or Replace as Necessary
C = Clean
R = Replace
* Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually.
Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.
TROUBLESHOOTING PAGE D - 3
Page 25
ULTRA V SERIES
OM-06013
PUMP MAINTENANCE AND REPAIR - SECTION E
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK
OPERATING PERFORMANCE.
STANDARD PERFORMANCE FOR PUMP MODEL VS4A60‐B, Including /WW
Based on 70F (21C) clear water at sea level with
minimum suction lift. Since pump installations are
seldom identical, your performance may be differ
ent due to such factors as viscosity, specific gravity,
elevation, temperature, and impeller trim.
Pump speed and operating condition
points must be within the continuous per
If your pump serial number is followed by an “N”,
your pump is NOT a standard production model.
Contact the Gorman‐Rupp Company to verify per
formance or part numbers.
MAINTENANCE & REPAIR PAGE E - 1
formance range shown on the curves.
NOTE
The horsepower shown in the above curve is total
combined horsepower for both the first and second
stage of the VS Model.
Page 26
OM-06013 ULTRA V SERIES
PARTS PAGE
SECTION DRAWING
Figure 1. Pump Model VS4A60-B (Including /WW)
MAINTENANCE & REPAIRPAGE E - 2
Page 27
ULTRA V SERIES
OM-06013
PARTS LIST
Pump Model VS4A60-B (Including /WW)
(From S/N 1333878 Up)
If your pump serial number is followed by an “N”, your pump is NOT a standard production model. Contact
the Gorman‐Rupp Company to verify part numbers.
ITEM
PART NAME PART
NO.
1 ULTRA‐MATE PUMP ASSY 46146-007 --- 1
2 SUPPORT BRACE 34455-010 --- 1
3 HEX HD CAPSCREW B0807 15991 4
4 DRIVE SCEW BM#04-03 17000 4
5 NAME PLATE 38818-149 13000 1
6 PUMP ASSEMBLY
VS4A60-B 46146-039 --- 1
VS4A60-B /WW 46146-040 --- 1
7 DISCHARGE GASKET 25113-034 --- 1
8 LOCK WASHER J10 15991 8
9 HEX HD CAPSCREW B1008 15991 6
10 SOC HD CAPSCREW BD1011 17000 2
NOT SHOWN:
LUBRICATION DECAL 38817-084 --- 1
G‐R DECAL GR-03 --- 1
“ULTRA V” DECAL 38816-342 --- 1
ROTATION DECAL 2613M --- 1
INSTRUCTION TAG 38817-023 --- 1
WARNING DECAL 2613FE --- 1
NUMBER
INDICATES PARTS RECOMMENDED FOR STOCK
MAT'L
CODE
QTY ITEM
NO.
OPTIONAL:
PART NAME PART
NUMBER
DISCHARGE STICKER 6588BJ --- 1
PRIMING STICKER 6588AH --- 1
SUCTION STICKER 6588AG --- 1
INSTRUCTION TAG 38817-011 --- 1
STAGED FLANGE KITS:
-NPT 48213-128 --- 1
-ASA SPOOL 48213-129 --- 1
-METRIC SPOOL 48213-130 --- 1
HI TEMP SHUT-DOWN KITS:
-145F 48313-186 --- 1
-130F 48313-256 --- 1
-120F 48313-257 --- 1
HIGH TEMP SHUT‐DOWN
THERMOSTAT KIT 145F 48313-172 --- 1
AIR RELEASE VALVES:
-10# COMP SPRING GRP33-07A --- 1
-25# COMP SPRING GRP33-07 --- 1
-80# COMP SPRING GRP33-07B --- 1
MAT'L
CODE
QTY
MAINTENANCE & REPAIR PAGE E - 3
Page 28
OM-06013 ULTRA V SERIES
SECTION DRAWING
Figure 2. Pump Assemblies 46146-039 and 46146-040
MAINTENANCE & REPAIRPAGE E - 4
Page 29
ULTRA V SERIES
PARTS LIST
Pump Assemblies 46146-039 and 46146-040
ITEM
PART NAME PART
NO.
1 PUMP CASING 38224-613 10000 1
2 REPAIR ROTATING ASSY
VS4A60-B 44163-458 --- 1
VS4A60-B /WW 44163-459 --- 1
3 STUD C1213 15991 4
4 PIPE PLUG P20 10009 1
5 WEAR PLATE ASSY 46451-760 24150 1
6 O‐RING 25152-273 --- 1
7 LOCK WASHER J06 15991 10
8 HEX NUT D06 15991 2
9 O‐RING S1674 --- 1
10 COVER PLATE ASSY 42111-831 --- 1
-WARNING PLATE 2613EV 13990 1
-DRIVE SCREW BM#04-03 17000 4
-PRESS RELIEF VALVE 26662-007 --- 1
-WARNING DECAL 38816-302 --- 1
11 ADJUSTING SCREW 31871-070 1500G 4
12 LOCK COLLAR 38115-551 23030 4
13 LOCK WASHER J08 15991 8
14 HEX HD CAPSCREW B0804 15991 4
15 BACK COVER NUT 31871-073 15000 4
16 HEX HD CAPSCREW B0604-1/2 15991 2
17 HANDLE 12354 13010 1
18 HEX HD CAPSCREW
VS4A60-B B1211 15991 8
VS4A60-B /WW B1215 15991 8
19 PIPE PLUG P04 15079 3
20 LOCK WASHER J12 15991 8
21 NPT SUCT FLG/VLV SEAT 38641-532 10000 1
22 GASKET 38683-660 19370 1
23 ROLL PIN 21154-229 --- 2
24 FLAP VALVE COVER 38346-619 17040 1
25 HEX HD CAPSCREW B0604 15991 6
26 FLAP VALVE PLUG 38349-415 19020 1
27 SQUARE HD BOLT A1014 15991 2
28 FILL PORT COVER ASSY 42111-437 --- 1
-FILL PORT GASKET 50G 19210 1
-WARNING PLATE 38816-097 13990 1
-DRIVE SCREW BM#04-03 17000 2
29 HEX HD CAPSCREW B1010S 15991 1
30 CLAMP BAR 38111-004 11010 1
NUMBER
MAT'L
CODE
QTY ITEM
NO.
31 HEX HD CAPSCREW B0806 15991 4
32 SPACER 33221-022 17040 4
33
34
35 PIPE PLUG P08 15079 2
NOT SHOWN:
OPTIONAL:
OM-06013
PART NAME PART
NUMBER
O‐RING S1676 --- 1
O‐RING 25152-273 --- 1
SUCTION SPOOL PARTS (VS4A60-B /WW ONLY)
-SPOOL FLANGE 11402B 10010 1
-FLANGE GASKET 1679G 18000 1
-FLANGE PIPE PLUG P20 10009 1
DISASSEMBLY TOOL 48711-020 --- 1
FLANGE KITS:
4” NPT DISCH KIT 48213-125 --- 1
6” X 4” ASA SUCTION/DISCHARGE
SPOOL KIT 48213-147 --- 1
-6” ASA SUCTION
SPOOL KIT 48213-146 --- 1
-4” ASA DISCHARGE
SPOOL KIT 48213-126 --- 1
6” X 4” METRIC SUCTION/DISCHARGE
SPOOL KIT 48213-127 --- 1
-6” METRIC SUCTION
SPOOL KIT 48213-148 --- 1
-4” METRIC DISCHARGE
SPOOL KIT 48213-149 --- 1
G‐R HARD IRON PARTS:
-WEAR PLATE ASSY 46451-760 24160 1
SST PARTS:
-WEAR PLATE ASSY 46451-760 24170 1
HI TEMP SHUT-DOWN KITS:
-145F 48313-186 --- 1
-130F 48313-256 --- 1
-120F 48313-257 --- 1
HIGH TEMP SHUT‐DOWN
THERMOSTAT KIT 145F 48313-172 --- 1
AIR RELEASE VALVES:
-10# COMP SPRING GRP33-07A --- 1
-25# COMP SPRING GRP33-07 --- 1
-80# COMP SPRING GRP33-07B --- 1
MAT'L
CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 5
Page 30
OM-06013 ULTRA V SERIES
SECTION DRAWING
Figure 3. 46146-007 Ultra Mate Pump Assembly
MAINTENANCE & REPAIRPAGE E - 6
Page 31
ULTRA V SERIES
PARTS LIST
46146-007 Ultra Mate Pump Assembly
ITEM
PART NAME PART
NO.
1 PUMP CASING 38219-307 10000 1
2 REPAIR ROTATING ASSY
VS4A60-B 44163-458 --- 1
VS4A60-B /WW 44163-459 --- 1
3 PIPE PLUG P08 15079 4
4 PIPE PLUG P12 15079 3
5 TRANSITION CHAMBER 38644-804 11010 1
6 LOCK WASHER J08 15991 19
7 PIPE PLUG P04 15079 1
8 HEX HD CAPSCREW B0808 15991 11
9 LOCK WASHER J06 15991 4
10 HEX NUT D06 15991 2
11 COVER PLATE ASSY 42111-831 --- 1
-WARNING PLATE 2613EV 13990 1
-DRIVE SCREW BM#04-03 17000 4
-PRESS RELIEF VALVE 26662-007 --- 1
-WARNING DECAL 38816-302 --- 1
12 LOCK COLLAR 38115-551 23030 4
13 ADJUSTING SCREW 31871-070 1500G 4
14 HEX HD CAPSCREW B0804 15991 4
15 BACK COVER NUT 31871-073 15000 4
16 HANDLE 12354 13010 1
17 HEX HD CAPSCREW B0604-1/2 15991 2
18 O‐RING S1674 --- 1
NUMBER
INDICATES PARTS RECOMMENDED FOR STOCK
MAT'L
CODE
QTY ITEM
NO.
19 O‐RING 25152-273 --- 1
20 WEAR PLATE ASSY 46451-760 24150 1
21 STUD C1213 15991 4
22 O‐RING 25152-279 --- 1
23 HEX HD CAPSCREW B0806 15991 4
24 SPACER 33221-022 17040 4
25 O‐RING S1676 --- 1
26 O‐RING 25152-273 --- 1
OPTIONAL:
OM-06013
PART NAME PART
NUMBER
DISASSEMBLY TOOL 48711-020 --- 1
G‐R HARD IRON PARTS:
-WEAR PLATE ASSY 46451-760 24160 1
SST PARTS:
-WEAR PLATE ASSY 46451-760 24170 1
HI TEMP SHUT-DOWN KITS:
-145F 48313-186 --- 1
-130F 48313-256 --- 1
-120F 48313-257 --- 1
HIGH TEMP SHUT‐DOWN
THERMOSTAT KIT 145F 48313-172 --- 1
AIR RELEASE VALVES:
-10# COMP SPRING GRP33-07A --- 1
-25# COMP SPRING GRP33-07 --- 1
-80# COMP SPRING GRP33-07B --- 1
MAT'L
CODE
QTY
MAINTENANCE & REPAIR PAGE E - 7
Page 32
OM-06013 ULTRA V SERIES
SECTION DRAWING
Figure 4. Repair Rotating Assemblies
MAINTENANCE & REPAIRPAGE E - 8
Page 33
ULTRA V SERIES
OM-06013
PARTS LIST
Repair Rotating Assemblies
Note: Order the complete Repair Rotating Assembly from the Pump Model Assembly Parts Lists on pages
E-2 or E-3. Rotating Assemblies for /WW models also include all standard parts listed below.
ITEM
PART NAME PART
NO.
NUMBER
MAT'L
CODE
QTY ITEM
NO.
PART NAME PART
NUMBER
MAT'L
CODE
QTY
1 IMPELLER 38615-104 11010 1
2 IMP ADJ SHIM SET 5091 17090 1
3 CARTRIDGE SEAL ASSY 46513-154 --- 1
4 SEAL PLATE 38272-360 10000 1
5 GASKET 38687-059 20000 1
6 OIL SEAL S1907 --- 3
7 LOCK WASHER J08 15991 4
8 HEX HD CAPSCREW B0806 15991 4
9 BEARING HOUSING 38251-521 10000 1
11 VENTED PIPE PLUG 4823A 15079 1
12 RED PIPE BUSING AP0802 15079 1
13 AIR VENT S1530 --- 1
14 PIPE PLUG P12 15079 2
15 SIGHT GAUGE S1471 --- 2
10 SOC HD PIPE PLUG PC20 10009 1
16 PIPE PLUG P04 15079 2
17 HEX HD CAPSCREW B0606 15991 6
18 LOCK WASHER J06 15991 6
20 BEARING CAP 38322-230 10000 1
21 GASKET 38683-474 18000 1
22 RETAINING RING S720 --- 1
23 THRUST WASHER 31133-268 15000 1
24 BALL BEARING 23287-014 --- 1
25 SHAFT KEY N0812 15990 1
INDICATES PARTS RECOMMENDED FOR STOCK
26 IMPELLER SHAFT 38514-828 16000 1
27 O‐RING 25154-026 --- REF
28 BALL BEARING 23251-019 --- 1
29 IMPELLER CAPSCREW F1004S 15991 1
30 IMPELLER WASHER 31167-029 17000 1
33 O‐RING 25152-273 --- 1
34 O‐RING S1676 --- 1
35 SPACER 33221-022 17040 4
36 SHIPPING PLUG 11495B 15079 2
31 DRIVE SCREW BM#04-03 17000 2
32 S/N PLATE 2613GG 13990 1
NOT SHOWN:
INSTRUCTION TAG 6588U --- 1
ROTATION DECAL 2613M --- 1
OPTIONAL:
G‐R HARD IRON PARTS:
-IMPELLER 38615-104 1102H 1
-SEAL PLATE 38272-360 1102H 1
SST PARTS:
-IMPELLER 38615-104 17070 1
-SEAL PLATE 38272-360 17070 1
-IMPELLER SHAFT 38514-828 1706H 1
-IMP CAPSCREW F1004S 1704G 1
-IMPELLER WASHER 31167-029 1706H 1
-CART SEAL ASSY 46513-159 --- 1
MAINTENANCE & REPAIR PAGE E - 9
Page 34
OM-06013 ULTRA V SERIES
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and decals
attached to the pump.
This pump requires little service due to its rugged,
minimum‐maintenance design. However, if it be
comes necessary to inspect or replace the wearing
parts, follow these instructions which are keyed to
the sectional views (see Figures 1, 2, 3 and 4) and
the accompanying parts lists.
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.
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.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment.
Many service functions may be performed by
draining the pump and removing the back cover
assembly. If major repair is required, the piping
and/or power source must be disconnected. The
following instructions assume complete disassem
bly is required.
Before attempting to service the pump, disconnect
or lock out the power source and take precautions
to ensure that it will remain inoperative. Close all
valves in the suction and discharge lines.
For power source disassembly and repair, consult
the literature supplied with the power source, or
contact your local power source representative.
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.
NOTE
The back cover and rotating assemblies are identi
cal for both the first stage pump and the Ultra Mate
second stage, therefore the service instructions are
the same. Because of these similarities, most of the
following instructions reference the first stage
MAINTENANCE & REPAIRPAGE E - 10
Page 35
ULTRA V SERIES
OM-06013
pump model drawing (Figure 2). Instructions spe
cific to the Ultra Mate second stage will reference
Figures 1 and/or 3 and will denote “Ultra Mate Sec
ond Stage Only”.
Support Plate Removal
(Figure 1)
Disassembly of the first or second stage pump
model requires removal of the support brace (2).
Disengage the hardware (3) and remove the plate.
Back Cover And Wear Plate Removal
(Figure 2)
The wear plate (5) is easily accessible and may be
serviced by removing the back cover assembly
(10). Before attempting to service the pump, re
move the pump casing drain plug (4) and drain the
pump. Clean and reinstall the drain plug.
The impeller (1) should be loosened while the rotat
ing assembly is still secured to the pump casing.
Before loosening the impeller, remove the seal cav
ity drain plug and drain the seal lubricant. This will
prevent the oil in the seal cavity from escaping
when the impeller is loosened. Clean and reinstall
the seal cavity drain plug.
Immobilize the impeller by wedging a block wood
between the vanes and the pump casing. Remove
the impeller capscrew and washer (28 and 29).
If removed, install the shaft key (24). Install a lathe
dog on the drive end of the shaft (25) with the “V”
notch positioned over the shaft key.
With the impeller rotation still blocked, see Figure 5
and use a long piece of heavy bar stock to pry
against the arm of the lathe dog in a counterclock
wise direction (when facing the drive end of the
shaft). Use caution not to damage the shaft or key
way. When the impeller breaks loose, remove the
lathe dog, key and wood block.
Remove the back cover nuts (15) and pry the back
cover and assembled wear plate from the pump
casing (1).
NOTE
An alternate method of removing the back cover
from the pump casing is to remove the back cover
nuts (15) and two diagonally opposing locking col
lars (12). Install two 1/2-16 UNC x 2 inch long
screws in the tapped holes in the back cover and
use them to press the back cover out of the pump
casing.
Inspect the wear plate, and replace it if badly
scored or worn. To remove the wear plate, disen
gage the hardware (7 and 8).
Inspect the back cover O‐rings (6 and 9) and re
place it if damaged or worn.
Rotating Assembly Removal
(Figure 4)
NOTE
Do not remove the impeller until the rotating assem
bly has been removed from the pump casing.
Turn
Counterclockwise
Lathe Dog Arm
“V” Notch
Heavy
Bar Stock
Figure 5. Loosening Impeller
(Figure 2)
Shaft Key
Impeller
Shaft
Lathe Dog
Setscrew
The rotating assembly may be serviced without
disconnecting the suction or discharge piping;
however, the power source must be removed to
provide clearance.
MAINTENANCE & REPAIR PAGE E - 11
Disengage the hardware (13 and 31) securing the
rotating assembly to the pump casing and remove
the spacers (32). Separate the rotating assembly
by pulling straight away from the pump casing.
Page 36
OM-06013 ULTRA V SERIES
NOTE
An optional disassembly tool is available from the
factory. If the tool is used, follow the instructions
packed with it. A similar tool may be assembled us
ing 1/2‐inch pipe (schedule 80 steel or malleable
iron) and a standard tee (see Figure 6). All threads
are 1/2‐inch NPT. Do not pre‐assemble the tool.
TEE
APPROX. 6 IN.
(152 MM) LONG
APPROX. 14 IN.
(356 MM) LONG
Seal Removal
(Figure 4)
Slide the shaft sleeve and rotating portion of the
seal off the shaft as a unit.
Use a pair of stiff wires with hooked ends to remove
the stationary element and seat.
An alternate method of removing the stationary
seal components is to remove the hardware (7 and
8) and separate the seal plate (4) and gasket (5)
from the bearing housing (9). Position the seal
plate on a flat surface with the impeller side down.
Use a wooden dowel or other suitable tool to press
on the back side of the stationary seat until the
seat, O‐rings, and stationary element can be re
moved.
Remove the shaft sleeve O‐ring (26).
If no further disassembly is required, refer to Seal
Installation.
Figure 6. Rotating Assembly Tool
To install the tool, remove the vented plug (10, Fig
ure 4) from the bearing housing, and screw the
longest length of pipe into the vent hole until fully
engaged. Install the tee, and screw the handles into
the tee. Use caution when lifting the rotating assem
bly to avoid injury to personnel or damage to the
assembly.
Remove the O‐rings (30 and 31).
Impeller Removal
(Figure 4)
With the rotating assembly removed from the
pump casing, unscrew the impeller from the shaft.
Use caution when unscrewing the impeller; ten
sion on the shaft seal spring will be released as the
impeller is removed. Inspect the impeller and re
place if cracked or badly worn.
Remove the impeller adjusting shims (2); tie and
tag the shims, or measure and record their thick
ness for ease of reassembly.
Shaft and Bearing Removal and Disassembly
(Figure 4)
When the pump is properly operated and main
tained, the bearing housing should not require dis
assembly. Disassemble the shaft and bearings
only when there is evidence of wear or damage.
Shaft and bearing disassembly in the field
is not recommended. These operations
should be performed only in a properly‐
equipped shop by qualified personnel.
Remove the bearing housing drain plug and drain
the lubricant. Clean and reinstall the drain plug.
Disengage the hardware (17 and 18) and slide the
bearing cap (19) and oil seal (6) off the shaft. Re
move the bearing cap gasket (20) and press the oil
seal from the bearing cap.
Place a block of wood against the impeller end of
the shaft (25) and tap the shaft and assembled
bearings (23 and 27) from the bearing housing.
Pry or press the oil seals (6) from the bearing hous
ing.
MAINTENANCE & REPAIRPAGE E - 12
Page 37
ULTRA V SERIES
OM-06013
After removing the shaft and bearings, clean and
inspect the bearings in place as follows.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and bear
ings are removed.
Clean the bearing housing, shaft and all compo
nent parts (except the bearings) with a soft cloth
soaked in cleaning solvent. Inspect the parts for
wear or damage and replace as necessary.
Most cleaning solvents are toxic and
flammable. Use them only in a well ven
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.
If bearing replacement is required, remove the out
board bearing retaining ring (21) and thrust wash
er (22). Use a bearing puller to remove the bear
ings from the shaft.
Pump Casing and Transition Chamber Removal
(Ultra Mate Second Stage Model Only)
(Figure 3)
The removal method for the Ultra Mate pump cas
ing (1) depends on the configuration of the casing
discharge port. If the discharge port is in a vertical
position, install two eye hooks in opposing holes in
the discharge flange. Use a suitable sling and hoist
to remove the casing.
If the discharge port is in a horizontal position, fab
ricate a lifting device as shown in Figure 7 and
screw it into the hole for the pipe plug (4). Make
certain that the threaded end of the tool fully en
gages the threads in the casing. Use a suitable
sling and hoist to remove the casing.
STANDARD
5/8‐11 UNC
LIFTING EYE
1” DIA. COLD
ROLLED STEEL
ROD DRILLED
AND TAPPED
5/8‐11 UNC
3/4-14 NPT
Bearings must be kept free of all dirt and
Figure 7. Casing Removal Tool
foreign material. Failure to do so will great
ly shorten bearing life. Do not spin dry
bearings. This may scratch the balls or
races and cause premature bearing fail
ure.
Do not attempt to lift the complete pump
unit using the lifting device. It is de
Rotate the bearings by hand to check for rough
ness or binding and inspect the bearing balls. If ro
tation is rough or the bearing balls are discolored,
replace the bearings.
The bearing tolerances provide a tight press fit
onto the shaft and a snug slip fit into the bearing
housing. Replace the bearings, shaft, or bearing
housing if the proper bearing fit is not achieved.
MAINTENANCE & REPAIR PAGE E - 13
signed to facilitate removal or installa
tion of individual components only. Ad
ditional weight may result in damage to
the pump or failure of the lifting device.
Remove the hardware (6 and 8) securing the pump
casing to the transition chamber (5). Separate the
pump casing and O‐ring (22) from the transition
chamber.
Page 38
OM-06013 ULTRA V SERIES
If the transition chamber requires removal from the
Ultra V first stage pump, support the chamber us
ing a suitable hoist and sling. See Figure 1 and re
move the external mounting hardware (8 and 9).
Reach through the back cover opening and re
move the socket head capscrews (10) and lock
washers (8). Use the hoist and sling to remove the
transition chamber and remove the gasket (7).
Pump Casing and Transition Chamber Installa
tion (Ultra Mate Second Stage Model Only)
(Figure 1)
Apply `Permatex Aviation No. 3 Form‐A‐Gasket' to
the mating surfaces and install a new gasket (7).
Using the hoist and sling, position the transition
chamber (5) on top of the first stage pump casing.
Reach through back cover opening and install the
socket head capscrews (10) and lock washers (8).
Finish securing the transition chamber by installing
the remaining hardware (8 and 9). Remove the
sling from the transition chamber.
soaked in cleaning solvent. Inspect the parts for
wear or damage as necessary.
Most cleaning solvents are toxic and
flammable. Use them only in a well ven
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
Inspect the shaft for distortion, nicks or scratches,
or for thread damage on the impeller end. Dress
small nicks and burrs with a fine file or emery cloth.
Replace the shaft if defective.
Position the inboard oil seal (6) in the bearing hous
ing bore with the lip positioned as shown in Figure
4, Detail C. Press the oil seal into the housing until
the face is just flush with the counterbored surface
toward the inside of the housing.
(Figure 3)
Lubricate a new O‐ring (22) with a generous
amount of grease and install it over the shoulder on
the transition chamber. Using the same lifting
method as used for disassembly, position the
pump casing (1) over the transition chamber
shoulder and secure it with the previously removed
hardware (6 and 8). Remove the sling and, if used,
the lifting device from the pump casing and rein
stall the pipe plug (4).
Do not attempt to lift the complete pump
unit using the lifting device. It is de
signed to facilitate removal or installa
tion of individual components only. Ad
ditional weight may result in damage to
the pump or failure of the lifting device.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and bear
ings are removed.
The bearings may be heated to ease installation.
An induction heater, hot oil bath, electric oven, or
hot plate may be used to heat the bearings. Bear
ings should never be heated with a direct flame or
directly on a hot plate.
NOTE
If a hot oil bath is used to heat the bearings, both the
oil and the container must be absolutely clean. If
the oil has been previously used, it must be thor
oughly filtered.
Shaft and Bearing Reassembly and Installation
(Figure 4)
Clean the bearing housing, shaft and all compo
nent parts (except the bearings) with a soft cloth
Heat the bearings to a uniform temperature no
higher than 250F (120C), and slide the bearings
onto the shaft, one at a time, until they are fully
seated. This should be done quickly, in one con
tinuous motion, to prevent the bearings from cool
ing and sticking on the shaft.
MAINTENANCE & REPAIRPAGE E - 14
Page 39
ULTRA V SERIES
OM-06013
After the bearings have been installed and allowed
to cool, check to ensure that they have not moved
away from the shaft shoulders in shrinking. If
movement has occurred, use a suitably sized
sleeve and a press to reposition the bearings
against the shaft shoulders.
If heating the bearings is not practical, use a suit
ably sized sleeve, and an arbor (or hydraulic) press
to install the bearings on the shaft.
When installing the bearings onto the
shaft, never press or hit against the outer
race, balls, or ball cage. Press only on the
inner race.
Install the thrust washer (22) and secure the out
board bearing (23) to the shaft with the snap ring
(21).
It is recommended that a sleeve be positioned
against the inboard oil seal (6) to prevent the lip of
the oil seal from rolling as the shaft and bearing are
installed in the bearing housing. The O.D. of the
sleeve should be just smaller than the bearing
housing bore, while the I.D. of the sleeve should be
just larger than the O.D. of the lip seal area of the
shaft.
Press the oil seal (6) into the bearing cap (19) with
the lip positioned as shown in Figure 2, Detail D.
Replace the bearing cap gasket (20) and secure
the bearing cap with the hardware (17 and 18). Be
careful not to damage the oil seal lip on the shaft
keyway.
Lubricate the bearing housing as indicated in LU
BRICATION.
Seal Installation
(Figures 4 and 8)
Most cleaning solvents are toxic and
flammable. Use them only in a well ven
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
Clean the seal cavity and shaft with a cloth soaked
in fresh cleaning solvent. Inspect the stationary
seat bore in the seal plate for dirt, nicks and burrs,
and remove any that exist. The stationary seat bore
must be completely clean before installing the
seal.
With the lip seal sleeve in place, lubricate the lip
seal area of the shaft, and slide the shaft and as
sembled bearings into the bearing housing until
the retaiining ring on the outboard bearing seats
against the bearing housing. Remove the lip seal
sleeve.
A new seal assembly should be installed
any time the old seal is removed from the
pump. Wear patterns on the finished faces
cannot be realigned during reassembly.
Reusing an old seal could result in prema
ture failure.
The seal is not normally reused because wear pat
terns on the finished faces cannot be realigned
When installing the shaft and bearings into
the bearing bore, push against the outer
race. Never hit the balls or ball cage.
Position the outboard oil seal (6) in the bearing
housing bore with the lip positioned as shown in
Figure 4, Detail C. Press the oil seal into the hous
ing until the face is just flush with the machined
surface on the housing.
MAINTENANCE & REPAIR PAGE E - 15
during reassembly. This could result in premature
failure. If necessary to reuse an old seal in an emer
gency, carefully wash all metallic parts in fresh
cleaning solvent and allow to dry thoroughly.
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leak
age. If any components are worn, replace the com
plete seal; never mix old and new seal parts.
Page 40
OM-06013 ULTRA V SERIES
If a replacement seal is being used, remove it from
the container and inspect the precision finished
faces to ensure that they are free of any foreign
matter.
To ease installation of the seal, lubricate the shaft
SPRING
RETAINER
IMPELLER
BELLOWS
IMPELLER
SHAFT
ROTATING
ELEMENT
sleeve, shaft sleeve O‐ring and the external station
ary seat O‐ring with a very small amount of light lu
bricating oil. See Figure 8 for seal part identifica
tion.
SEAL PLATE
O‐RINGS
SEAL SLEEVE
O‐RING
INTEGRAL
SHAFT
STATIONARY
SLEEVE
ELEMENT
IMPELLER
SHIMS
DRIVE BAND
Figure 8. Cartridge Seal Assembly
This seal is not designed for operation at
temperatures above 160F (71C). Do not
use at higher operating temperatures.
If the seal plate was removed, install the seal plate
gasket (5). Position the seal plate over the shaft
and secure it to the bearing housing with the hard
ware (7 and 8).
To prevent damaging the shaft sleeve O‐ring (26)
on the shaft threads, stretch the O‐ring over a piece
of plastic tubing that the I.D. is a little larger than the
O.D. of the shaft. Slide the tube over the shaft
threads, then slide the O‐ring off the tube and onto
the shaft. Remove the tube, and continue to slide
STATIONARY
SEAT
the O‐ring down the shaft until it seats against the
shaft shoulder.
When installing a new cartridge seal assembly,
remove the seal from the container, and remove
the mylar storage tabs, if so equipped, from be
tween the seal faces.
Some cartridge seal assemblies are
equipped with mylar storage tabs between
the seal faces. These storage tabs must be
removed before installing the seal.
Lubricate the external stationary seat O‐ring with
light oil. Slide the seal assembly onto the shaft until
MAINTENANCE & REPAIRPAGE E - 16
Page 41
ULTRA V SERIES
OM-06013
the external stationary seat O‐ring engages the
bore in the seal plate.
Clean and inspect the impeller as described in Im
peller Installation and Adjustment. Install the full
set of impeller shims (2) provided with the seal, and
screw the impeller onto the shaft until it is seated
against the seal (see Figure 9).
O‐RING ENGAGED
WITH SEAL PLATE
BORE
SHEAR RING
(UNSHEARED)
Figure 9. Seal Partially Installed
Continue to screw the impeller onto the shaft. This
will press the stationary seat into the seal plate
bore.
NOTE
A firm resistance will be felt as the impeller presses
the stationary seat into the seal plate bore.
STATIONARY SEAT
FULLY SEATED IN
SEAL PLATE BORE
break the nylon shear ring. This allows the sleeve
to slide down the shaft until seated against the
shaft shoulder. Continue to screw the impeller onto
the shaft until the impeller, shims, and sleeve are
fully seated against the shaft shoulder (see Figure
10).
Measure the impeller‐to‐seal plate clearance, and
remove impeller adjusting shims to obtain the
proper clearance as described in Impeller Instal
lation and Adjustment.
If necessary to reuse an old seal in an emer
gency, carefully separate the rotating and station
ary seal faces from the bellows retainer and sta
tionary seat.
A new seal assembly should be installed
any time the old seal is removed from the
pump. Wear patterns on the finished faces
cannot be realigned during reassembly.
Reusing an old seal could result in prema
ture failure.
Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate precision
finished faces; even fingerprints on the faces can
shorten seal life. If necessary, clean the faces with a
non‐oil based solvent and a clean, lint‐free tissue.
Wipe lightly in a concentric pattern to avoid
scratching the faces.
Carefully wash all metallic parts in fresh cleaning
solvent and allow to dry thoroughly.
Do not attempt to separate the rotating
portion of the seal from the shaft sleeve
when reusing an old seal. The rubber bel
lows will adhere to the sleeve during use,
SHEAR RING
(SHEARED)
and attempting to separate them could
damage the bellows.
Figure 10. Seal Fully Installed
As the stationary seat becomes fully seated, the
seal spring compresses, and the shaft sleeve will
MAINTENANCE & REPAIR PAGE E - 17
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leak
age. Inspect the integral shaft sleeve for nicks or
cuts on either end. If any components are worn, or
Page 42
OM-06013 ULTRA V SERIES
the sleeve is damaged, replace the complete seal;
never mix old and new seal parts.
Install the stationary seal element in the stationary
seat. Press this stationary subassembly into the
seal plate bore until it seats squarely against the
bore shoulder. A push tube made from a piece of
plastic pipe would aid this installation. The I.D. of
the pipe should be slightly larger than the O.D. of
the shaft sleeve.
Slide the rotating portion of the seal (consisting of
the integral shaft sleeve, spring centering washer,
spring, bellows and retainer, and rotating element)
onto the shaft until the seal faces contact.
Proceed with Impeller Installation and Adjust
ment.
Impeller Installation And Adjustment
(Figure 4)
Inspect the impeller, and replace it if cracked or
badly worn. Inspect the impeller and shaft threads
for dirt or damage, and clean or dress the threads
as required.
this clearance, and add or remove impeller adjust
ing shims as required.
NOTE
Proceed with Rotating Assembly Installation be
fore installing the impeller capscrew and washer
(28 and 29). The rotating assembly must be in
stalled in the pump casing in order to torque the im
peller capscrew.
After the rotating assembly is installed in the pump
casing, coat the threads of the impeller capscrew
(28) with `Never‐Seez' or equivalent compound,
and install the impeller washer (30) and capscrew;
torque the capscrew to 90 ft. lbs. (1080 in. lbs. or
12,4 m. kg.).
Rotating Assembly Installation
(Figure 2)
Install the O‐rings (33 and 34) and lubricate them
with light grease. Ease the rotating assembly into
the pump casing using the installation tool. Be
careful not to damage the O‐ring.
Install the rotating assembly adjusting spacers
(32) and secure the rotating assembly to the pump
casing with the hardware (13 and 31).
The shaft and impeller threads must be
completely clean before reinstalling the im
peller. Even the slightest amount of dirt on
the threads can cause the impeller to seize
to the shaft, making future removal difficult
or impossible without damage to the im
peller or shaft.
Install the same thickness of impeller adjusting
shims (2) as previously removed. Apply `Never‐
Seez' or equivalent to the shaft threads and screw
the impeller onto the shaft until tight.
NOTE
At the slightest sign of binding, immediately back
the impeller off, and check the threads for dirt. Do
not try to force the impeller onto the shaft.
A clearance of .025 to .040 inch (0,64 to 1,02 mm)
between the impeller and the seal plate is recom
mended for maximum pump efficiency. Measure
To set the impeller and wear plate clearance, refer
to the Back Cover Installation And Adjustment.
Back Cover Installation And Adjustment
(Figures 2 and 11)
If the wear plate (5) was removed for replacement,
carefully center it on the back cover and secure it
with the hardware (7 and 8). The wear plate must
be concentric to prevent binding when the back
cover is installed.
Clearance between the impeller and wear plate is
adjusted using four adjusting screws and locking
collars. There are 18 detents on the I.D. of each
locking collar (12). Indexing the collars one detent
on the adjusting screws represents approximately
.005 inch (0,13 mm) of wear plate clearance. The
recommended clearance between the wear plate
and the impeller is .010 to .020 inch (0,25 to 0,50
mm).
Replace the back cover O‐rings (6 and 9) and lubri
cate them with a generous amount of No. 2 grease.
MAINTENANCE & REPAIRPAGE E - 18
Page 43
ULTRA V SERIES
OM-06013
Clean any scale or debris from the contacting sur
faces in the pump casing that might interfere or
prevent a good seal with the back cover.
USE TWO REMAINING
ADJUSTING SCREWS AND
LOCKING COLLARS TO
SET FACE CLEARANCE
USE TWO
OPPOSING
BACK COVER NUTS
TO PRESS
BACK COVER
INTO PUMP
CASING
INDEX COLLARS 3
DETENTS COUNTER‐
CLOCKWISE, THEN
TURN CLOCKWISE
UNTIL SCREW
HOLES ALIGN
Figure 11. Installing and Adjusting Back Cover
Screw the four adjusting screws (11) into the
tapped holes in the back cover plate until they are
just flush with the machined surface on the back
side of the cover plate.
Align the back cover plate over the studs (3) and
slide it into the pump casing. Use two back cover
nuts (15) on diagonally opposing studs to press
the back cover into the pump casing until the wear
plate just touches the impeller when the shaft is
turned by hand. Tighten the back cover nuts
evenly to avoid binding.
With the wear plate just touching the impeller, turn
the two free adjusting screws until they engage the
pump casing. Position the locking collars over the
adjusting screws so the holes in the collars for the
locking screws align approximately with the holes
in the cover plate.
Loosen the back cover nuts used to press the back
cover into the pump casing one full turn.
Pull the collars off the adjusting screws, index them
three detents counterclockwise, and reinstall the
collars on the adjusting screws. Use the collars to
turn the adjusting screws clockwise until the holes
in the locking collars realign with the tapped screw
holes in the back cover plate. Secure the locking
collars to the back cover plate with the hardware
(13 and 14). Install the two remaining back cover
nuts snugly against the adjusting screws.
Remove the first two back cover nuts from their
studs. Turn the adjusting screws clockwise until
they engage the pump casing. Install the locking
collars and hardware (13 and 14). Reinstall the
back cover nuts.
Be sure the wear plate does not scrape against the
impeller.
Over time it may be necessary to repeat the adjust
ment process to compensate for normal wear be
tween the impeller and wear plate. When all of the
adjustment has been used on the back cover side
of the pump, an additional 0.125 inch (3,2 mm) of
adjustment may be obtained by removing the ro
tating assembly spacers (32).
Allow an installed pump to completely cool before
draining liquid from the pump casing. Remove the
back cover. Remove the rotating assembly adjust
ing shims, then reinstall the hardware securing the
rotating assembly to the pump casing. Perform the
back cover adjustment procedure described
above to obtain the proper face clearance.
PRESSURE RELIEF VALVE
MAINTENANCE
(Figure 2)
The back cover is equipped with a pressure relief
valve to provide additional safety for the pump and
operator (refer to Liquid Temperature And Over
heating in OPERATION).
It is recommended that the pressure relief valve as
sembly be replaced at each overhaul, or any time
the pump overheats and activates the valve. Never
replace this valve with a substitute which has not
been specified or provided by the Gorman‐Rupp
Company.
Periodically, the valve should be removed for in
spection and cleaning. When reinstalling the relief
valve, apply `Loctite Pipe Sealant With Teflon No.
592', or equivalent compound on the relief valve
threads. Position the valve as shown in Figure 2
with the discharge port pointing down.
Final Pump Assembly
(Figure 2)
Install the shaft keys (24, Figure 4) in the keyways
of both shafts and reconnect the power source. Be
MAINTENANCE & REPAIR PAGE E - 19
Page 44
OM-06013 ULTRA V SERIES
sure to install any guards used over the rotating
members.
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.
Install the suction and discharge lines and open all
valves. Make certain that all piping connections are
tight, properly supported and secure.
Be sure the pump and power source have been
properly lubricated, see LUBRICATION.
Remove the fill cover assembly (28) and fill the
pump casing with clean liquid. Reinstall the fill
cover, install the clamp bar (30) and secure it with
the capscrew (29). Refer to OPERATION, Section
C, before putting the pump back into service.
Bearings
(Figure 4)
The bearing housing was fully lubricated when
shipped from the factory. Check the oil level regu
larly through the bearing cavity sight gauge (14)
and maintain it at the middle of the gauge. When
lubrication is required, add SAE No. 30 non‐deter
oil through the hole for the air vent (12). Do not
gent
over‐lubricate. Over‐lubrication can cause the
bearings to over‐heat, resulting in premature bear
ing failure.
NOTE
The white reflector in the sight gauge must be posi
tioned horizontally to provide proper drainage.
Under normal conditions, drain the bearing hous
ing once each year and refill with approximately 24
ounces (710 ml) of clean oil. Change the oil more
frequently if the pump is operated continuously or
installed in an environment with rapid temperature
change.
LUBRICATION
Seal Assembly
(Figure 4)
Before starting the pump, remove the vented plug
(10) and fill the seal cavity with approximately 132
ounces (3,9 liters) of SAE No. 30 non‐detergent oil
to the middle of the seal level sight gauge (14) and
maintain it at the middle of the gauge. Clean and
reinstall the vented plug. Maintain the oil at this
level.
NOTE
The white reflector in the sight gauge must be posi
tioned horizontally to provide proper drainage.
Monitor the condition of the bearing lubri
cant regularly for evidence of rust or mois
ture condensation. This is especially im
portant in areas where variable hot and
cold temperatures are common.
For cold weather operation, consult the factory or a
lubricant supplier for the recommended grade of
oil.
Power Source
Consult the literature supplied with the power
source, or contact your local power source repre
sentative.
MAINTENANCE & REPAIRPAGE E - 20
Page 45
For U.S. and International Warranty Information,
Please Visit www.grpumps.com/warranty
or call:
U.S.: 419-755-1280
International: +1-419-755-1352
For Canadian Warranty Information,
Please Visit www.grcanada.com/warranty
or call:
519-631-2870
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA
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