CDS OM-05665-01 June 17, 2004 Rev. E 06‐03‐2014 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST SUPER U SERIES PUMP MODEL U4A60S-B INCLUDING: /F, /FM GORMAN‐RUPP PUMPS www.grpumps.com 2004 Gorman‐Rupp Pumps Printed in U.S.A.
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TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE I - 1 SAFETY - SECTION A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE A - 1 INSTALLATION - SECTION B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 1 Pump Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (continued) TROUBLESHOOTING - SECTION D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP MAINTENANCE AND REPAIR - SECTION E . . . . . . . . . . . . . . . . PERFORMANCE CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARTS LISTS: Pump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPER U SERIES OM-05665 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 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.
SUPER U SERIES OM-05665 SAFETY - SECTION A This information applies to the Super U Series basic pumps. Gorman‐Rupp has no control over or particular knowledge of the power source which will be used. Refer to the manual accompanying the power source before attempting to be gin operation. This manual will alert personnel to known procedures which require spe cial attention, to those which could damage equipment, and to those which could be dangerous to personnel.
OM-05665 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. SUPER U SERIES damage to the pump or components can occur if proper lifting procedures are not observed.
SUPER U SERIES OM-05665 INSTALLATION - SECTION B Review all SAFETY information in Section A. Since pump installations are seldom identical, this section offers only general recommendations and practices required to inspect, position, and ar range the pump and piping. Most of the information pertains to a standard static lift application where the pump is posi tioned above the free level of liquid to be pumped.
OM-05665 PREINSTALLATION INSPECTION The pump assembly was inspected and tested be fore shipment from the factory. Before installation, inspect the pump for damage which may have oc curred during shipment. Check as follows: a. Inspect the pump for cracks, dents, damaged threads, and other obvious damage. b. Check for and tighten loose attaching hard ware. Since gaskets tend to shrink after dry ing, check for loose hardware at mating sur faces. c.
SUPER U SERIES (254 mm) must be maintained to permit removal of the cover. SUCTION AND DISCHARGE PIPING Pump performance is adversely effected by in creased suction lift, discharge elevation, and fric tion losses. See the performance curve and oper ating range shown on Page E‐1 to be sure your overall application allows pump to operate within the safe operation range.
OM-05665 SUPER U SERIES 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. 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.
SUPER U SERIES OM-05665 DISCHARGE LINES minimize the chance of plugging. Siphoning 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.
OM-05665 SUPER U SERIES AUTOMATIC AIR RELEASE VALVE 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.
SUPER U SERIES OM-05665 DISCHARGE PIPE CLEAN‐OUT COVER INSTALL AIR RELEASE VALVE IN HORIZONTAL POSITION 90 LONG RADIUS ELBOW SUPPORT BRACKET BLEED LINE 1” (25,4 MM) DIA. MIN. (CUSTOMER FUR NISHED) EXTEND 6” (152 MM) BELOW PUMP OFF LIQUID LEVEL DISCHARGE CHECK VALVE PUMP DISCHARGE SELF‐PRIMING CENTRIFUGAL PUMP SUCTION LINE WET WELL OR SUMP Figure 3. Typical Automatic Air Release Valve Installation Connect the valve outlet to a bleed line which slopes back to the wet well or sump.
OM-05665 SUPER U SERIES Adjusting the alignment in one direction may alter the alignment in another direc tion. check each procedure after altering alignment. Coupled Drives Figure 5. Aligning Non‐Spider Type Couplings 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.
SUPER U SERIES OM-05665 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.
OM-05665 SUPER U SERIES 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 page E‐1.
OM-05665 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 SUPER U SERIES 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.
OM-05665 SUPER U SERIES 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.
OM-05665 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 PAGE C - 4 SUPER U SERIES AND REPAIR). Bearing overheating can also be caused by shaft misalignment and/or excessive vi bration.
SUPER U SERIES OM-05665 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.
OM-05665 SUPER U SERIES TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE Strainer clogged. Check strainer and clean if neces sary. Suction intake not submerged at proper level or sump too small. Check installation and correct sub mergence as needed. Impeller or other wearing parts worn or damaged. Replace worn or damaged parts. Check that impeller is properly centered and rotates freely. Impeller clogged. Free impeller of debris.
SUPER U SERIES OM-05665 TROUBLE POSSIBLE CAUSE PROBABLE REMEDY BEARINGS RUN TOO HOT Bearing temperature is high, but within limits. Check bearing temperature regu larly to monitor any increase. Low or incorrect lubricant. Check for proper type and level of lubricant. Suction and discharge lines not properly supported. Check piping installation for proper support. Drive misaligned. Align drive properly.
OM-05665 SUPER U SERIES Preventive Maintenance Schedule Service Interval* Item General Condition (Temperature, Unusual Noises or Vibrations, Cracks, Leaks, Loose Hardware, Etc.
OM-05665 SUPER U SERIES 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 U4A60S‐B Including /F, /FM Based on 70 F (21 C) clear water at sea level with minimum suction lift. Since pump installations are seldom identical, your performance may be dif ferent due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.
OM-05665 SUPER U SERIES PARTS PAGE SECTION DRAWING DRIVE END VIEW TOP VIEW PRESSURE EQUALIZING PASSAGE (KEEP OPEN) Figure 1.
OM-05665 SUPER U SERIES PARTS LIST Pump Model U4A60S-B Including /F, /FM (From S/N 1289519 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 NO.
OM-05665 SUPER U SERIES SECTION DRAWING DRIVE END VIEW Figure 2.
OM-05665 SUPER U SERIES PARTS LIST 44163-422 Repair Rotating Assembly ITEM NO.
OM-05665 SUPER U 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 and 2) and the accompanying parts lists.
SUPER U SERIES OM-05665 Remove the back cover nuts (22) 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 (22) and two diagonally opposing locking col lars (21). Install two 1/2-13 UNC2B 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. Install the shaft key (17).
OM-05665 SUPER U SERIES 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 4). All threads are 1/2‐inch NPT. Do not pre‐assemble the tool. TEE APPROX. 6 IN. (152 MM) LONG Use a pair of stiff wires with hooked ends to remove the stationary element and seat.
SUPER U SERIES 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.
OM-05665 SUPER U SERIES 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. Heat the bearings to a uniform temperature no higher than 250 F (120 C), and slide the bearings onto the shaft, one at a time, until they are fully seated.
SUPER U SERIES OM-05665 RETAINER SEAL PLATE SPRING O‐RINGS IMPELLER SLEEVE O‐RING IMPELLER SHIMS IMPELLER SHAFT ROTATING ELEMENT BELLOWS STATIONARY ELEMENT INTEGRAL SHAFT SLEEVE SHEAR RING (SHEARED) SPRING CENTERING WASHER STATIONARY SEAT DRIVE BAND Figure 5. 46513-151 Cartridge Seal Assembly When installing a new cartridge seal assembly, remove the seal from the container, and remove the mylar storage tabs from between the seal faces.
OM-05665 SUPER U SERIES O‐RING ENGAGED WITH SEAL PLATE BORE 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. SHEAR RING (UNSHEARED) Figure 6. Seal Partially Installed Continue to screw the impeller onto the shaft. This will press the stationary seat into the seal plate bore.
SUPER U SERIES OM-05665 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 (Figure 2) 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.
OM-05665 SUPER U SERIES and the impeller is .003 to .010 inch (0,07 to 0,25 mm). Replace the suction back cover and wear plate O‐ rings (15 and 19) and lubricate them with a gener ous amount of No. 2 grease. Clean any scale or de bris from the contacting surfaces in the pump cas ing that might interfere or prevent a good seal with the back cover.
SUPER U SERIES OM-05665 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 1 with the discharge port pointing down. Final Pump Assembly (Figure 1) If the discharge flange (7) or blind flange assembly (37) were removed, replace the respective gaskets (6 and 43). Apply `Permatex Aviation No.
OM-05665 SUPER U SERIES Power Source Consult the literature supplied with the power source, or contact your local power source repre sentative.
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 GORMAN‐RUPP OF CANADA LIMITED MANSFIELD, OHIO ST.
