GORMAN-RUPP PUMPS 6500 Series Application guide

OM-06682-01

October 27, 2014

GORMAN‐RUPP PUMPS

www.grpumps.com

e2014 Gorman‐Rupp Pumps Printed in U.S.A.

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

6500 SERIES PUMP

MODEL

6506A60-B

Gorman‐Rupp pump online at

www.grpumps.com

Valid serial number and e‐mail address required.

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

Please record your pump model and serial number in the

spaces provided below. Your Gorman‐Rupp distributor

needs this information when you require parts or service.

Pump Model:

Serial Number:

TABLE OF CONTENTS

INTRODUCTION PAGE I - 1.................................................

SAFETY ‐ SECTION A PAGE A - 1............................................

INSTALLATION - SECTION B PAGE B - 1....................................

PREINSTALLATION INSPECTION PAGE B - 1............................................

POSITIONING PUMP PAGE B -1.......................................................

Lifting PAGE B - 1.................................................................

Mounting 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 - 2...............................................................

Suction Lines In Sumps PAGE B - 2.................................................

Suction Line Positioning PAGE B - 3................................................

DISCHARGE LINES PAGE B - 4........................................................

Siphoning PAGE B - 4.............................................................

Valves PAGE B - 4................................................................

ALIGNMENT PAGE B - 4..............................................................

Coupled Drives PAGE B - 4........................................................

V‐Belt Drives PAGE B - 5...........................................................

ELECTRICAL CONNECTIONS PAGE B - 5...............................................

OPERATION - SECTION C PAGE C - 1......................................

PRIMING PAGE C - 1.................................................................

Hand Primers PAGE C - 1..........................................................

Exhaust Primers PAGE C - 1.......................................................

Auxiliary Ejectors PAGE C - 2.......................................................

Vacuum Pumps PAGE C - 2........................................................

STARTING PAGE C - 2................................................................

Rotation PAGE C - 2..............................................................

OPERATION PAGE C - 2..............................................................

Leakage PAGE C - 2..............................................................

Liquid Temperature And Overheating PAGE C - 2.....................................

Strainer Check PAGE C - 3.........................................................

Pump Vacuum Check PAGE C - 3..................................................

Operational Checks PAGE C - 3....................................................

STOPPING PAGE C - 3................................................................

Cold Weather Preservation PAGE C - 4..............................................

BEARING TEMPERATURE CHECK PAGE C - 4..........................................

LUBRICATION PAGE C - 4.............................................................

Power Source PAGE C - 5.........................................................

TABLE OF CONTENTS

(continued)

TROUBLESHOOTING - SECTION D PAGE D - 1..............................

PREVENTIVE MAINTENANCE PAGE D - 3...............................................

PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................

STANDARD PERFORMANCE CURVE PAGE E - 1........................................

PARTS LIST:

Pump End Assembly PAGE E - 3...................................................

Repair Rotating Assembly PAGE E - 5...............................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 6.........................

Suction Head and Wear Ring Removal PAGE E - 7....................................

Pump Casing Removal PAGE E - 7.................................................

Draining Oil From Seal Cavity PAGE E - 7............................................

Impeller Removal PAGE E - 7......................................................

Seal Removal PAGE E - 7..........................................................

Separating Rotating Assembly From Power Source PAGE E - 8........................

Shaft and Bearing Removal And Disassembly PAGE E - 8.............................

Shaft and Bearing Reassembly and Installation PAGE E - 9............................

Securing Rotating Assembly to Power Source PAGE E - 10.............................

Seal Reassembly and Installation PAGE E - 10........................................

Impeller Installation and Adjustment PAGE E - 11......................................

Pump Casing Installation PAGE E - 12................................................

Suction Head and Wear Ring Installation PAGE E - 12..................................

LUBRICATION PAGE E - 12.............................................................

Seal Assembly PAGE E - 12.........................................................

Bearings PAGE E - 12..............................................................

6500 SERIES OM-06682

PAGE I - 1INTRODUCTION

INTRODUCTION

Thank You for purchasing a Gorman‐Rupp pump.

Read this manual carefully to learn how to safely

install and operate your pump. Failure to do so

could result in personal injury or damage to the

pump.

Because pump installations are seldom identical,

this manual cannot possibly provide detailed in

structions and precautions for every aspect of

each specific application. Therefore, it is the re

sponsibility of the owner/installer of the pump to

ensure that applications not addressed in this

manual are performed only after establishing that

neither operator safety nor pump integrity are com

promised by the installation. Pumps and related

equipment must be installed and operated ac

cording to all national, local and industry stan

dards.

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:

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

For information or technical assistance on the

power source, contact the power source manufac

turer's local dealer or representative.

HAZARD AND INSTRUCTION

DEFINITIONS

The following are used to alert maintenance per

sonnel to procedures which require special atten

tion, to those which could damage equipment, and

to those which could be dangerous to personnel:

Immediate hazards which WILL result in

severe personal injury or death. These

instructions describe the procedure re

quired and the injury which will result

from failure to follow the procedure.

Hazards or unsafe practices which

COULD result in severe personal injury

or death. These instructions describe

the procedure required and the injury

which could result from failure to follow

the procedure.

Hazards or unsafe practices which COULD

result in minor personal injury or product

or property damage. These instructions

describe the requirements and the possi

ble damage which could result from failure

to follow the procedure.

NOTE

Instructions to aid in installation, operation, and

maintenance or which clarify a procedure.

6500 SERIES OM-06682

PAGE A - 1SAFETY

SAFETY ‐ SECTION A

This information applies to 6500 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.

Because pump installations are seldom

identical, this manual cannot possibly

provide detailed instructions and pre

cautions for each specific application.

Therefore, it is the owner/installer's re

sponsibility to ensure that applications

not addressed in this manual are per

formed only after establishing that nei

ther operator safety nor pump integrity

are compromised by the installation.

Before attempting to open or service the

pump:

1. Familiarize yourself with this man

ual.

2. 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

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.

Death or serious personal injury and

damage to the pump or components

can occur if proper lifting procedures

are not observed. Make certain that

hoists, chains, slings or cables are in

good working condition and of suffi

cient capacity and that they are posi

tioned so that loads will be balanced

and the pump or components will not be

damaged when lifting. Suction and dis

charge hoses and piping must be re

moved from the pump before lifting. Lift

the pump or component only as high as

necessary and keep personnel away

from suspended objects.

After the pump has been installed, make

certain that the pump and all piping or

hose connections are tight, properly

supported and secure before operation.

Do not operate the pump without the

shields and/or guards in place over the

drive shaft, belts, and/or couplings, or

other rotating parts. Exposed rotating

parts can catch clothing, fingers, or

tools, causing severe injury to person

nel.

Do not operate the pump against a

closed discharge valve for long periods

of time. If operated against a closed dis

6500 SERIESOM-06682

PAGE A - 2 SAFETY

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.

Overheated pumps can cause severe

burns and injuries. If overheating of the

pump occurs:

1. Stop the pump immediately.

2. Ventilate the area.

3. Allow the pump to completely cool.

4. Check the temperature before

opening any covers, plates,

gauges, or plugs.

5. Vent the pump slowly and cau

tiously.

6. Refer to instructions in this manual

before restarting the pump.

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.

Never run this pump backwards. Be cer

tain that rotation is correct before fully

engaging the pump.

Pumps and related equipment must be in

stalled and operated according to all na

tional, local and industry standards.

6500 SERIES OM-06682

PAGE B - 1INSTALLATION

INSTALLATION - SECTION B

Review all SAFETY information in Section A.

Since pump installations are seldom identical, this

section offers only general recommendations and

practices required to inspect, position, and ar

range the pump and piping.

Most of the information pertains to a flooded suc

tion application where the liquid is supplied to the

pump under pressure. Since the pressure sup

plied to the pump is critical to performance and

safety, be sure to limit the incoming pressure to

50% of the maximum permissible operating pres

sure as shown on the pump performance curve

(see Section E, Page 1).

For further assistance, contact your Gorman‐Rupp

distributor or the Gorman‐Rupp Company.

Pump Dimensions

See Figure 1 for the approximate physical dimen

sions of this pump.

OUTLINE DRAWING

Figure 1. Pump Model 6506A60-B

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 and engine for cracks,

dents, damaged threads, and other obvious

damage.

b. Check for and tighten loose attaching hard

ware. Since gaskets tend to shrink after dry

ing, check for loose hardware at mating sur

faces.

c. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties

indicated.

d. Check levels and lubricate as necessary. Re

fer to LUBRICATION in the MAINTENANCE

OM-06682 6500 SERIES

PAGE B - 2 INSTALLATION

AND REPAIR section of this manual and per

form duties as instructed.

e. If the pump has been stored for more than 12

months, some of the components or lubri

cants may have exceeded their maximum

shelf life. These must be inspected or re

placed to ensure maximum 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

Death or serious personal injury and

damage to the pump or components

can occur if proper lifting procedures

are not observed. Make certain that

hoists, chains, slings or cables are in

good working condition and of suffi

cient capacity and that they are posi

tioned so that loads will be balanced

and the pump or components will not be

damaged when lifting. Suction and dis

charge hoses and piping must be re

moved from the pump before lifting. Lift

the pump or component only as high as

necessary and keep personnel away

from suspended objects.

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.

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.

Proper mounting of the pump, driver and base is

critical to the performance of the pump. Improper

mounting can result in vibration, which can cause

damage to the pump and/or other system compo

nents.

The pumping unit must be securely mounted to a

foundation that is heavy enough to absorb any vi

bration, strain or shock, while providing perma

nent, rigid support for the unit.

Because pump installations vary due to the specif

ic application, this manual cannot possibly antici

pate and provide detailed instructions for every in

stallation. Therefore, it is recommended that the in

staller of the unit follow the recommendations pro

vided by the Hydraulic Institute in their Rotodynam

ic Centrifugal Pump Design and Application manu

al when designing and fabricating the foundation

upon which the pump, base and driver will be

mounted.

SUCTION AND DISCHARGE PIPING

The following is provided as general information for

suction and discharge piping. Because pump in

stallations vary due to the specific application, this

manual cannot possibly anticipate and provide de

tailed instructions for every installation. Therefore,

it is recommended that the installer follow the rec

ommendations provided by the Hydraulic Institute

in their Pump Piping for Rotodynamic Pumps man

ual for layout, design and installation of the system

piping.

Materials

Materials used in piping must be compatible with

the liquid being pumped. Using piping couplings

in suction lines is not recommended.

Line Configuration

Keep suction and discharge lines as straight as

possible to minimize friction losses. Make mini

mum use of elbows and fittings, which substan

tially increase friction loss. If elbows are necessary,

use the long‐radius type to minimize friction loss.

6500 SERIES OM-06682

PAGE B - 3INSTALLATION

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.

Gauges

Most pumps are drilled and tapped for installing

discharge pressure and vacuum suction gauges.

If these gauges are desired for pumps that are not

tapped, drill and tap the suction and discharge

lines not less than 18 inches (457,2 mm) from the

suction and discharge ports and install the lines.

Installation closer to the pump may result in erratic

readings.

SUCTION LINES

To avoid air pockets which could affect pump prim

ing, the suction line must be as short and direct as

possible.

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 for

isolation purposes, install it with the stem horizon

tal to avoid air pockets.

Strainers

If a strainer is installed by the pump user, make cer

tain that the total area of the openings in the strain

er is at least three or four times the cross section of

the suction line, and that the openings will not per

mit passage of solids larger than the solids han

dling 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 pump perfor

mance, all connections in the suction line should

be sealed with pipe dope to ensure an airtight seal.

Follow the sealant manufacturer's recommenda

tions when selecting and applying the pipe dope.

The pipe dope should be compatible with the liquid

being pumped.

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 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.

If the application involves a high discharge

head, gradually close the discharge

throttling valve before stopping the pump.

ALIGNMENT

This pump is designed for direct coupled

drive only. Use of a V‐belt drive will dam

age the pump and void the pump warranty.

The alignment of the pump and its power source is

critical for trouble‐free mechanical operation. The

driver and pump must be mounted so that their

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