Gorman-Rupp Pumps PA12A60-B-6068H-ESP User Manual

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Page 1

ACDEU

OM-06261-01

May 11, 2009

Rev. A 12‐12‐13

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

PA SERIES PUMP

MODEL

PA12A60-B-6068H-ESP

THE GORMAN‐RUPP COMPANY  MANSFIELD, OHIO

GORMAN‐RUPP OF CANADA LIMITED  ST. THOMAS, ONTARIO, CANADA Printed in U.S.A

www.grpumps.com.

2009 The Gorman‐Rupp Company

Page 2

Gorman‐Rupp pump online at

www.grpumps.com

Valid serial number and e‐mail address required.

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

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............................................

Battery Installation PAGE B - 2.....................................................

POSITIONING PUMP PAGE B - 2.......................................................

Lifting PAGE B - 2.................................................................

Mounting PAGE B - 2.............................................................

SUCTION AND DISCHARGE PIPING PAGE B - 3.........................................

Materials PAGE B - 3..............................................................

Line Configuration PAGE B - 3......................................................

Connections to Pump PAGE B - 3..................................................

Gauges PAGE B - 3...............................................................

SUCTION LINES PAGE B - 3...........................................................

Fittings PAGE B - 3...............................................................

Strainers PAGE B - 3..............................................................

Sealing PAGE B - 4...............................................................

Suction Line Positioning PAGE B - 4................................................

DISCHARGE LINES PAGE B - 5........................................................

Siphoning PAGE B - 5.............................................................

Valves PAGE B - 5................................................................

ALIGNMENT PAGE B - 5..............................................................

AUTO‐START PAGE B - 5.............................................................

Float Switch Installation PAGE B - 6.................................................

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

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

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

STARTING PAGE C - 1................................................................

Manual Starting PAGE C - 1........................................................

Automatic Starting PAGE C - 2.....................................................

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

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

Pump Vacuum Check PAGE C - 2..................................................

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

Strainer Check PAGE C - 2.........................................................

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

BEARING TEMPERATURE CHECK PAGE C - 3..........................................

Cold Weather Preservation PAGE C - 3..............................................

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........................................

Page 4

TABLE OF CONTENTS

(continued)

PARTS LISTS:

Pump Model PAGE E - 3..........................................................

Pump Model Assembly PAGE E - 10.................................................

612M60-B Pump Model Assembly PAGE E - 12......................................

Priming Chamber Kit PAGE E - 16...................................................

Priming Chamber Assembly PAGE E - 17.............................................

Engine Drive Assembly PAGE E - 18.................................................

Impeller Assembly Machining Tolerances PAGE E - 19.................................

Drive Assembly PAGE E - 14........................................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 20.........................

Priming Chamber Removal And Disassembly PAGE E - 20..............................

Discharge Check Valve Removal and Disassembly PAGE E - 21.........................

Suction Head And Wear Ring Removal PAGE E - 21...................................

Pump Casing Removal PAGE E - 21.................................................

Impeller Removal PAGE E - 22......................................................

Seal Removal PAGE E - 22..........................................................

Pedestal Assembly Removal PAGE E - 22.............................................

Pump Shaft and Bearing Removal and Disassembly PAGE E - 23........................

Engine Drive Disassembly PAGE E - 23..............................................

Bearing Cleaning And Inspection PAGE E - 24........................................

Engine Drive Reassembly PAGE E - 24...............................................

Pump Shaft and Bearing Reassembly and Installation PAGE E - 26......................

Pedestal Assembly Installation PAGE E - 27...........................................

Seal Reassembly and Installation PAGE E - 28........................................

Impeller Installation PAGE E - 30.....................................................

Pump Casing Installation PAGE E - 30................................................

Suction Head And Wear Ring Installation PAGE E - 30..................................

Discharge Check Valve Assembly and Installation PAGE E - 31..........................

Priming Chamber Assembly And Installation PAGE E - 31...............................

LUBRICATION PAGE E - 31.............................................................

Seal Assembly PAGE E - 31.........................................................

Bearings PAGE E - 31..............................................................

Engine PAGE E - 32................................................................

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OM-06261

INTRODUCTION

Thank You for purchasing a Gorman‐Rupp pump. Read this manual carefully to learn how to safely

install and operate your pump. Failure to do so could result in personal injury or damage to the pump.

This pump is a sound‐attenuated PA Series, pri ming‐assisted environmental silent pump. The centrifugal pump unit is designed for handling non‐volatile, non‐flammable liquids containing specified entrained solids. The basic material of pump construction is ductile iron, with stainless steel shaft and ductile iron wearing parts.

Because pump installations are seldom identical, this manual cannot possibly provide detailed in structions and precautions for every aspect of each specific application. Therefore, it is the re sponsibility of the owner/installer of the pump to ensure that applications not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity are com promised by the installation. Pumps and related equipment must be installed and operated ac cording to all national, local and industry stan dards.

If there are any questions regarding the pump which are not covered in this manual or in other lit erature accompanying the 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

The following are used to alert personnel to proce dures which require special attention, 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 de scribe the requirements and the possible damage which could result from failure to follow the procedure.

NOTE

Instructions to aid in installation, operation, and maintenance or which clarify a procedure.

For information or technical assistance on the en gine, contact the engine manufacturer's local dealer or representative.

PAGE I - 1INTRODUCTION

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PA SERIES

SAFETY ‐ SECTION A

This information applies to Prime Aire Series pumps. Refer to the manual ac companying the engine or power source before attempting to begin oper ation.

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.

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OM-06261

the positive battery cable before per forming any maintenance. Failure to do so may result in serious personal injury.

This pump is designed to handle most non‐volatile, non‐flammable liquids containing specified entrained solids. Do not attempt to pump volatile, corro sive, or flammable liquids which may damage the pump or endanger person nel as a result of pump failure.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Shut down the engine and discon nect the positive battery cable to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4. Check the temperature and make sure the pump is cool before open ing 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.

This pump is equipped with an automat ic starting system, and is subject to au tomatic restart. Keep hands and cloth ing away from the unit to prevent injury during automatic operation. Disconnect

Do not operate the pump against a closed discharge valve. If operated against a closed discharge valve, pump

PAGE A - 1SAFETY

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components will deteriorate, and the liquid could come to a boil, build pres sure, and cause the pump casing to rup ture or explode. Momentary closure of a discharge valve is acceptable only when required for startup or shutdown procedures.

PA SERIESOM-06261

Make sure the pump is level. Lower jack stands and chock the wheels, if so equipped. Use caution when positioning the skid‐mounted unit to prevent damage to the fuel tank.

Do not remove plates, covers, gauges, pipe plugs, or fittings from an over heated pump. Vapor pressure within the pump can cause parts being disen gaged to be ejected with great force. Al low the pump to cool completely before servicing.

This pump may be used to handle mate rials which could cause illness through direct exposure or emitted fumes. Wear adequate protective clothing when working on the pump or piping.

Do not operate an internal combustion engine in an explosive atmosphere. When operating an internal combustion engine in an enclosed area, make sure exhaust fumes are piped to the outside. These fumes contain carbon monoxide, a deadly gas that is colorless, tasteless and odorless.

Fuel used by internal combustion en gines presents an extreme explosion and fire hazard. Make certain that all fuel lines are securely connected and free of leaks. Never refuel a hot or run ning engine. Avoid overfilling the fuel tank. Always use the correct type of fuel.

Never tamper with the governor to gain more power. The governor establishes

Do not operate the pump without guards in place over the rotating parts. Ex posed rotating parts can catch clothing, fingers or tools, causing severe injury to personnel.

PAGE A - 2 SAFETY

safe operating limits that should not be exceeded. Refer to the Performance Curve in Section, Page E‐1 for the maxi mum continuous operating speed for this pump.

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PA SERIES OM-06261

INSTALLATION - SECTION B

Review all SAFETY information in Section A.

Since pump installations are seldom identical, this section offers only general recommendations and practices required to inspect, position, and ar range the pump and piping.

Most of the information pertains to a standard static lift application where the pump is positioned above the free level of liquid to be pumped.

If installed in a flooded suction application where the liquid is supplied to the pump under pressure, some of the information such as mounting, line

OUTLINE DRAWING

configuration, and priming must be tailored to the specific application. Since the pressure supplied to the pump is critical to performance and safety, be sure to limit the incoming pressure to 50% of the maximum permissible operating pressure as shown on the pump performance curve.

For further assistance, contact your Gorman‐Rupp distributor or the Gorman‐Rupp Company.

Pump Dimensions

See Figure 1 for the approximate physical dimen sions of this pump.

Figure 1. Pump Model PA12A60-B-6068H-ESP

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.

PAGE B - 1INSTALLATION

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OM-06261 PA SERIES

c. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties indicated. Note that the pump shaft rotates in the required direction.

Only operate this pump in the direction in dicated by the arrow on the pump body and on the accompanying decal. Other wise, the impeller could become loosened from the shaft and seriously damage the pump.

d. Check levels and lubricate as necessary. Re

fer to LUBRICATION in the Maintenance and Repair Manual and perform duties as in structed.

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

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.

Battery Installation

Unless otherwise specified on the pump order, the engine battery is not included with engine driven units.

Refer to the information accompanying the battery and/or electrolyte solution for activation and charg ing instructions.

Before installing the battery, clean the positive and negative cable connectors, and the battery termi nals. Secure the battery by tightening the holddown brackets. The terminals and clamps may be coated with petroleum jelly to retard corro sion. Connect and tighten the positive cable first, then the negative cable.

PAGE B - 2 INSTALLATION

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 and eliminate vibration.

For engine driven units, the pump must be posi tioned as level as possible to ensure sufficient lubri cation and fuel supply to the engine.

If the pump has been mounted on a moveable base, make certain the base is stationary by setting the brake and blocking the wheels before attempt ing to operate the pump.

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PA SERIES OM-06261

to secure them when filled with liquid and under pressure.

If the pump has been mounted on a mov able base, do not attempt to operate the pump unless the unit is level. Be sure the leveling stands are positioned on a solid surface, and the wheels are chocked.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in creased suction lift, discharge elevation, and fric tion losses. See the performance curve and oper ating range shown on Page E‐1 to be sure your overall application allows pump to operate within the safe operation range.

Materials

Either pipe or hose maybe used for suction and discharge lines; however, the materials must be compatible with the liquid being pumped. If hose is used in suction lines, it must be the rigid‐wall, rein forced type to prevent collapse under suction. Us ing piping couplings in suction lines is not recom mended.

Line Configuration

Keep suction and discharge lines as straight as possible to minimize friction losses. Make mini mum use of elbows and fittings, which substan tially increase friction loss. If elbows are necessary, use the long‐radius type to minimize friction loss.

Connections to Pump

Gauges

The pump is drilled and tapped for installing dis charge pressure and vacuum suction gauges. It is recommended that gauges be installed to monitor pump performance. Seal the gauge threads with pipe dope to ensure an airtight seal. Follow the sealant manufacturer's recommendations when selecting and applying the pipe dope. The pipe dope should be compatible with the liquid being pumped.

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

Be certain to use the strainer furnished with the pump; any spherical solids which pass through the strainer will also pass through the pump itself.

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

If a strainer not furnished with the pump 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.

PAGE B - 3INSTALLATION

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OM-06261 PA SERIES

Sealing

Since even a slight leak will affect priming, head, and capacity, especially when operating with a high suction lift, all connections in the suction line should be sealed with pipe dope to ensure an air tight seal. Follow the sealant manufacturer's rec ommendations when selecting and applying the pipe dope. The pipe dope should be compatible with the liquid being pumped.

Suction Lines In Sumps

If a single suction line is installed in a sump, it should be positioned away from the wall of the sump at a distance equal to 1 1/2 times the diame ter of the suction line.

If there is a liquid flow from an open pipe into the sump, the flow should be kept away from the suc tion inlet because the inflow will carry air down into the sump, and air entering the suction line will re duce pump efficiency.

If it is necessary to position inflow close to the suc tion inlet, install a baffle between the inflow and the suction inlet at a distance 1‐1/2 times the diameter of the suction pipe. The baffle will allow entrained

air to escape from the liquid before it is drawn into the suction inlet.

If two suction lines are installed in a single sump, the flow paths may interact, reducing the efficiency of one or both pumps. To avoid this, position the suction inlets so that they are separated by a dis tance equal to at least 3 times the diameter of the suction pipe.

Suction Line Positioning

The depth of submergence of the suction line is critical to efficient pump operation. Figure 2 shows recommended minimum submergence vs. velocity.

Although not recommended, the vacuum assisted priming feature allows the pump to be operated temporarily in a “slurping” application with varying water levels.

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 - 4 INSTALLATION

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PA SERIES OM-06261

Figure 2. 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

This pump is designed with a check valve in the discharge line.

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 be installed in the discharge line to protect the pump from excessive shock pres sure and reverse rotation when it is stopped.

If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.

ALIGNMENT

The alignment of the pump, air compressor and engine is critical for trouble‐free mechanical opera tion. See Section E, Securing Intermediate And

Drive Assembly To Engine in MAINTENANCE AND REPAIR, for details.

AUTO‐START

The standard pump is equipped with an auto‐start control system which allows the pump to start and stop as the liquid level in the wet well or sump rises and falls.

Refer to the information which follows for installa tion details for the liquid level sensing system pro vided with your pump.

PAGE B - 5INSTALLATION

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OM-06261 PA SERIES

Float Switch Installation

The Float Switch autostart system employs either a single or double float switch, where a bulb raises or lowers (floats) with the liquid level, thus activating an enclosed miniature switch. The floats are equipped with a socket type connector that plugs into a matching receptacle on the auto‐start control box.

Standard floats are equipped with 50 feet (15,2 m) of cable.

When installing the floats, note the following:

a. Be sure to provide sufficient room in the wet

well or sump so that floats do not get ob structed or drawn into the suction line. If a flex ible suction hose is used, it may be extended to lay along the bottom of the wet well or sump and the float can be attached to the hose above the point where it bends along the bot tom. Direct the suction line toward the flow, and the float(s) away from the flow. If a stand

pipe is available, attach the float switch cable to the standpipe in the sump at the approxi mate desired liquid level.

b. In a single float system, the cable can be teth

ered to the suction line or standpipe approxi mately 6 inches (152 mm) above the float. This setting allows approximately 9 inches (229 mm) of liquid rise between pump start/ stop. The start/stop interval may be increased by extending the float end of the cable. The liquid level in the sump will increase approxi mately 8 inches (203 mm) between start/stop intervals for every 6 inches (152 mm) of cable increase.

c. If a double float switch system is used, posi

tion the “Start” float at the desired high water level in the sump, and the “Stop” float at the desired low water level in the pump.

d. Refer to Figure 3 for additional float switch

data.

ENGINE

CONTROL

BOX

CABLE

TETHER

POINT

1.25” Pipe (Not Furnished)

(Emptying)

OFF

(Filling)

OPERATING

RANGE

(See Table Below)

OFF

(Emptying)

(Filling)

Figure 3. Float Switch Data

3.0

(0.9)

2.5

(.76)

2.0

(0.6)

1.5

(.46)

1.0

(0.3)

0.5

(.15)

1.0

(0.3)

APPROXIMATE FREE CORD LENGTH IN FT. (M)

2.0

(0.6)

3.0

(0.9)

4.0

(1.2)

PAGE B - 6 INSTALLATION

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OPERATION - SECTION C

Review all SAFETY information in Section A.

Follow the instructions on all tags, labels and decals attached to the pump.

OPERATION

Pump speed and operating condition points must be within the continuous per formance range shown on the perfor mance curve in Section E on page E-1.

PRIMING

The pump will begin to prime upon startup. The air in the suction line will be discharged from the educ tor discharge line. Complete priming is indicated by a positive discharge pressure reading.

If full priming is not achieved, the discharge check valve may be malfunctioning. If this occurs, shut down the pump and consult Maintenance and

Repair, Section E for further details.

STARTING

Check the fuel level and oil levels in the engine, air compressor, pump bearings and seal housing.

Make sure the pump is level. Lower the jack stands and chock the wheels, if so equipped.

Make sure the pump is level. Lower jack stands and chock the wheels, if so equipped. Use caution when positioning the skid‐mounted unit to prevent damage to the fuel tank.

This pump is equipped with automatic liquid level controls, and is subject to automatic restart. Keep hands and clothing away from the unit to prevent injury during automatic operation. Dis connect the positive battery cable be fore performing any maintenance. Fail ure to do so may result in serious per sonal injury.

Consult the engine operations manual before at tempting to start the unit.

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).

OPERATION PAGE C - 1

Manual Starting

On initial start‐up, set the engine speed at in the half‐throttle position. Turn the keyswitch to `MANU AL'. After the engine starts and the unit is fully primed, adjust the engine RPM until the desired flow rate is achieved.

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OM-06261 PA SERIES

Automatic Starting

With the float system installed, follow the proce dures outlined for manual starting and throttle ad justment. Switch the keyswitch to `OFF' until the water level rises above the on point for the float sys tem, then turn the keyswitch to the `AUTO' setting. The unit will run until the float signals the control that the water in the wet well is at the float off point, at which time the unit will shut down automatically. When the float signals the control that the water in the wet well is at the float on point, the unit will re‐ start automatically, repeating the cycle.

Allow an over‐heated pump to com pletely cool before servicing. Do not re move plates, covers, gauges, or fittings from an overheated pump. Liquid within 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 cools, drain the liquid from the pump by removing the casing drain plug. Use caution when removing the

OPERATION

plug to prevent injury to personnel from hot liquid.

Leakage

Once the pump is fully primed, no leakage should be visible at pump mating surfaces, or at pump connections or fittings. Keep all line connections and fittings tight to maintain maximum pump effi ciency.

Pump Vacuum Check

Read the vacuum gauge with the pump primed and at operation speed. Shut off the pump. The vacuum gauge reading will immediately drop pro portionate to static suction lift, and should then sta bilize. 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 installa tion of the vacuum gauge.

Liquid Temperature And Overheating

The maximum liquid temperature for this pump is 160 F (71C). Do not apply it at a higher operating temperature.

Overheating can occur if operated with the valves in the suction or discharge lines closed. Operating against closed valves could bring the liquid to a boil, build pressure, and cause the pump to rup ture or explode. If overheating occurs, stop the pump immediately and allow it to completely cool before servicing it. Approach any over‐heated pump cautiously.

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 over‐heat ing does occur, stop the pump immediately and al low it to cool before servicing it. Approach any over‐heated pump cautiously. It is recom mended 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 specified or provided by the Gorman‐Rupp Company.

Strainer Check

Check the strainer regularly, and clean it as neces sary. The strainer should also be checked if pump flow rate begins to drop. Monitor and record the vacuum suction gauge 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.

STOPPING

Never halt the flow of liquid suddenly. If the liquid being pumped is stopped abruptly, damaging

OPERATIONPAGE C - 2

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OM-06261

shock waves can be transmitted to the pump and piping system. Close all connecting valves slowly.

Reduce the throttle speed slowly and allow the en gine to idle briefly before stopping.

If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.

After stopping the pump, switch off the engine igni tion and remove the key to ensure that the pump will remain inoperative.

BEARING TEMPERATURE CHECK

Bearings normally run at higher than ambient tem peratures because of heat generated by friction. Temperatures up to 160F (71C) are considered normal for bearings, and they can operate safely to at least 180F (82C).

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 temperatures 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 the Maintenance and Repair Manual). Bearing overheating can also be caused by shaft misalignment and/or excessive vibration.

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.

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.

OPERATION PAGE C - 3

Page 17

PA SERIES

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. Shut down the engine and discon nect the positive battery cable to en sure that the pump will remain inop erative.

3. Allow the pump to completely cool if overheated.

4. Check the temperature and make sure pump is cool before opening any covers, plates, or plugs.

5. Close the suction and discharge valves.

6. Vent the pump slowly and cautiously.

7. Drain the pump.

OM-06261

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO PRIME

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE

Discharge check valve contami nated, damaged, or unable to seat.

Air compressor head 180 out. Consult factory.

Air leak in suction line. Correct leak.

Lining of suction hose collapsed. Replace suction hose.

Leaking or worn seal or pump gasket. Check pump vacuum. Replace

Suction lift or discharge head too high. Check piping installation and install

Air compressor damaged or belts bro ken.

Strainer clogged. Check strainer and clean if neces

Eductor clogged. Check and clean eductor.

Air leak in suction line. Correct leak.

Lining of suction hose collapsed. Replace suction hose.

Leaking or worn seal or pump gasket. Check pump vacuum. Replace

Clean or replace check valve.

leaking or worn seal or gasket.

bypass line if needed. See INSTAL LATION.

Check and repair/replace.

sary.

leaking or worn seal or gasket.

TROUBLESHOOTING PAGE D - 1

Page 18

OM-06261

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PA SERIES

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE (cont.)

PUMP REQUIRES TOO MUCH POWER

Strainer clogged.

Discharge check valve clogged.

Suction intake not submerged at proper level or sump too small.

Impeller or other wearing parts worn or damaged.

Discharge head too high.

Suction lift too high.

Pump speed too slow. Check engine output; consult en

Belt or flexible coupling broken. Check and replace as necessary.

Pump speed too high. Check engine output.

Extreme ambient temperature. Reduce pump output.

Discharge head too low. Fuel filter clogged. Check & replace often in extreme

Check strainer and clean if neces sary.

Check and clean check valve.

Check installation and correct submergence as needed.

Replace worn or damaged parts. Check that impeller is properly centered and rotates freely.

Free impeller of debris.Impeller clogged.

Install bypass line.

Measure lift w/vacuum gauge. Re duce lift and/or friction losses in suction line.

gine operation manual.

Adjust discharge valve.

operating conditions.

PUMP CLOGS FREQUENTLY

EXCESSIVE NOISE

Dilute if possible.Liquid solution too thick.

Check and replace as required.Fuel contaminated.

Pump or jack shaft bearing(s) frozen. Disassemble, check and replace

bearing(s) as required..

Discharge flow too slow.

Suction check valve or foot valve clogged or binding.

Liquid solution too thick.

Cavitation in pump. Reduce suction lift and/or friction

Pumping entrained air.

Impeller clogged or damaged.

Open discharge valve fully to in crease flow rate, and run engine at maximum governed speed.

Clean valve.

Dilute if possible.

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.Pump or drive not securely mounted.

Clean out debris; replace damaged parts.

TROUBLESHOOTINGPAGE D - 2

Page 19

PA SERIES

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

OM-06261

BEARINGS RUN TOO HOT

Bearing temperature is high, but within limits.

Low or incorrect lubricant.

Suction and discharge lines not prop erly supported.

Excessive tension on drive belt.

PREVENTIVE MAINTENANCE

Since pump applications are seldom identical, and pump wear is directly affected by such things as the abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however, following a routine pre ventive maintenance schedule will help assure trouble‐free performance and long life from your Gorman‐Rupp pump. For specific questions con cerning your application, contact your Gorman‐ Rupp distributor or the Gorman‐Rupp Company.

Record keeping is an essential component of a good preventive maintenance program. Changes in suction and discharge gauge readings (if so

Check bearing temperature regu larly to monitor any increase.

Check for proper type and level of lubricant.

Check piping installation for proper support.

Align drive properly.Drive misaligned.

Check belt tension. Adjust as required.

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.

TROUBLESHOOTING PAGE D - 3

Page 20

OM-06261

PA SERIES

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

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.

TROUBLESHOOTINGPAGE D - 4

Page 21

PA SERIES

OM-06261

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 PA12A60-B-6068H-ESP

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.

Contact the Gorman‐Rupp Company to verify per formance or part numbers.

Pump speed and operating condition

If your pump serial number is followed by an “N”, your pump is NOT a standard production model.

MAINTENANCE & REPAIR PAGE E - 1

points must be within the continuous per formance range shown on the curve.

Page 22

OM-06261 PA SERIES

PARTS PAGE

ILLUSTRATION

Figure 1. Pump Model PA12A60-B-6068H-ESP

MAINTENANCE & REPAIRPAGE E - 2

Page 23

PA SERIES

OM-06261

PARTS LIST

Pump Model PA12A60-B-6068H-ESP

(From S/N 1501367 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 NO.

2 J.D. 6068H ENGINE 29224-332 --- 1 4 BASE ASSEMBLY 41565-593 24150 1

7 6” DIA. x 48” LG. FLEX DUCTING 18533-171 --- 1 10 HOSE BARB FITTING 26523-386 --- 2 13 FLAT WASHER K12 15991 18 14 HEX NUT D12 15991 22 15 FUEL TANK ASSEMBLY 46711-094 24150 1 16 GASKET 4991G 18000 2 17 HEX HD CAPSCREW B1210 15991 20 18 LOCK WASHER J12 15991 20 19 12” SPOOL 46353-844 --- 2 20 LOCK WASHER J14 15991 24 21 HEX HD CAPSCREW B1415 15991 24 22 HEX NUT D14 15991 24 28 ENGINE RAIL ASSEMBLY 41828-015 24150 1 30 CHECK VALVE SUPPORT ASSEMBLY 41881-968 --- 1 31 CONTROL PANEL SUPPORT 34812-001 15120 1 32 CONTROL PANEL 29284-028 --- 1 33 FLAT WASHER K08 15991 10 35 HEX NUT D08 15991 6 37 HALF PIPE COUPLING AES06 15070 4 38 HEX HD CAPSCREW B0808 15991 4 39 FLAT WASHER K10 15991 12 40 HEX HD CAPSCREW B1008 15991 8 41 LOCK WASHER J10 15991 8 42 HEX NUT D10 15991 8 55 PUMP SUPPORT ASSEMBLY 41581-041 --- 1 56 VACUUM HOSE ASSEMBLY 46341-021 --- 1 57 HOSE BARB FITTING 26523-015 --- 2 58 HOSE ASSEMBLY 46341-026 --- 1 62 CONNECTOR 26351-059 --- 1 63 BALL VALVE 26631-054 --- 1 66 AIR CLEANER SUPPLIED W/ENGINE --- 1 69 LOCK WASHER J06 15991 13 70 HEX NUT D06 15991 9 75 HEX HD CAPSCREW B0604 15991 5 78 STRAIGHT PIPE 31418-154 15000 1 79 WEATHER CAP 29334-313 --- 1 80 HOSE BARB FITTING 26523-392 --- 2 81 HOSE CLAMP 26518-724 --- 2 84 3/4” I.D. x 54” LG. HOSE 18513-305 --- 1 85 3/8” I.D. x 60” LG. HOSE 18513-302 --- 1 86 3/16” I.D. x 48” LG. HOSE 18513-301 --- 1 91 REDUCER PIPE BUSHING AP0604 14100 1 92 HOSE CLAMP 26518-641 --- 2 99 HEX ADAPTOR 26523-188 --- 1

100 ELBOW 26341-310 --- 1 102 FLANGED CAPSCREW 21643-505 --- 2 103 16/4 x 96” LG. CABLE 188141-147 --- 1 104 SOCKET CONNECTOR 27263-001 --- 1 107 HEX HD CAPSCREW B0615 15991 4

PART NAME

PART NUMBER

MAT'L CODE

QTY

MAINTENANCE & REPAIR PAGE E - 3

Page 24

OM-06261 PA SERIES

ILLUSTRATION

Figure 2. Pump Model PA12A60-B-6068H-ESP (Cont'd)

MAINTENANCE & REPAIRPAGE E - 4

Page 25

PA SERIES

OM-06261

PARTS LIST

Pump Model PA12A60-B-6068H-ESP

(From S/N 1501367 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 NO.

5 5/8” I.D. x 18” LG. HOSE 18513-304 --- 1 8 4” FLEX EXHAUSTE TUBE x 48” LG. 29334-409 --- 1

9 4” BAND CLAMP 29334-283 --- 1 11 HEX JAM NUT AT12 15991 2 12 THREADED ROD 31345-090 15000 2 13 FLAT WASHER K12 15991 18 14 HEX NUT D12 15991 22 17 HEX HD CAPSCREW B1210 15991 20 18 LOCK WASHER J12 15991 20 26 BATTERY BOX ASSEMBLY 42432-003 --- 1 27 BATTERY SEE OPTIONS --- 1 29 ENGINE RAIL ASSEMBLY 41828-016 24150 1 43 REDUCER PIPE BUSHING AP0806 15079 1 44 HOSE BARB FITTING 26523-389 --- 1 45 HOSE BARB FITTING 26523-391 --- 7 59 HOSE CLAMP 26518-642 --- 2 60 POS BATTERY CABLE ASSEMBLY 47311-111 --- 1 61 NEG BATTERY CABLE ASSEMBLY 47311-185 --- 1 65 AIR CLEANER MOUNT PLATE 33541-076 15080 1 67 HEX HD CAPSCREW B0607 15991 8 68 FLAT WASHER K06 15991 8 69 LOCK WASHER J06 15991 13 70 HEX NUT D06 15991 5 71 AIR INTAKE ELBOW SUPPLIED W/ENGINE 1 72 INTAKE TUBE ASSEMBLY 46671-502 24150 1 73 4” EXHAUST ELBOW 31912-042 15000 1 74 MUFFLER MOUNTING BRACKET 29334-281 --- 2 76 MUFFLER 29334-109 --- 1 77 U‐BOLT 29334-268 --- 4 80 HOSE BARB FITTING 26523-392 --- 2 82 FLANGED CAPSCREW 21634-515 --- 5 83 FLANGED HEX NUT 21765-314 --- 5 87 5/8” I.D. x 66” LG. HOSE 18513-304 --- 1 88 T‐BOLT CLAMP SUPPLIED W/ENGINE 3 89 3/8” I.D. x 36” LG. HOSE 18513-302 --- 1 90 5/8” I.D. x 36” LG. HOSE 18513-304 --- 1

105 HOSE CLAMP 26518-666 --- 5

PART NAME

PART NUMBER

MAT'L CODE

QTY

MAINTENANCE & REPAIR PAGE E - 5

Page 26

OM-06261 PA SERIES

ILLUSTRATION

Figure 3. Pump Model PA12A60-B-6068H-ESP (Cont'd)

MAINTENANCE & REPAIRPAGE E - 6

Page 27

PA SERIES

OM-06261

PARTS LIST

Pump Model PA12A60-B-6068H-ESP (Cont'd)

(From S/N 1501367 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 NO.

1 PUMP MODEL ASSEMBLY 46133-726 --- 1

8 4” FLEX EXHAUSTE TUBE x 48” LG. 29334-409 --- 1

9 4” BAND CLAMP 29334-283 --- 2 23 BUSHING 24131-531 --- 1 24 SPROCKET 24271-001 --- 1 25 PUMP DRIVE BELT 24154-001 --- 1 33 FLAT WASHER K08 15991 10 34 LOCK WASHER J08 15991 2 35 HEX NUT D08 15991 6 36 HEX HD CAPSCREW B0804 15991 2 46 PIPE TEE U08 11999 1 47 PRESSURE RELIEF VALVE 26662-028 --- 1 48 PIPE COUPLING AE12 15079 1 49 REDUCER PIPE BUSHING AP1208 15079 1 50 VENTURI 26817-001 --- 1 51 VENTURI MUFFLER 29334-091 --- 1 52 STREET ELBOW AGS16 11999 1 53 PIPE COUPLING AE16 15079 1 54 CONNECTOR 26351-065 --- 1 55 PUMP SUPPORT ASSEMBLY 41581-041 --- 1 56 VACUUM HOSE ASSEMBLY 46341-021 --- 1 57 HOSE BARB FITTING 26523-015 --- 2 58 HOSE ASSEMBLY 46341-026 --- 1 63 BALL VALVE 26631-054 --- 2 64 ENGINE DRIVE ASSEMBLY 44162-179 --- 1 74 MUFFLER MOUNTING BRACKET 29334-281 --- 2 76 MUFFLER 29334-109 --- 1 93 EXHAUST BLANKET 29334-282 --- 1 94 EXHAUST BLANKET 29334-292 --- 1 95 REDUCER BUSHING AP2416 11999 1 96 PIPE NIPPLE T1624 15079 1

106 4” STRAIGHT PIPE 31418-156 15000 1

PART NAME

PART NUMBER

MAT'L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 7

Page 28

OM-06261 PA SERIES

ILLUSTRATION

Figure 4. Pump Model PA12A60-B-6068H-ESP (Cont'd)

MAINTENANCE & REPAIRPAGE E - 8

Page 29

PA SERIES

OM-06261

PARTS LIST

Pump Model PA12A60-B-6068H-ESP (Cont'd)

(From S/N 1501367 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 NO.

3 BAIL/GUARD ASSY 42358-002 --- 1

4 BASE ASSEMBLY 41565-593 24150 1

6 ENCLOSURE ASSEMBLY 42164-028 --- 1 45 HOSE BARB FITTING 26523-391 --- 7 60 POS BATTERY CABLE ASSEMBLY 47311-111 --- 1 61 NEG BATTERY CABLE ASSEMBLY 47311-185 --- 1 62 CONNECTOR 26351-059 --- 1 96 PIPE NIPPLE T1624 15079 1 97 ELBOW R16 11999 1 98 REDUCER BUSHING AP1608 11999 1

101 PLUG CONNECTOR 27261-301 --- 1 103 16/4 x 96” LG. CABLE 188141-147 --- 1 104 SOCKET CONNECTOR 27263-001 --- 1

PART NAME

NOT SHOWN:

INSTRUCTION DECAL 38818-144 --- 1 GUARD WARNING STICKER 38816-063 --- 1 ACCESS PANEL DECAL 38817-089 --- 1 WARNING DECAL 38816-203 --- 2 WARNING DECAL 38816-345 --- 2 OIL DRAIN LABEL 38816-323 --- 1 RADIATOR DRAIN LABEL 38816-322 --- 1 FUEL TANK DRAIN LABEL 38816-321 --- 1 PUMP DRAIN LABEL 38816-320 --- 1 NAME PLATE 38818-127 13000 1 DRIVE SCREW BM#04-03 17000 4 LUBRICATION DECAL 38816-074 --- 1 G‐R DECAL GR-03 --- 1 DISCHARGE STICKER 6588BJ --- 1 SUCTION STICKER 6588AG --- 1 ENGINE STARTUP TAG 38816-269 --- 1 OIL LEVEL DECAL 38816-123 --- 2 PRIME AIRE DECAL 38812-078 --- 2 BATTERY TAG 38818-506 --- 1 WARNING DECAL 2613FE --- 2 CAUTION DECAL 2613FJ --- 1 LEVEL CONTROL LABEL 38816-332 --- 1 38' FOAM TAPE 18668-001 --- 1 FLOAT SWITCH KIT 48312-980 --- 1 INSTRUCTION DECAL 38817-024 --- 1 SILENT UNIT DECAL KIT 48154-812 --- 1

PART NUMBER

MAT'L CODE

QTY

MAINTENANCE & REPAIR PAGE E - 9

Page 30

OM-06261 PA SERIES

ILLUSTRATION

Figure 5. 46133-726 Pump Model Assembly

MAINTENANCE & REPAIRPAGE E - 10

Page 31

PA SERIES

OM-06261

PARTS LIST

46133-726 Pump Model Assembly

ITEM NO.

1 PUMP ASSMEBLY 612M60-B --- 1

2 HEX HD CAPSCREW B1416 15991 12

3 LOCKWASHER J14 15991 24

4 HEX NUT D14 15991 24

5 12” CHECK VALVE 26642-128 --- 1

6 FLANGE GASKET 4991G 18000 1

7 PIPE PLUG P04 15079 1

8 12” SPOOL 38642-622 10000 1

9 BLIND FLANGE GASKET 25113-034 --- 1 10 4” BLIND FLANGE ASSY 42111-358 --- 1 11 LOCKWASHER J10 15991 8 12 HEX HD CAPSCREW B1007 15991 8 13 HEX HD CAPSCREW B1413 15991 12 14 NAME PLATE 38818-127 13000 REF 15 DRIVE SCREW BM#04-03 17000 REF 16 PRIMING CHAMBER KIT 48275-006 --- 1

PART NAME

-FLAPPER 26688-003 --- 1

-COVER GASKET 26688-004 --- 1

PART NUMBER

MAT'L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 11

Page 32

OM-06261 PA SERIES

ILLUSTRATION

SEE FIG. 7

Figure 6. 612M60-B Pump Model Assembly

MAINTENANCE & REPAIRPAGE E - 12

Page 33

PA SERIES

PARTS LIST

612M60-B Pump Model Assembly

ITEM

PART NAME PART

NO.

1 PUMP CASING 38219-305 10010 1 2 IMP/WEAR RING ASSY 46151-022 24110 1

-IMPELLER NOT AVAILABLE 1

-WEAR RING 4182A 11030 1

3 SEAL ASSEMBLY 46512-109 --- 1 4 STUD C1013 15991 3 5 STUD C1011 15991 9

6 GASKET 38674-434 18000 1 7 SOCKET HD CAPSCREW BD1206 15990 1 8 IMPELLER WASHER 31167-022 15030 1

9 ROLL PIN S2197 --- 1 10 HOSE CLAMP 26518-642 --- 2 11 MALE CONNECTOR 26523-409 --- 2 12 BOTTLE OILER BRKT 41881-811 24150 1 13 FLAT WASHER K10 15991 1 14 LOCK WASHER J10 15991 22 15 HEX NUT D10 15991 24 16 MACHINE SCREW X0405 15991 2 17 LOCK WASHER J04 15991 2 18 SIGHT GAUGE S1471 --- 2 19 VENTE PIPE PLUG 38649-009 15079 1 20 PEDESTAL 38257-520 10000 1 21 PIPE PLUG P04 15079 1 22 HEX HD CAPSCREW B0605 15991 12 23 OIL SEAL 25258-845 --- 3 24 BEARING CAP 38322-429 10000 1 25 O‐RING 25152-249 --- 1 26 BEARING ADJ SHIM SET 48261-055 --- 1 27 BEARING LOCKNUT 23962-015 --- 1 28 BEARING LOCK WASHER 23962-515 --- 1 29 BEARING CAP GASKET 4184G 18000 1 30 BALL BEARING 23413-015 --- 2

31 SHAFT KEY N1016 15990 1 32 IMPELLER SHAFT 38512-522 17040 1 33 IMPELLER KEY N0809 15990 1

NUMBER

MAT'L CODE

QTY ITEM

NO.

34 35 BEARING CAP 38322-425 10010 1 36 AIR VENT S1730 --- 1

37 38 PIPE COUPLING AE06 15079 1 39 PIPE NIPPLE T0608 15079 1 40 SEAL PLATE 38272-717 10000 1 41 PIPE PLUG P12 15079 2 42 IMP ADJ SHIM SET 48261-033 --- REF 43 PIPE PLUG P06 15079 2 44 CASING DRAIN PLUG P24 10009 1 45 SEAL PLATE COVER 38242-708 10000 1 46 HEX HD CAPSCREW B0503-1/2 15991 6 47 LOCK WASHER J05 15991 6 48 .38” ID X 11” LG HOSE 18513-054 --- 1 49 SUCTION HEAD 4180 10010 1 50 SPIRAL PIN 21137-123 --- 3

51 WEAR RING 4181A 140001 1 52 GASKET 4180G 18000 1 53 STUD C1009 15991 12 54 BOTTLE OILER 26713-004 --- 1

55 SNAP RING 24124-057 --- 1 56 DRIVE SCREW BM#04-03 17000 4 57 NAME PLATE 38818-127 13000 1

NOT SHOWN:

OM-06261

PART NAME PART

NUMBER

ROLLER BEARING 23528-005 --- 1

BEARING CAP O‐RING 25151-266 --- 1

SUCTION STICKER 6588AG --- 1 ROTATION DECAL 2613M --- 1 STRAINER 46641-012 24150 1 G‐R DECAL GR-06 --- 1 WARNING DECAL 2613FE --- 1 PAPER INSTR TAG 38817-024 --- 1 LUBRICATION DECAL 38816-079 --- 2 PAPER INSTR TAG 38817-011 --- 1 OIL LEVEL DECAL 38816-123 --- 1 DISCHARGESTICKER 6588BJ --- 1

MAT'L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 13

Page 34

OM-06261 PA SERIES

ILLUSTRATION

SEE FIG. 6

Figure 7. 612M60-B Pump Model Assembly (Cont'd)

MAINTENANCE & REPAIRPAGE E - 14

Page 35

PA SERIES

PARTS LIST

612M60-B Pump Model Assembly (Cont'd)

ITEM

PART NAME PART

NO.

1 PUMP CASING 38219-305 10010 1

2 IMP/WEAR RING ASSY 46151-022 24110 1

-IMPELLER NOT AVAILABLE 1

-WEAR RING 4182A 11030 1

3 SEAL ASSEMBLY 46512-109 --- 1

4 STUD C1013 15991 3

5 STUD C1011 15991 9

6 GASKET 38674-434 18000 1

7 SOCKET HD CAPSCREW BD1206 15990 1

8 IMPELLER WASHER 31167-022 15030 1

31 SHAFT KEY N1016 15990 1 32 IMPELLER SHAFT 38512-522 17040 1 33 IMPELLER KEY N0809 15990 1

NUMBER

MAT'L CODE

QTY ITEM

NO.

34 35 BEARING CAP 38322-425 10010 1 36 AIR VENT S1730 --- 1

51 WEAR RING 4181A 140001 1 52 GASKET 4180G 18000 1 53 STUD C1009 15991 12 54 BOTTLE OILER 26713-004 --- 1

55 SNAP RING 24124-057 --- 1 56 DRIVE SCREW BM#04-03 17000 4 57 NAME PLATE 38818-127 13000 1

NOT SHOWN:

OM-06261

PART NAME PART

NUMBER

ROLLER BEARING 23528-005 --- 1

BEARING CAP O‐RING 25151-266 --- 1

MAT'L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 15

Page 36

OM-06261 PA SERIES

ILLUSTRATION

Figure 8. 48275-006 Priming Chamber Kit

ITEM NO.

1 BALL VALVE 26631-054 --- 1 2 STREET ELBOW RS16 11999 1 3 PRIMING CHAMBER ASSEMBLY 46112-709 --- 1 4 HEX NUT D08 15991 4 5 LOCK WASHER J08 15991 4 6 STUD C0809 15991 4 7 BAFFLE 31113-011 17000 1 8 GASKET 38687-053 19060 1

INDICATES PARTS RECOMMENDED FOR STOCK

PART NAME

PART NUMBER

MAT'L CODE

MAINTENANCE & REPAIRPAGE E - 16

QTY

Page 37

PA SERIES

OM-06261

ILLUSTRATION

Figure 9. 46112-709 Priming Chamber Assembly

ITEM NO.

1 PRIMING VALVE 26664-007 --- 1

2 HEX HD CAPSCREW B0806 15991 8 3 LOCKWASHER J08 15991 8 4 PRIMING VALVE GASKET 38683-657 19060 1 5 PRIMING CHAMBER 38343-020 10000 1 6 STRAINER ASSY 46641-222 17000 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 17

PART NAME

-ORIFICE BUTTON 26688-021 --- REF

PART NUMBER

MAT'L CODE

QTY

Page 38

OM-06261 PA SERIES

ILLUSTRATION

Figure 10. 44162-179 Engine Drive Assembly

ITEM NO.

1 RETAINING RING 24121-075 --- 1 2 RETAINING RING S215 --- 4 3 BALL BEARING 23282-012 --- 1 4 OUTPUT SHAFT 38512-051 1706H 1 5 KEY N0612 15990 1 6 BEARING HOUSING 38251-001 11010 1 7 SOCKET HEAD CAPSCREW BD0606-1/2 15991 8 8 LOCK WASHER J06 15991 8

9 ALLEN HEAD SETSCREW GA0703-1/2 15990 REF 10 BUSHING 24131-496 --- 1 11 COUPLING 24391-103 --- 1 12 BALL BEARING 23431-012 --- 1 13 KEY N0807 15990 1 14 SPROCKET 24271-004 --- 1 15 TAPER LOCK BUSHING 24131-526 --- 1

INDICATES PARTS RECOMMENDED FOR STOCK

PART NAME

PART NUMBER

MAT'L CODE

MAINTENANCE & REPAIRPAGE E - 18

QTY

Page 39

PA SERIES

OM-06261

ILLUSTRATION

IMPELLER

WEAR RING

NOTE: UNLESS OTHERWISE SPECIFIED,

MACHINED SURFACES TO BE 125 RMS.

Figure 11. Impeller Assembly Machining Tolerances

MAINTENANCE & REPAIR PAGE E - 19

Page 40

PA SERIESOM-06261

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Review all SAFETY information in Section A.

Follow the instructions on all tags, label and de cals 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 illustrations (see Figures 1 through 11) and the accompanying parts list.

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 service the pump, shut down the engine and take precautions to ensure that the pump will remain inoperative. Close all valves in the suction and discharge lines.

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 may be used to handle mate rials which could cause illness through direct exposure or emitted fumes. Wear adequate protective clothing when working on the pump or piping.

No instructions are provided in this manual for disassembly and/or removal of the pump enclosure. If removal of the enclo sure is required for pump service, be sure to use safe shop practices so as not to en danger personnel, and use caution to pre vent damage to the enclosure.

For engine disassembly and repair, consult the lit erature supplied with the engine, or contact your local engine representative.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Shut down the engine and discon nect the postiive battery cable to ensure that the pump will remain inoperative.

MAINTENANCE & REPAIRPAGE E - 20

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OM-06261PA SERIES

Priming Chamber Removal And Disassembly

(Figure 8)

Disconnect both the suction piping and the air dis charge tubing from the priming valve assembly (3). Support the priming valve assembly using a sling and a suitable lifting device. Disengage the hard ware (4 and 5) and separate the priming valve as sembly, gasket (8) and baffle (7) from the spool (8, Figure 5).

(Figure 9)

Remove the hardware (2 and 3) securing the prim ing valve (1) to the priming chamber (6). Carefully lift the valve components from the priming cham ber. Remove the gasket (4) and clean the mating surfaces.

If the priming valve float is stuck or the strainer (6) is clogged, it can usually be cleaned without further disassembly.

The only serviceable part of the priming valve is the orifice button (not shown). If liquid continues to by pass through the priming chamber after adjusting the orifice button (see Priming Chamber Reas sembly and Installation for adjustment), the but ton may require replacement. To replace the orifice button, remove one of the “e‐clips” from the pivot pin closest to the orifice button and remove the piv ot pin. This will allow the linkage to be raised high enough to access the orifice button.

Suction Head And Wear Ring Removal

(Figure 6)

Unless replacment of the spool gasket (6, Figure 5) is required, the suction head (49) may be removed without separating it from the spool. However, if the spool gasket must be replaced, support the spool with a suitable hoist and sling, remove the hard ware (3 and 4, Figure 5) and separate the suction spool and gasket from the suction head.

Remove the hardware securing the suction head (49) to the base. Support the suction head using a suitable hoist and sling. Disengage the hardware (14 and 15) and separate the suction head and wear ring (51) from the pump casing. Remove the suction head gasket (52) and clean the mating sur faces.

Inspect the wear ring for excessive wear or scoring. The wear ring is a press fit into the suction head and is additionally secured with the spiral pins (50). If replacement is required, use a small bit to drill three holes horizontally, 180 apart, through the wear ring between each of the spiral pins. Use a chisel or other suitable tool to complete the cuts through the wear ring. Use caution not to damage the suction head bore. Remove the wear ring sec tions from the suction head. Pull the spiral pins from the suction head.

If no further disassembly is required, see Suction Head and Wear Ring Installation.

Remove the hex nut and lockwasher securing the orifice button to the linkage bar and unscrew the orifice button from the linkage bar.

Discharge Check Valve Removal and Disassembly

(Figure 5)

Support the discharge check valve assembly (5) using a sling and a suitable lifting device. Remove the hardware (3 and 4) and separate the discharge check valve assembly and gasket (6) from the pump assembly (1).

The flapper and cover gasket are the only service able parts of the check valve. If the flapper requires replacement, remove the hardware securing the cover. Separate the valve cap and remove the flap per and gasket.

MAINTENANCE & REPAIR PAGE E - 21

Pump Casing Removal

(Figure 6)

Support the pump casing using a suitable hoist and sling.

Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or dam age to equipment. If slings or chains are used to move the pump or components, make sure that the load is balanced; otherwise serious personal injury or death could result. Suction and dis charge hoses and piping must be re moved from the pump before lifting.

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PA SERIESOM-06261

NOTE

When removing the pump casing, use a wire to se cure the assembled bottle oiler (54, Figure 7) and bracket (12, Figure 7) above the level of the oil in the seal cavity. This will prevent oil from leaking out of the oiler during disassembly.

If the impeller (2) is to be removed, the impeller screw (7) should be loosened before removing the pump casing. Immobilize the impeller by inserting a wood block through the pump discharge and into the impeller vanes. Remove the impeller screw and washer (8). Remove the wood block from the pump discharge.

Remove the hardware (13, 14 and 15, Figure 7) se curing the pump casing and bottle oiler bracket to the pedestal (20, Figure 7).

Pull the pump casing straight away from the ped estal to prevent binding on the impeller. Remove the casing gasket (6) and clean the contacting sur faces.

Impeller Removal

(Figure 6)

Before removing the impeller, loosen the hose clamp (10, Figure 7) and remove the hose (48, Fig ure 7) from the lower connector (11, Figure 7). Re move the bottle oiler and bracket assembly and drain the seal cavity. This will prevent the oil in the oiler from escaping when the impeller is removed.

With the impeller screw and washer removed as described in Pump Casing Removal, insert a pair of wedges 180 apart between the impeller and the seal plate (40, Figure 7). Tap the wedges alternate ly to force the impeller off the shaft. Retain the im peller key (33, Figure 7).

to properly install the new wear ring and machine and balance the impeller assem bly can result in premature shaft, seal or bearing failure, or other damage to the pump.

To replace the wear ring, grind off the three weld spots securing the wear ring to the impeller. Use caution not to damage the impeller. Pry or carefully grind the wear ring off the impeller.

Seal Removal

(Figures 6 and 13)

This pump is designed with two seals; a primary mechanical seal (3) located directly behind the im peller and a secondary oil seal (23, Figure 7) lo cated in the seal plate cover (45, Figure 7). If the liq uid being pumped leaks past the oil seal, both seals should be replaced immediately.

Remove the impeller shims (42). Tie and tag the shims for ease of reassembly. Remove the seal spring. Slide the rotating portion of the seal (con sisting of the shaft sleeve and O‐ring, bellows and retainer, and rotating element) off the shaft as a unit.

Apply oil to the sleeve and work it up under the rub ber bellows. Slide the bellows and retainer off the sleeve. Remove the sleeve O‐ring.

Slide the seal plate and remaining seal compo nents off the shaft. Disengage the hardware (46 and 47, Figure 7) and separate the seal plate cover and O‐ring (37, Figure 7) from the seal plate.

Use a suitably sized dowel to press the stationary portion of the seal out of the seal plate. Press the oil seal out of the seal plate cover.

If no further disassembly is required, refer to Seal Installation.

Inspect the impeller wear ring for excessive wear or scoring.

Proper replacement of the impeller wear ring requires machining and dynamic bal ancing the impeller assembly after the new wear ring is welded to the impeller. Failure

Pedestal Assembly Removal

(Figure 2)

Disassembly of the pedestal requires separation of the pump and driver. Disengage the hardware se curing the belt guard to the lifting bail and remove the guard.

See Figure 1 and loosen, but do not remove, the hardware (13, 14, 17 and 18) securing the pump support assembly (55) to the base.

MAINTENANCE & REPAIRPAGE E - 22

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OM-06261PA SERIES

Loosen the outer hardware (13 and 14) on the threaded rods (22). Unscrew the jam nuts (11) until they engage the adjusting brackets. Continue to unscrew the jam nuts in an alternating sequence to “push” the pump assembly (1, Figure 3) and pump support assembly toward the discharge check valve. When sufficient clearance is obtained, re move the pump drive belt (25, Figure 3) from the sprocket and drive assembly (24 and 64, Figure 3).

Remove the hardware (14, 17 and 18) securing the pedestal to the pump support assembly. Use a suitable hoist and sling to remove the pedestal as sembly.

Pump Shaft and Bearing Removal and Disassembly

(Figure 3)

When the pump is properly operated and main tained, the pedestal should not require disassem bly. Disassemble the shaft and bearings only when there is evidence of wear or damage.

seal (23). Remove the bearing shims (26). Press the oil seal from the bearing cap.

Straighten the tab on the washer (28) securing the bearing lock nut (27). Use a spanner wrench to re move the lock nut. Remove the tab washer.

Disengage the capscrews (22) and remove the in board bearing cap (35) and oil seal (23). Remove the bearing cap gasket (29) and clean the mating surfaces. Press the oil seal from the bearing cap.

Place a block of wood against the impeller end of the shaft (32) and tap the shaft and assembled bearings (30 and 34) out of the pedestal.

After removing the shaft and bearings, clean and inspect the bearings in place as described in Bearing Cleaning And Inspection.

The bearing tolerances provide a tight press fit onto the shaft and a snug slip fit into the pedestal. Replace the bearings, shaft, or pedestal if the proper bearing fit is not achieved.

If bearing replacement is required, remove the re taining ring (55) and use a bearing puller to remove the inboard and outboard bearings from the shaft.

Shaft and bearing disassembly in the field is not recommended. These operations should be performed only in a properly equipped shop by qualified personnel.

The sprocket and bushing (23 and 24) must be re moved from the drive end of the shaft before disas sembling the pedestal (20, Figure 7). To remove the sprocket, remove the screws securing the sprocket to the hub, then reinstall the screws in the tapped holes in the sprocket. Tighten the screws in an alternating sequence to press against the hub shoulder and “jack” the sprocket off the hub.

With the sprocket removed, the hub can be pulled or pried off the shaft. Remove the shaft key.

(Figure 7)

Before disassembling the pedestal, remove the pedestal drain plug (21) and drain the oil from the pedestal. Clean and reinstall the pipe plug.

Engine Drive Disassembly

(Figure 10)

This engine is equipped with a jackshaft type drive assembly as shown in Figure 10.

To remove the sprocket (14), remove the caps crews securing the taperlock bushing (15) to the sprocket. Reinstall the capscrews in the tapped holes in the bushing and use a suitable puller to pull the bushing and sprocket off the output shaft (4). Retain the key (13).

Further disassembly requires separating the re maining drive components from the engine. Re move the hardware (not shown, supplied with the engine) securing the bearing housing (16) to the engine. Pull the shaft and bearing housing straight away from the engine. The rubber drive element of the coupling (11) will separate from the drive ring secured to the engine flywheel with the hardware (7 and 8). Disengage the hardware to remove the drive ring from the flywheel.

Disengage the capscrews (22) and and remove the outboard bearing cap (24), O‐ring (25) and oil

MAINTENANCE & REPAIR PAGE E - 23

To remove the flexible portion of the coupling from the output shaft, unscrew the two allen head set

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PA SERIESOM-06261

screws (9) from the bushing (10). Screw one of the setscrews into the hole on the circumference of the bushing to separate the coupling and bushing. When the parts separate, remove the bushing, and slide the coupling off the shaft. Remove the key (5).

When properly operated and maintained, the out put shaft and bearings should not require disas sembly. 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.

To remove the shaft and bearings (3 and 12), use snap ring pliers to remove the retaining ring (1). Use a wood block to tap the shaft and bearings from the bearing housing from the driven end.

Bearing Cleaning And Inspection

(Figure 7)

Clean the pedestal, bearing housing, shafts and all component 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.

After removing the shaft and bearings, clean and inspect the bearings in place as described in Bearing Cleaning And Inspection.

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 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.

If bearing replacement is required, remove the out board retaining rings (2) and use a bearing puller to remove the inboard (3) and outboard (12) bearings from the shaft.

Bearings must be kept free of all dirt and 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.

Rotate the bearings by hand to check for rough ness or binding. Inspect the bearing balls (or roll ers) on open‐type bearings. If rotation is rough or the balls or rollers are discolored, replace the bear ings.

Engine Drive Reassembly

(Figure 10)

Inspect the output shaft for distortion, nicks, scratches, damaged keyways or galling on the bearing seating surfaces. Dress small nicks and burrs with a fine file or emery cloth. Replace the shaft if defective.

If removed, install the inboard bearing retaining rings (2) on the output shaft (4).

It is not necessary to remove the inboard bearing retaining rings unless replacement is required. Use snap ring pliers to remove the retaining rings as required.

To prevent damage during removal from

MAINTENANCE & REPAIRPAGE E - 24

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OM-06261PA 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.

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.

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. This should be done quickly, in one con tinuous motion, to prevent the bearings from cool ing and sticking on the shaft.

Use caution when handling hot bearings to prevent burns.

After the bearings have been installed and allowed to cool, check to ensure that they have not moved in shrinking. If movement has occurred, use a suit ably sized sleeve and a press to reposition the bearings.

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.

Slide the shaft and assembled bearings into the bearing housing until the outboard bearing is fully seated against the bearing housing shoulder.

Secure the shaft and bearings in the bearing hous ing with the bearing retaining ring (1).

Install the key (5) in the output shaft keyway. Posi tion the flexible portion of the coupling assembly (3) on the shaft as shown in Figure 9.

NOTE

The flexible portion of the coupling must be proper ly positioned on the shaft. The heads of the caps crews in the center of the coupling must be posi tioned toward the drive end of the shaft.

Align the keyway in the bushing (10) with the shaft key, and slide the bushing onto the shaft. Rotate the flexible portion of the coupling until the tapped holes for the two setscrews align with those in the bushing and install the setscrews. Position the coupling to the dimension shown in Figure 10.

Make certain that the flexible portion of the coupling is mounted as shown in Figure 9. The end of the shaft must protrude 1.06 to

1.19 inches (26,9 to 30,2 mm) from the face of the bushing. This dimension is critical. If the coupling is not properly positioned on the shaft, the coupling parts may not ful ly engage, or a pre‐load condition can cause premature bearing failure.

With the flexible portion of the coupling and the bushing properly positioned on the shaft, tighten the two setscrews in an alternating sequence until the bushing and coupling are fully secured. Torque the setscrews to 23 ft. lbs. (280 in. lbs. or 3,2 m. kg.) maximum.

Position the key (13) in the shaft keyway. Position the drive sprocket over the shaft. Align the keyway in the taperlock bushing (15) with the shaft key and slide the bushing onto the shaft. Align the holes in the bushing with those in the sprocket, and install the bushing capscrews.

Position the sprocket on the shaft to the dimension shown in Figure 9 and tighten the bushing caps

When installing the shaft and bearings into the bearing bore, push against the outer race. Never hit the balls or ball cage.

MAINTENANCE & REPAIR PAGE E - 25

crews in an alternating sequence until the bushing and coupling are fully secured. Torque the set screws to 60 ft. lbs. (720 in. lbs. or 8.3 m. kg.).

Page 46

If the complete coupling assembly is being re placed, apply `Loctite Retaining Compound No. 242' or equivalent compound to the threads of the hardware (7and 9), and secure the outer ring of the coupling to the engine flywheel by torquing the hardware to 45 ft. lbs. (540 in. lbs. or 6,2 m. kg.).

PA SERIESOM-06261

Use caution when handling hot bearings to prevent burns.

Position the drive assembly so the flexible portion of the coupling seats inside the drive ring attached to the engine flywheel. Secure the bearing housing (6) to the engine bellhousing with the previously re moved hardware.

NOTE

To ease installation, lightly lubricate the rubber por tion of the coupling with a non‐petroleum based lubricant such as vegetable oil or glycerin, or a sili con‐based lubricant such as “WD40” or equivalent. Do not use petroleum‐based lubricants, or any oth er substance which may soften or otherwise dam age the rubber.

Pump Shaft and Bearing Reassembly and Installation

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). Position the roller

bearing (34) on the shaft with the internal snap ring positioned away from the impeller end of the shaft. Slide the roller bearing onto the shaft until fully seated against the shaft shoulder. This should be done quickly, in one continuous motion, to prevent the bearings from cooling and sticking on the shaft.

After the bearing has been installed and allowed to cool, check to ensure that it has not moved away from the shaft shoulder in shrinking. If movement has occurred, use a suitably sized sleeve and a press to reposition the bearing against the shaft shoulder.

(Figure 7)

Inspect the impeller shaft (32) for distortion, nicks or scratches, or damaged keyways. Dress small nicks and burrs with a fine file or emery cloth. Re place the shaft if defective.

Secure the roller bearing on the shaft with the bear ing retaining ring (55).

Slide the heated outboard bearings (30) onto the shaft, one at a time, with the larger inner races of each bearing positioned away from each other as shown in Figure 7.

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.

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

MAINTENANCE & REPAIRPAGE E - 26

Page 47

OM-06261PA SERIES

sleeve and a press to reposition the bearings against the shaft shoulder.

Secure the assembled shaft and bearings by clamping on the surface between the bearings. Use caution not to scratch or mar the part number etched into the shaft in this area. Install the tab washer (28) and bearing lock nut (27). Torque the lock nut to 150 ft. lbs. (1800 in. lbs. or 20,7 m. kg.). Locate the tab on the lockwasher that aligns with a slot in the lock nut, and bend the tab over into the slot.

Slide the shaft and assembled bearings into the pedestal from the drive end until the retaining in board bearing (30) seats against the pedestal bore.

When installing the shaft and bearings into the bearing bore, push against the outer race. Never hit the balls or ball cage.

Position the hub and sprocket to the dimensions shown in Figure 12 and torque the mounting caps crews to 75 ft. lbs. (900 in. lbs. or 10.4 m. kg.)

Figure 12. Hub and Sprocket Installation

Press the oil seal (23) into the bearing cap (24) with the lip positioned as shown in Figure 7. Lubricate and install a new bearing cap O‐ring (25) and se cure the bearing cap with the capscrews (22). Use caution not to cut or roll the lip of the oil seal when installing the bearing cap.

Press the oil seal (23) into the bearing cap (35) with the lip positioned as shown in Figure 6. Replace the bearing cap gasket (29) and secure the bear ing cap with the capscrews (22). Use caution not to cut or roll the lip of the oil seal when installing the bearing cap.

Lubricate the pedestal as indicated in LUBRICA TION.

Install the sprocket and hub onto the impeller shaft as follows.

(Figures 7 and 12)

Install the key (31) in the shaft keyway. Align the keyway in the hub with the shaft key, and slide the hub onto the shaft with the shoulder positioned to ward the pedestal.

Slide the sprocket over the hub, align the mounting screw holes and install the mounting screws.

Make certain that the hub and sprocket are mounted as shown in Figure 12. This is critical. If the sprocket is not properly posi tioned on the shaft, the pump drive belt will not be properly aligned, which can cause premature belt or bearing failure.

Pedestal Assembly Installation

(Figure 2)

See Figure 1 and use a suitable hoist and sling to position the pedestal assembly on the pump sup port assembly (55). Secure the pedestal to the pump support assembly using the previously re moved hardware (14, 17 and 18).

Install the pump drive belt (25, Figure 3) after as sembling the remaining pump components.

To adjust the drive belt tension, find the center of the belt span between the pump and engine sprockets. Use a belt deflection gauge to measure deflection across the width of the belt at this point. Use the hardware (13 and 14) to adjust belt tension to 3/8 inch (9,5 mm) of deflection at 30 lbs. (13,6 kg.) of pressure. Do not over‐tighten the drive belt.

MAINTENANCE & REPAIR PAGE E - 27

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PA SERIESOM-06261

Install a new O‐ring (37) in the groove in the seal plate and secure the seal plate cover to the seal plate with the hardware (46 and 47).

The inner edge of the pump pulley must be aligned with the outer edge of the drive pulley in order to prevent side wear of the cog belt.

Do not over‐tighten the drive belt. Over‐ tightening will cause premature belt and/or bearing failure.

After tensioning, secure the pump support assem bly by tightening the jam nuts (11) and remaining hardware (13 and 14).

Seal Reassembly and Installation

(Figures 6, 7 and 13)

Clean the bore of the seal plate (40), the seal plate cover (45) and the shaft (32) with a cloth soaked in fresh cleaning solvent.

Lay the seal plate cover on a flat surface with the inner side facing up. Press the oil seal (23) into the seal plate cover with the lip positioned as shown in Detail E, Figure 7.

Since the mechanical seal is the primary seal in the pump, special consideration should be given to ensure proper installation.

The seal is not normally reused because wear pat terns on the finished faces cannot be realigned 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.

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.

Inspect the seal components for wear, scoring, grooves, and other damage that might cause leak age. Clean and polish the shaft sleeve, or replace it if there are nicks or cuts on either end. If any com ponents are worn, replace the complete seal; never mix old and new seal parts.

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 bel lows and stationary seat O‐rings with water or a very small amount of oil, and apply a drop of light lubricating oil on the finished faces. Assemble the seal as follows, (see Figure 13).

MAINTENANCE & REPAIRPAGE E - 28

Page 49

OM-06261PA SERIES

IMPELLER

SHAFT

KEY

IMPELLER

SHAFT

SLEEVE

IMPELLER

SHIMS

SHAFT

RETAINER

SLEEVE O‐RING

ROTATING

ELEMENT

BELLOWS

SPRING

SEAL PLATE

STATIONARY

ELEMENT

O‐RINGS

STATIONARY

SEAT

Figure 13. Seal Assembly

The standard seal is not designed for oper ation at temperatures above 160F (71C). Do not use at higher operating tempera tures.

Lubricate the outboard stationary seat O‐ring with water or light oil. Position the seal plate with the im peller side up and press the stationary subas sembly (consisting of the stationary seat, O‐rings and stationary element) into the front of the seal plate until it seats squarely against the bore shoul der.

Slide the seal plate and stationary portion of the seal over the shaft until it is seated against the ped estal (20). Be careful not to damage the stationary element or roll or cut the lip of the oil seal (23) on the shaft keyway. Temporarily secure the seal plate to

the pedestal with three 1/2‐inch by 2‐inch long capscrews and nuts (not supplied).

Lubricate the seal sleeve O‐ring with a small amount of light oil and install it in the groove in the I.D. of the sleeve.

Lubricate the seal sleeve with a small amount of light oil and slide the rotating subassembly (con sisting of rotating element, bellows and retainer), onto the sleeve until the rotating element is just flush with the turned end of the sleeve.

Slide the sleeve and subassembled seal onto the shaft until the seal faces contact and the sleeve seats against the shaft shoulder.

Install the seal spring. Lubricate the seal as indi cated in LUBRICATION after the impeller, remain ing pump components, bottle oiler and piping are installed.

MAINTENANCE & REPAIR PAGE E - 29

Page 50

PA SERIESOM-06261

Impeller Installation

(Figure 6)

Proper wear ring replacement requires machining and dynamic balancing the im peller assembly after the wear ring is welded to the impeller. Failure to properly install the wear ring and machine and bal ance the impeller assembly can result in premature shaft, seal or bearing failure, or other damage to the pump.

Inspect the impeller, and replace it if cracked or badly worn. If the impeller wear ring was removed, chill the impeller by refrigeration and use an induc tion heater or oven to heat the new wear ring. Slide the wear ring onto the impeller until fully seated against the shoulder and allow it to cool.

A clearance of approximately .025 to .040 inch (0,63 to 1,04 mm) between the impeller and the seal plate is recommended for maximum pump ef ficiency. Measure this clearance, and add or re move impeller adjusting shims as required.

After the impeller clearance has been set, align the pin (9) in the impeller washer (8) with the hole in the impeller and install the washer. Apply “Never‐ Seez” or equivalent compound on the threads of the impeller capscrew (7). Immobilize the shaft and secure the the impeller by torquing the capscrew to 225 ft. lbs. (2700 in. lbs. or 31 m. kg.).

Pump Casing Installation

(Figure 6)

Install the casing gasket (6) over the pump casing studs (4 and 5). Remove the hardware temporarily securing the seal plate to the pedestal. Use a suit able hoist and sling to position the volute over the impeller and slide the studs through the seal plate and pedestal mounting holes.

The wear ring must seat squarely on the impeller; otherwise binding and/or exces sive wear will occur. Use caution when han dling hot parts to prevent burns.

Spot weld the wear ring to the impeller at three places, equally spaced at the vanes. After welding, machine the wear ring as shown in Figure 11.

The impeller assembly must be machined and balanced as shown in Figure 11. Otherwise, premature shaft, seal or bear ing failure, or other damage to the pump may occur.

After machining, dynamically balance the impeller assembly per plane 1.05 oz./in. (11.7 g/cm).

Install the same thickness of impeller adjusting shims (42) as previously removed. Install the shaft key (33, Figure 7) and press the impeller assembly onto the shaft until fully seated.

(Figure 7)

Install the bottle oiler bracket (12) over the volute studs. Secure the bracket and volute casing with the hardware (13, 14,and 15). Reconnect the hose (48) to the connector (11) in the seal plate and se cure it with the hose clamp (10).

Suction Head And Wear Ring Installation

(Figure 6)

If the wear ring (51) was removed, chill the wear ring by refrigeration and heat the suction head. Slide the wear ring into the suction head until fully seated and allow it to cool.

The wear ring must seat squarely in the suction head; otherwise binding and/or ex cessive wear will occur. Use caution when handling hot parts to prevent burns.

The wear ring is secured to the suction head with the spiral pins (50). Drill three evenly spaced 3/16‐inch diameter x 3/4‐inch deep holes through the wear ring and into the suction head. Tap the spiral pins into the holes until fully seated.

MAINTENANCE & REPAIRPAGE E - 30

Page 51

OM-06261PA SERIES

Install the suction head gasket (52). Position the suction head over the studs (53) and secure it with the hardware (14 and 15).

Turn the impeller shaft by hand and check for any scraping or binding and correct it before putting the pump into service.

Discharge Check Valve Assembly and Installation

(Figure 5)

The flapper and gasket are the only serviceable parts of the check valve. If the flapper requires re placement, remove the hardware securing the cover and gasket. Separate the valve cap and re place the flapper.

Install the valve cap gasket and secure the cap with the previously removed hardware.

Support the discharge check valve assembly (5) using a sling and a suitable lifting device. Secure the discharge check valve assembly and gasket (6) to the pump assembly (1) using the hardware (2, 3 and 4).

See Figure 1, reinstall the spool and gasket (16 and

19) and secure them to the check valve and sup port (30) with the hardware (20, 21 and 22).

Priming Chamber Assembly And Installation

(Figure 9)

Clean and inspect the components of the priming valve (1). Inspect the linkage and ensure the orifice button squarely engages the valve seat. Replace the orifice button if required (see Priming Cham ber Removal and Disassembly for orifice button removal).

threads on the orifice button. When adjustment is complete, install and tighten the lock washer and hex nut securing the orifice button.

Install the strainer (6) and priming valve gasket (4).

Lower the float into the priming chamber (5) and secure the priming valve with the previously re moved hardware (1 and 2).

(Figure 8)

Install the baffle (7) and gasket (8) and use a sling and suitable lifting device to position the priming chamber assembly against the pump suction flange. Secure the priming chamber assembly with the hardware (4 and 5).

Reconnect both the suction piping and the air dis charge tubing to the priming chamber assembly.

LUBRICATION

Seal Assembly

(Figure 7)

Fill the bottle oiler (54) and seal cavity with approxi mately 85 ounces (2,5 liters) of SAE No. 30 non‐de tergent oil. Check the oil level regularly and refill as required.

Bearings

(Figure 7)

The pedestal was fully lubricated when shipped from the factory. Check the oil level regularly through the sight gauges (18) and maintain it at the midpoint of the gauges. When lubrication is re quired, remove the vented plug (19) and add SAE No. 30 non‐detergent oil through the opening. Clean and reinstall the vented plug. Do not over‐lu bricate. Over‐lubrication can cause the bearings to over‐heat, resulting in premature bearing failure.

If the orifice button was removed, screw the new orifice button into the linkage bar until fully seated. Align the hole in the linkage bar with the holes in the bracket and reinstall the pivot pin. Secure the pivot pin with the previously removed “e‐clip”.

Adjust the orifice button seating as necessary by screwing the orifice button into or out of the linkage bar. Proper adjustment is achieved when the ori fice button fully seats against the orifice before the linkage bar on the float bottoms against the

MAINTENANCE & REPAIR PAGE E - 31

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 14 ounces (0,4 liter) of clean oil. Change the oil more frequently if the pump is operated continuously or installed in an environment with rapid temperature change.

NOTE

Page 52

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.

PA SERIESOM-06261

For cold weather operation, consult the factory or a lubricant supplier for the recommended grade of oil.

Engine

Consult the literature supplied with the engine, or contact your local engine representative.

MAINTENANCE & REPAIRPAGE E - 32

Page 53

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