Gorman-Rupp Pumps PA4A60C-B-E30 User Manual

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Page 1

ACDEU

OM−06440−01

April 11, 2011

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

PA SERIES PUMPS

MODELS

PA4A60C-B-E30 460/575/3

PA4A60C−B−(E30)

THE GORMAN-RUPP COMPANY  MANSFIELD, OHIO

www.grpumps.com

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

2011 The Gorman-Rupp Company

Page 2

Gorman-Rupp pump online at

www.grpumps.com

Valid serial number and e-mail address required.

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

Please record your pump model and serial number in the spaces provided below. Your Gorman-Rupp distributor needs this information when you require parts or service.

Pump Model:

Serial Number:

Page 3

TABLE OF CONTENTS

INTRODUCTION PAGE I − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY - SECTION A PAGE A − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION − SECTION B PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Dimensions PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREINSTALLATION INSPECTION PAGE B − 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 Lines In Sumps PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Line Positioning PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISCHARGE LINES PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Siphoning PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CONNECTIONS PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grouding Methods PAGE B − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Field Wiring Connections (Incoming Power) PAGE B − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Imbalance PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Cable Connections PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Box Adjustment PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALIGNMENT PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTO-START PAGE B − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Float Switch Installation PAGE B − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Submersible Transducer Installation PAGE B − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION − SECTION C PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING AND OPERATION PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Box Function PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Function PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotation PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leakage PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Vacuum Check PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Discharge Line PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature And Overheating PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainer Check PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STOPPING PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Stopping PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 4

TABLE OF CONTENTS

(continued)

Automatic Stopping PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CHECKS PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Cavity and Bearing Lubrication PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearing Temperature Check PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Compressor Drive Belt PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COLD WEATHER PRESERVATION PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING − SECTION D PAGE D − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREVENTIVE MAINTENANCE PAGE D − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

STANDARD PERFORMANCE CURVE PAGE E − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS LISTS:

Pump Model PAGE E − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump End Assembly PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Rotating Assembly PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Kit PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Assembly PAGE E − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Compressor Assembly PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Removal And Disassembly PAGE C − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Discharge Check Valve Removal and Disassembly PAGE C − 14. . . . . . . . . . . . . . . . . . . . . . . . .

Back Cover Plate and Wear Plate Removal PAGE C − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Separating Pump And Drive Assembly From Engine PAGE C − 14. . . . . . . . . . . . . . . . . . . . . . . .

Draining Oil From Seal Cavity PAGE C − 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loosening Impeller PAGE C − 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Casing Removal PAGE C − 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Removal PAGE C − 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Removal PAGE C − 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft and Bearing Removal and Disassembly PAGE C − 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft and Bearing Reassembly and Installation PAGE C − 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Reassembly and Installation PAGE C − 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Installation And Adjustment PAGE C − 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Casing Installation PAGE C − 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing Pump End To Power Source PAGE C − 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wear Plate and Back Cover Installation And Adjustment PAGE C − 20. . . . . . . . . . . . . . . . . . . .

Discharge Check Valve Reassembly And Installation PAGE C − 21. . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Assembly And Installation PAGE C − 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE C − 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Assembly PAGE C − 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearings PAGE C − 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 5

INTRODUCTION

OM−06440PA SERIES

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 PA Series, priming-assisted centrifugal model. The unit is designed for handling nonvolatile, non-flammable liquids containing specified entrained solids. The basic material of 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 instructions and precautions for every aspect of each specific application. Therefore, it is the responsibility 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 compromised by the installation. Pumps and related equipment must be installed and operated according to all national, local and industry standards.

If there are any questions regarding the pump which are not covered in this manual or in other literature accompanying the unit, please contact your Gorman-Rupp distributor or The GormanRupp Company:

The following are used to alert personnel to procedures 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 required 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.

The Gorman-Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901−1217

Phone: (419) 755−1011

or:

Gorman-Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631−2870

For information or technical assistance on the engine, contact the local power source representative.

Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. These instructions describe 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.

PAGE I − 1INTRODUCTION

Page 6

PA SERIES

OM−06440

SAFETY - SECTION A

This information applies to Prime Air Series pumps. Refer to the manual accompanying the engine or power source before attempting to begin operation.

This manual will alert personnel to known procedures 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 instructions and precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance personnel to ensure that only safe, established maintenance procedures are used, and that any procedures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such practices.

Before attempting to install, operate, or wire the pump control box, familiarize yourself with this manual, and with all other literature shipped with the control box. Unfamiliarity with all aspects of control operation covered in this manual could lead to destruction of equipment, injury, or death to personnel.

Before connecting any cable to the control box, be sure to ground the control box. See Section B for suggested grounding methods.

The control box provides overload protection and power control. Do not connect the pump motor directly to the incoming power lines. If the power circuit breaker or overload relay is tripped during operation, correct the problem before resetting or replacing.

The electrical power used to operate the pump control box is high enough to cause injury or death. Obtain the services of a qualified electrician to make all electrical connections. Make certain that the enclosure is properly grounded; never use gas pipe as an electrical ground. Be sure that the incoming power matches the voltage and phase of the control before connecting the power source. Do not make electrical connections if the voltage is not within the limits. If the overload unit is tripped during operation, correct the problem before restarting.

The electrical power used to operate the pump control box is high enough to cause injury or death. Make certain that the control handle on the control box is in the OFF position and locked out before attempting to service the pump. Before attempting to open or service the control box, disconnect and/or lock out the power supply to the control box. Tag electrical circuits to prevent accidental start-up.

PAGE A − 1SAFETY

Page 7

Obtain the services of a qualified electrician to troubleshoot, test and/or service the electrical components of the control box.

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

2. Lock out the power from the control box to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4. Check the temperature before opening any covers, plates, or plugs.

5. Close the suction and discharge valves.

6. Vent the pump slowly and cautiously.

7. Drain the pump.

PA SERIESOM−06440

are disengaged. Allow the pump to completely cool before servicing it.

This pump is designed to handle most non-volatile, non-flammable liquids containing specified entrained solids. Do not attempt to pump volatile, corrosive, or flammable liquids which may damage the pump or endanger personnel as a result of pump failure.

Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or damage to equipment. Attach lifting equipment to the lifting device fitted to the pump. If chains or cable are wrapped around the pump to lift it, make certain that they are positioned so as not to damage the pump, and so that the load will be balanced. The bail is intended for use in lifting the pump assembly only. Suction and discharge hoses and piping must be removed from the pump before lifting.

This pump may be equipped with an optional automatic starting system, and therefore subject to automatic restart. Keep hands and clothing away from the unit to prevent injury during automatic

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.

operation. Lock out the power from the control box to ensure that the pump will remain inoperative. Failure to do so may result in serious personal injury.

Do not operate the pump against a closed discharge valve. If operated against a closed discharge valve, pump components will deteriorate, and the

Do not attempt to disengage any part of an overheated pump unit. Vapor pressure within the pump casing can eject these parts with great force when they

PAGE A − 2 SAFETY

liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode. Momentary closure of a discharge valve is acceptable only

Page 8

PA SERIES

OM−06440

when required for startup or shutdown procedures.

Do not remove plates, covers, gauges, pipe plugs, or fittings from an overheated pump. Vapor pressure within the pump can cause parts being disengaged to be ejected with great force. Allow the pump to cool completely before servicing.

Do not operate the pump without guards

in place over the rotating parts. Exposed rotating parts can catch clothing, fingers or tools, causing severe injury to personnel.

Pumps and related equipment must be installed and operated according to all national, local and industry standards.

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

PAGE A − 3SAFETY

Page 9

PA SERIES OM−06440

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 arrange 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 dimensions of this pump.

Figure 1. Pump Model PA4A60C−B−E30 460/575/3

PAGE B − 1INSTALLATION

Page 10

OM−06440 PA SERIES

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested before shipment from the factory. Before installation, inspect the pump for damage which may have occurred 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 drying, check for loose hardware at mating surfaces.

c. Compare the amperes, phase, voltage and

hertz indicated on the pump motor nameplate to the ratings indicated for the control box.

d. 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.

POSITIONING PUMP

Lifting

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

e. Check levels and lubricate as necessary. Re-

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

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

months, some of the components or lubricants 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 determine the repair or updating policy. Do not put the pump into service until appropriate action has been taken.

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.

The pump assembly can be seriously damaged if the chains or cables used to lift and move the unit are improperly wrapped around the pump.

Mounting

Locate the pump in an accessible place as close as practical to the liquid being pumped. Level mounting is essential for proper operation.

The pump may have to be supported or shimmed to provide for level operation or to eliminate vibration.

PAGE B − 2 INSTALLATION

Page 11

PA SERIES OM−06440

to secure them when filled with liquid and under pressure.

If the pump has been mounted on a movable 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 increased suction lift, discharge elevation, and friction losses. See the performance curve and operating 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, reinforced type to prevent collapse under suction. Using piping couplings in suction lines is not recommended.

Line Configuration

Keep suction and discharge lines as straight as possible to minimize friction losses. Make minimum use of elbows and fittings, which substantially 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 discharge 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 priming, 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 installed with the flat part of the reducers uppermost to avoid creating air pockets. Valves are not normally used in suction lines, but if a valve is used, install it with the stem horizontal to avoid air pockets.

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 exactly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or couplings.

Lines near the pump must be independently supported 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

Page 12

OM−06440 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 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 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 diameter 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 suction inlet because the inflow will carry air down into the sump, and air entering the suction line will reduce pump efficiency.

If it is necessary to position inflow close to the suction 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 distance 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

Page 13

PA SERIES OM−06440

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 siphon breaker is used in the line. Otherwise, a siphoning 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 pressure 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.

ELECTRICAL CONNECTIONS

Obtain the services of a qualified electrician to make all electrical connections and to service the control box.

The electrical power used in this control box is high enough to cause injury or death. Make certain that the control box is properly grounded after installation. Make certain that the power source phase and voltage matches the data on

PAGE B − 5INSTALLATION

Page 14

OM−06440 PA SERIES

the control box. Complete all electrical connections before connecting the power supply to the control box. Make certain to ground the appropriate lead of the power source before connecting power to the control. Make certain that the control box is properly grounded after installation.

Grounding Methods

Electrically ground the installation before connecting the field wiring to the control box. Install a

a) PLATE ELECTRODE b) DRIVEN ELECTRODE c) BURIED ELECTRODE

SOIL

1/4 INCH STEEL

PLATE 2 SQ. FEET

(1858,1 SQ. CM) SURFACE AREA

(MINIMUM)

SOIL

3/4 INCH (19,1

MM) NOMINAL

DIAMETER

(MINIMUM)

grounding terminal to the enclosure and connect it to a properly embedded electrode.

The material used for the electrode must be an excellent conductor of electricity, such as copper. If iron or steel is used, it must be galvanized or otherwise metal plated to resist corrosion. Do not coat the electrode with any material of poor conductivity, such as paint or plastic.

The electrode must conform to the recommendations of N.E.C. ARTICLE 250. Follow all installation requirements of the N.E.C., and all applicable codes. See Figure 3 for some suggested grounding methods.

SOIL

8 FEET (2,4 M)

3/4 INCH (19,1 MM)

NOMINAL DIAMETER

(MINIMUM) 8 FEET

(2,4 M) LONG

ROCK

Figure 3. Suggested Grounding Methods

a. Plate Electrode: An iron or steel plate, 1/4

inch (6,4 mm) thick, completely impeded in the ground. The plate must present a surface area of at least 2 square feet (1858,1 sq. cm).

b. Driven Electrode: A rod or pipe, 3/4 inch

(19,1 mm) in diameter minimum, 8 feet (2,4 m) long, completely driven into the ground.

c. Buried electrode: If rock or stone prevents

embedding the full 8 foot (2,4 m) length of the ground rod, bury it horizontally in a trench.

Space the ground rod or plates at least 6 feet (1,8 m) from any other electrode or ground rod, such as those used for signal circuits, radio grounds, lightning rods, etc.

The earth surrounding the ground rod or plate must contain enough moisture to make a good electrical connection. In dry or sandy areas, pour water around the rod, or consult qualified personnel to devise a method of improving the connection.

Field Wiring Connections (Incoming Power)

The electrical power used to operate this pump is high enough to cause injury or death. Obtain the services of a qualified electrician to make all electrical connections. Make certain that the pump and enclosure are properly grounded; never use gas pipe as an electrical ground. Be sure that the incoming power matches the voltage and phase of the pump and control before connecting the power source. Do not run the pump if the voltage is not within the limits.

The control is designed to regulate the power supply. The field wiring must be properly sized to ensure an adequate voltage supply. The voltage

PAGE B − 6 INSTALLATION

Page 15

PA SERIES OM−06440

available at the pump motor must be within the in- dicated range.

Table 1. Pump Motor Voltage Limits

Nominal Voltage

460 3 414 506

575 3 517 632

If the voltage is not within the recommended limits, obtain the services of a qualified electrician to determine the correct field wiring size and other details to ensure an adequate voltage supply.

Make certain all connections are tight and that cable entry points are rainproof. Support the cable weight, if required, to prevent excessive strain on cable clamps and cable.

Phase

Minimum Voltage

Maximum Voltage

NOTE

After the power cables have been connected to the control box, make certain the connection is waterproof.

Voltage Imbalance

Each phase of the incoming three-phase power must be balanced with the other two as accurately as a commercial voltmeter will read. If the phases are out of balance, contact your power company and request that they correct the condition.

When necessary to change or connect power cables to the control box, make certain the incoming power is OFF and LOCKED OUT. Make certain the control box is properly grounded and that the electrical data on the control matches the pump motor name plate data.

Connect the power cable to the control box as shown in the wiring diagrams in this section or inside the control box door. Use conduit or cable clamps to secure the power and accessory cables to the control box. Make certain that all connections are tight and that cable entry points are rainproof.

Control Box Adjustments

For control adjustments and settings, refer to the information inside the control box door.

To maintain overcurrent, short circuit and ground fault protection, the manufacturer’s instructions for selection of the heater pack and setting of the instantaneous trip circuit breaker (current interrupter) or control interface module must be followed. Failure to follow these instructions can result in damage to the pump and/or serious injury to personnel.

ALIGNMENT

Power Cable Connections

The electrical power used to operate the control box is high enough to cause injury or death. Obtain the services of a qualified electrician to make all electrical connections. Make certain that incoming power to the control box is in the off position and locked out, or that the power supply to the control box has been otherwise cut off and locked out, before connecting power or accessory cables.

The alignment of the pump and motor is critical for trouble-free mechanical operation. In a flexible coupling system, the driver and pump must be mounted so that their shafts are aligned with and parallel to each other. It is imperative that alignment be checked after the pump and piping are installed, and before operation.

NOTE

Check Rotation, Section C, before final alignment of the pump.

When mounted at the Gorman-Rupp factory, driver and pump are aligned before shipment. Misalignment will occur in transit and handling. Pumps

must be checked and realigned before operation.

PAGE B − 7INSTALLATION

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OM−06440 PA SERIES

Before checking alignment, tighten the foundation bolts. The pump casing feet and/or pedestal feet, and the driver mounting bolts should also be tightly secured.

When checking alignment, disconnect the power source to ensure that the pump will remain inoperative.

Adjusting the alignment in one direction may alter the alignment in another direction. Check each procedure after altering alignment.

AUTO-START

The pump may be equipped with an optional autostart 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 installation details for the optional liquid level sensing system.

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 obstructed or drawn into the suction line. If a flexible 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 bottom. Direct the suction line toward the flow, and the float(s) away from the flow. If a standpipe is available, attach the float switch cable to the standpipe in the sump at the approximate desired liquid level.

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

ered to the suction line or standpipe approximately 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 approximately 8 inches (203 mm) between start/stop intervals for every 6 inches (152 mm) of cable increase.

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

PAGE B − 8 INSTALLATION

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 4 for additional float switch

data.

Page 17

PA SERIES OM−06440

PUMP

CONTROL

BOX

(Emptying)

OFF

(Filling)

OPERATING

CABLE

TETHER

RANGE

(See Table Below)

POINT

OFF

(Emptying)

1.25" Pipe (Not Furnished)

(Filling)

Figure 4. Float Switch Data

Submersible Transducer Installation

The Electronic Pressure Switch (EPS) autostart system employs a submersible transducer level sensor with 75 feet (22,9 m) of signal cable connected to the EPS.

The transducer sensor converts pressure to an electrical signal proportional to liquid level. This electrical signal is distributed to the digital display on the EPS through a scaling circuit which converts the electrical signal to feet of water".

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)

c. Allow slack in the signal cable so that the sen-

sor weight does not pull on the connection.

d. The wet well or sump must be vented to atmo-

sphere.

e. The EPS is scaled in feet of water column. If

the measured medium is other than 1.0 specific gravity, the reading on the EPS should be divided by the specific gravity of the measured medium to obtain the actual level.

4.0

(1.2)

When installing the transducer sensor, note the following:

a. Handle the signal cable and transducer sen-

sor with care during installation. Carefully lower the sensor into the wet well or sump; do not drop it to the bottom. To avoid clogging, suspend the sensor off the bottom.

b. Be sure to provide sufficient room in the wet

well or sump so that the sensor does not get drawn into the suction line. To prevent this, a flexible suction hose may be extended to lay along the bottom of the wet well or sump. The sensor can then be attached to the hose above the point where it bends along the bottom. See Figure 5 for a typical installation.

f. Thoroughly clean the sensor after each use

to prevent clogging.

Do not disassemble the transducer sensor or loosen the compression nut at the signal cable entry. This will void warranty. There are no user-serviceable parts inside. Do not nick or cut the jacket of the signal cable; this will cause leakage and void warranty. Connect the signal cable only to the EPS terminals for this purpose and to no other power source.

PAGE B − 9INSTALLATION

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OM−06440 PA SERIES

SUCTION

DISCHARGE

LINE

SIGNAL CABLE

(ATTACH TO

SUCTION LINE)

SUBMERSIBLE

TRANSDUCER

(DOWNSTREAM

FROM SUCTION)

Figure 5. Typical Submersible Transducer AutoStart Pump Installation

SUCTION

STRAINER

FLOW

PAGE B − 10 INSTALLATION

Page 19

PA SERIES OM−06440

Transducer Connections

The submersible transducer sensor cable is factory-equipped with a female connector which mates with a male connector on the back of the EPS control. If removal or replacement of the female con-

TRANSDUCER

SHD −V +VSIG

+ BATT

− BATT

SHIELD

−

MOTOR

RUN

+ TEMP

RELAY

CAUTION−

nector is required, reconnect the cable to the connector as shown in Figure 6.

Once the connections are made, simply plug the female connector into the male connector on the back of the EPS, and refer to Section C for operational procedures.

MALE

TRANSDUCER

CONNECTOR

SHIELD

BLACK

FEMALE

TRANSDUCER

CONNECTOR

RED

WHITE

TRANSDUCER

SENSOR

CABLE

HORN RELAY

THIS COVER PLATE MUST

BE INSTALLED FOR PROPER

CONTROL OPERATION

Figure 6. Back Side of Transducer Showing Sensor Cable Connections

PAGE B − 11INSTALLATION

Page 20

PA SERIES

OM−06440

OPERATION − SECTION C

Review all SAFETY information in Section A.

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

The electrical power used to operate this control box is high enough to cause injury or death. Make certain that the control handle on the control box is in the OFF position and locked out, or that the power supply to the control box has been otherwise cut off and locked out, before attempting to open or service the control box. Tag electrical circuits to prevent accidental start-up.

Obtain the services of a qualified electrician to make all electrical connections, and to troubleshoot, test and/or service the electrical components of the control box.

This pump is designed to handle most non-volatile, non-flammable liquids containing specified entrained solids and corrosives. Do not attempt to pump volatile, corrosive, or flammable liquids which may damage the pump or endanger personnel as a result of pump failure.

Pump operating condition points must be within the continuous performance range shown on the Performance Curve in Section E.

STARTING AND OPERATION

Control Box Function

The control box provides overload protection and power control. Do not connect the pump motor directly to the incoming power lines.

The control box is provided to facilitate operation of the pump. It contains controls for starting and stopping the pump, and provides overload protection for the pump motor. The pump control also contains low voltage circuits for the optional automatic liquid level sensing device.

Component Function

The control box contains the following hand-operated switches and controls:

 The control handle operates the control

box circuit breakers. In the OFF position, the control handle opens the circuit breakers to interrupt incoming power through the control box and prevent pump operation. In the ON position, it closes the circuit breakers to permit pump operation. The circuit breakers will open or trip" automatically in the event of a short circuit overload current. When tripped, move the control handle to OFF and back to ON to reset the circuit breakers.

 The selector switch controls the mode of

operation. In the OFF position, it prevents all operation of the pump. In the HAND position, it allows the pump to run continuously. When used in conjunction with the optional liquid level controls, the AUTO position allows the pump to be controlled automatically by the liquid level control system.

 The reset pushbutton resets the motor over-

load after it has been TRIPPED by an overload. The overload relay will trip automatically if the current drawn by the motor exceeds design specifications. Allow 10 seconds for

OPERATION PAGE C − 1

Page 21

OM−06440 PA SERIES

the relay to cool after tripping before pressing the reset.

If replacing the heater pack, press the reset button to set the relay.

NOTE

If the circuit breaker trips, do not reset it immediately. Wait at least ten minutes before resetting the control handle back to the ON position. If the overload unit continues to trip, operational problems exist.

The pump motor will restart as soon as the RESET pushbutton is pressed, unless the selector switch is in the OFF position. Turn the selector switch to OFF and move the control handle to OFF before approaching the pump.

 The optional liquid level system operates in

conjunction with the 3-position switch (HAND-OFF-AUTO) on the control box. After the float(s) have been installed as described in INSTALLATION, Section B, pump operation may be automatically controlled for filling or dewatering functions.

 The green run light indicates the pump is

running. The light will be energized when the 3-position switch is in the HAND position or when the pump is running with the switch in the AUTO position.

Always terminate incoming power to the control box before investigating control box circuitry problems.

the pump, but does not terminate incoming power through the field wiring connected to the control box.

Rotation

The correct direction of pump rotation is indicated by an arrow on the pump body or accompanying decals. If the pump is operated in the wrong direction, the impeller could become loosened from the shaft and seriously damage the pump.

The pump must operate in the direction indicated by the arrow on the pump, or accompanying decals. Reverse rotation could damage the pump and adversely affect performance.

Disconnect the pump from the motor before checking motor rotation. To check rotation, operate the motor independently while observing the direction of the motor shaft, or cooling fan.

If rotation is incorrect, have a qualified electrician interchange any two of the three phase wires at the line connection to change direction.

Priming

The pump will begin to prime upon startup. The air in the suction line will be discharged from the priming chamber 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 the separate Mainte-

nance and Repair manual for further details.

Always terminate power to the control box before performing service functions.

Power through the control box may be terminated by moving the control handle to the OFF position, thereby opening the circuit breakers. This stops

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 efficiency.

OPERATIONPAGE C − 2

Page 22

PA SERIES

OM−06440

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 proportionate to static suction lift, and should then stabilize. If the vacuum reading falls off rapidly after stabilization, an air leak exists. Before checking for the source of the leak, check the point of installation of the vacuum gauge.

Priming Chamber Discharge Line

Check the priming chamber discharge line for liquid bypass. If bypass occurrs, shut down the pump. Refer to the Maintenance and Repair Manual, disassemble and clean the float and valve assembly inside the priming chamber.

Liquid Temperature And Overheating

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 rupture or explode. If overheating occurs, stop the pump immediately and allow it to completely cool before servicing it. Approach any over-heated

pump cautiously.

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 necessary, liquid pressure must be limited to 50% of the maximum permissible operating pressure shown on the pump performance curve.

STOPPING

Manual Stopping

Turn the selector switch on the control box to the OFF position.

After stopping the pump, lock out and tag out the control box to ensure that the pump will remain inoperative.

Automatic Stopping

In the automatic mode, the pump will stop when the liquid in the wet well or sump lowers and activates the Off" float switch(s). The pump will restart automatically when the liquid rises and activates the On" float switch(s).

PERIODIC CHECKS

Seal And Bearing Cavity Lubrication

Both the seal and bearing cavities were fully lubricated at the factory. Check the lubrication levels before startup, and regularly thereafter as indicated in the Maintenance and Repair Manual.

Do not remove plates, covers, gauges, pipe plugs, or fittings from an over-

When lubrication is required, use only SAE No. 30 non-detergent oil.

heated pump. Vapor pressure within the pump can cause parts being disen-

Bearing Temperature Check

gaged to be ejected with great force. Allow the pump to completely cool before servicing.

Strainer Check

Check the strainer regularly, and clean it as necessary. 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.

OPERATION PAGE C − 3

Bearings normally run at higher than ambient temperatures 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 inaccurate. Bearing temperatures can be measured accurately by placing a contact-type thermometer against the housing. Record this temperature for future reference.

Page 23

OM−06440 PA SERIES

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 correct 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. Continued operation should bring the temperatures down to normal levels.

Air Compressor Drive Belt

Like all V-belts, the adjustable V-belt may require periodic adjustment to maintain the correct tension. Check the air compressor V-belt after the first 24 hours of operation, then regularly therafter to

ensure proper tension. Refer to the separate document accompanying the unit for V-belt replacement and adjustment procedures.

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 rotating parts. If the pump will be idle for more than a few hours, or if it has been pumping liquids containing 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 preventing 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.

OPERATIONPAGE C − 4

Page 24

PA SERIES

OM−06440

TROUBLESHOOTING − SECTION D

Review all SAFETY information in Section A.

The following information is divided into two categories; Pump Troubleshooting and Control Box Troubleshooting. Additionally, there is a Pump Preventive Maintenance Schedule at the end of this section. Refer to the appropriate chart for possible causes and remedies for your specific problem.

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

2. Turn the control box selector switch to ‘OFF’ and lock it out to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4. Check the temperature before opening any covers, plates, or plugs.

5. Close the suction and discharge valves.

6. Vent the pump slowly and cautiously.

7. Drain the pump.

This pump may be equipped with an optional automatic starting system, and therefore subject to automatic restart. Keep hands and clothing away from the unit to prevent injury during automatic operation. Disconnect the positive battery cable before performing any maintenance. Failure to do so may result in serious personal injury.

Obtain the services of a qualified electrician to troubleshoot, test and/or service the electrical components of the control box.

Pump Troubleshooting

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO PRIME

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE

Discharge check valve contaminated, damaged, or unable to seat.

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/belts broken. Check and repair/replace.

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.

sary.

leaking or worn seal or gasket.

TROUBLESHOOTING PAGE D − 1

Page 25

OM−06440

Pump Troubleshooting (Cont’d)

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 necessary.

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. Reduce 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 increase flow rate, and run engine at maximum governed speed.

Clean valve.

Dilute if possible.

losses in suction line. Record vacuum 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 26

PA SERIES

Pump Troubleshooting (Cont’d)

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

OM−06440

BEARINGS RUN TOO HOT

Bearing temperature is high, but within limits.

Low or incorrect lubricant.

Suction and discharge lines not properly supported.

Excessive tension on drive belt.

Check bearing temperature regularly 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.

Control Box Troubleshooting

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO START, OVERLOAD UNIT NOT TRIPPED (MANUAL MODE)

Power source incompatible with control Correct power source. box.

No voltage at line side of circuit beaker. Check power source for blown fuse,

open overload unit, broken lead, or loose connection.

OVERLOAD UNIT TRIPS

No voltage at line terminals on bottom Check power source for blown fuse, of overload unit in control box. open disconnect, broken wire, or

loose connection.

Low or high voltage, or excessive volt- Measure voltage at control box. age drop between pump and control Check that wiring is correct type, size, box. and length. (See Field Wiring

Connections,Section B).

Power input phases not If imbalance exceeds 1 percent, balanced. notify power company

Control box not compatible with pump. Electrical data on control box and

pump name plate must agree. Replace control box if not in agreement.

Foreign object locking impeller or Remove foreign material or replace bearing frozen. damaged bearing. If bearing is

damaged, check for water in motor housing.

Motor windings short-circuited. Check motor windings with

ohmmeter.

TROUBLESHOOTING PAGE D − 3

Page 27

OM−06440

PA SERIES

PUMP 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 preventive maintenance schedule will help assure trouble-free performance and long life from your Gorman-Rupp pump. For specific questions concerning your application, contact your GormanRupp 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

equipped) between regularly scheduled inspections can indicate problems that can be corrected before system damage or catastrophic failure occurs. 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 inspections should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently.

Preventive Maintenance Schedule

Service Interval*

Item

General Condition (Temperature, Unusual

Noises or Vibrations, Cracks, Leaks,

Loose Hardware, Etc.) I Pump Performance (Gauges, Speed, Flow) I Bearing Lubrication I R Seal Lubrication (And Packing Adjustment,

If So Equipped) I R V-Belts (If So Equipped) I Air Release Valve Plunger Rod (If So Equipped) I C Front Impeller Clearance (Wear Plate) I Rear Impeller Clearance (Seal Plate) I Check Valve I Pressure Relief Valve (If So Equipped) C Pump and Driver Alignment I Shaft Deflection I Bearings I Bearing Housing I Piping I Driver Lubrication − See Mfgr’s Literature

Daily Weekly Monthly Semi-

Annually

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

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PA SERIES

OM−06440

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 PA4A60C−B−E30 460/575/3

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 different due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.

Contact the Gorman-Rupp Company to verify performance 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 performance range shown on the curve.

Page 29

OM−06440 PA SERIES

PARTS PAGE

ILLUSTRATION

Figure 1. Pump Model PA4A60C−B−E30 460/575/3

MAINTENANCE & REPAIRPAGE E − 2

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PA SERIES

OM−06440

Pump Model PA4A60C−B−E30 460/575/3

Parts List

(From S/N 1482736 Up)

If your pump serial number is followed by an N", your pump is NOT a standard production model. Contact the Gorman-Rupp Company to verify part numbers.

ITEM

PART NAME PART

NO.

NUMBER

MAT’L CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

MAT’L CODE

QTY

1 PUMP END ASSY PA4A60C−B−(E30) 1 2 HEX HEAD CAP SCREW B0606 15991 10 3 LOCK WASHER J06 15991 10 4 COUPLING 24340−104 −−− 1 5 THREADED INSERT 21769−163 −−− 10 6 COUPLING GUARD ASSY 42342−258 24150 1 7 ELECTRIC MOTOR

−460V 28264−442 −−− 1

−575V 28264−465 −−− 1 8 HEX NUT D08 15991 14 9 LOCK WASHER J08 15991 15

10 HOIST BAIL ASSY 44713−053 24150 1 11 MOTOR SUPPORT ASSY 41833−011 24150 1 12 HEX NUT D04 15991 5 13 LOCK WASHER J04 15991 5 14 MOUNTING BRKT ASSY 41888−231 24150 1 15 FLAT WASHER K04 15991 5 16 HEX HEAD CAP SCREW B0404 15991 5 17 CONTROL BOX

−460V 27515−305 −−− 1

−575V 47631−183 −−− 1

18 FLAT WASHER K08 15991 8 19 HEX HEAD CAP SCREW B0809 15991 4 20 HEX HEAD CAP SCREW B0805 15991 10 21 CABLE 47325−015 −−− 1

22 HEX HEAD CAP SCREW B1007 15991 4 23 FLAT WASHER K10 15991 4 24 FLEX SKID BASE ASSY 41565−601 24150 1 25 LOCK WASHER J10 15991 12 26 HEX NUT D10 15991 12 27 HEX HEAD CAP SCREW B1009 15991 4 28 PUMP SUPPORT ASSY 41581−024 24150 1 29 HEX HEAD CAP SCREW B1006 15991 4 30 HEX HEAD CAP SCREW B0804 15991 1 31 CLAMP 27111−348 −−− 1

NOT SHOWN:

MOTOR VOLTAGE TAG

−460V 38816−460 −−− 1

−575V 38816−128 −−− 1 OIL FILL DECAL 38816−194 −−− 1 G-R DECAL GR−06 −−− 2 PRIME AIRE DECAL 38812−078 −−− 4 WARNING DECAL 38816−345 −−− 2 INSTRUCTION TAG 38817−085 −−− 1 INSTRUCTION DECAL 38816−331 −−− 2 GUARD WARNING DECAL 38816−062 −−− 1 460V CBL ASSY INST 47111−006 −−− 1

−460V HEATER PACK 27521−209 −−− 1 575V CBL ASSY INST 47111−005 −−− 1

−575V HEATER PACK 27521−223 −−− 1

MAINTENANCE & REPAIR PAGE E − 3

Page 31

OM−06440 PA SERIES

ILLUSTRATION

Figure 2. Pump End Assembly PA6C60−B−(E50)

MAINTENANCE & REPAIRPAGE E − 4

Page 32

PA SERIES

ITEM

PART NAME PART

NO.

PA4A60C−B−(E30) Pump End Assembly

Parts List

NUMBER

MAT’L CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

OM−06440

MAT’L CODE

QTY

1 PUMP END ASSEMBLY 46133−311 −−− 1 2 PRIMING CHAMBER KIT 48275−005 −−− 1 3 CONNECTOR S1598 −−− 1 4 HOSE BARB FTG 26523−047 −−− 1 5 1/2" ID x 30" LG HOSE 18513−113 −−− 1 6 HOSE BARB FITTING 26523−446 −−− 2 7 CHECK VALVE 26641−092 −−− 1 8 AIR COMPRESSOR ASSY 46181−907 −−− 1 9 SYNCHRONOUS BELT 24186−008 −−− 1

10 BELT GUARD ASSY 42351−326 24150 1 11 HEX HEAD CAP SCREW B0402 15991 2 12 LOCK WASHER J04 15991 2 13 FLAT WASHER K04 15991 2 14 HOSE BARB FITTING 26523−386 −−− 1 15 HOSE CLAMP 26518−641 −−− 1 16 HOSE CLAMP 26518−642 −−− 1 17 HEX HEAD CAP SCREW B0610 15991 4 18 LOCK WASHER J06 15991 4 19 FLAT WASHER K06 15991 4 20 SPACER 31141−034 15000 4 21 3/16" ID X 24" LG HOSE 18513−301 −−− 1 22 1/2" ID X 20" LG HOSE 18513−113 −−− 1

23 CLAMP 27111−348 −−− 1 24 SPROCKET 24271−112 −−− 1 25 BUSHING 24131−496 −−− 1 26 CHECK VALVE KIT 48274−003 −−− 1

−CHECK VALVE 26642−124 −−− 1

−−CHK VLV FLAPPER 26688−005 −−− 1

−−COVER O-RING 25152−366 −−− 1

−GASKET 25113−034 −−− 1 27 STUD C1011 15991 8 28 GASKET 1676G 18000 1 29 PIPE PLUG P04 15079 1 30 LOCK WASHER J10 15991 8 31 HEX NUT D10 15991 8 32 4" HOPPER SPOOL 38644−802 10000 1 33 GASKET 38689−037 18000 1 34 COVER PLATE 38244−021 15080 1 35 LOCK WASHER J08 15991 2 36 HEX HEAD CAP SCREW B0804 15991 2

NOT SHOWN:

STRAINER ASSEMBLY 2690C 24000 1 G-R DECAL GR−06 −−− 1

MAINTENANCE & REPAIR PAGE E − 5

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OM−06440 PA SERIES

ILLUSTRATION

Figure 3. 46133−311 Pump End Assembly

MAINTENANCE & REPAIRPAGE E − 6

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PA SERIES

OM−06440

PARTS LIST

46133−311 Pump End Assembly

ITEM NO.

1 PUMP CASING 38218−015 10000 1 2 HEX NUT D06 15991 2 3 LOCK WASHER J06 15991 2 4 SIGHT GAUGE S1471 −−− 1 5 PIPE PLUG P08 15079 1 6 PIPE PLUG P06 15079 1 7 WEAR PLATE ASSY 10532B 15990 1 8 REPAIR ROTATING ASSY 44163−451 −−− 1

9 HEX HEAD CAP SCREW B0806 15991 4 10 LOCK WASHER J08 15991 4 11 BEARING HOUSING O-RING S1674 −−− 1 12 ROT ASSY ADJ SHIM SET 13130 17040 4 13 SEAL PLATE O-RING 25152−273 −−− 1 14 NAME PLATE 38818−127 13000 1 15 DRIVE SCREW BM#04−03 17000 4 16 PIPE CAP V08 15079 1 17 PIPE NIPPLE T0822 15079 1 18 STREET ELBOW RS08 11999 1 19 CASING DRAIN PLUG P12 15079 1

NOT SHOWN:

PART NAME

OIL LEVEL DECAL 38816−123 −−− 1 SUCTION STICKER 6588AG −−− 1 ROTATION DECAL 2613M −−− 1 WARNING DECAL 2613FE −−− 1 DISCHARGE STICKER 6588BJ −−− 1 LUBRICATION DECAL 11421A −−− 1

PART NUMBER

MAT’L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E − 7

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OM−06440 PA SERIES

ILLUSTRATION

Figure 4. 44163−451 Repair Rotating Assembly

MAINTENANCE & REPAIRPAGE E − 8

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PARTS LIST

44163−451 Repair Rotating Assembly

ITEM NO.

1 IMPELLER 10528 11010 1

2 IMPELLER ADJ. SHIM SET 37J 17090 REF

3 CARTRIDGE SEAL ASSY 46513−151 −−− 1

4 SEAL PLATE 38272−234 10010 1

5 SEAL PLATE GASKET 10959G 20000 1

6 OIL SEAL S1352 −−− 2

6A MOUNTING FLANGE OIL SEAL S1352 −−− 1

7 LOCK WASHER J08 15991 4

8 HEX HEAD CAP SCREW B0805−1/2 15991 4

9 BEARING HOUSING 38251−423 10000 1 10 VENTED PIPE PLUG 4823A 15079 1 11 REDUCER PIPE BUSHING AP0802 15079 1 12 AIR VENT S1530 −−− 1 13 SEAL CAVITY SIGHT GAUGE S1471 −−− 1

13A BEARING CAVITY SIGHT GAUGE S1471 −−− 1

14 PIPE PLUG P12 15079 1 15 SEAL CAVITY DRAIN PLUG P04 15079 1

15A BEARING CAVITY DRAIN PLUG P04 15079 1

16 HEX HEAD CAP SCREW 21632−934 −−− 8 17 LOCK WASHER J06 15991 8 18 MOUNTING FLANGE 38545−013 11010 1 19 MOUNTING FLANGE GASKET 38683−275 18000 1 20 INTERMEDIATE GUARD 42381−509 24152 2 21 RETAINING RING S442 −−− 1 22 BALL BEARING S375 −−− 1 23 SHAFT KEY N0607 15990 2 24 IMPELLER SHAFT 38514−822 1706H 1 25 BALL BEARING S1088 −−− 1 26 SHAFT SLEEVE O-RING 25154−022 −−− REF 27 SEAL PLATE O-RING 25152−273 −−− 1 28 ROT ASSY ADJ SHIM SET 13130 17040 4 29 BEARING HOUSING O-RING S1674 −−− 1 30 SHIPPING PLUG 11495B 15079 2

NOT SHOWN:

PART NAME

INSTRUCTION TAG 6588U −−− 1

PART NUMBER

MAT’L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E − 9

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OM−06440 PA SERIES

ILLUSTRATION

Figure 5. 48275−005 Priming Chamber Kit

ITEM NO.

1 PRIMING CHAMBER ASSY 46112−709 −−− 1

2 PIPE BUSHING AP1608 11999 1

3 STREET ELBOW RS08 11999 1

4 BALL VALVE 26631−052 −−− 1

5 STUD C0809 15991 4

6 HEX NUT D08 15991 4

7 LOCK WASHER J08 15991 4

8 GASKET 38687−053 19060 1

9 BAFFLE 31113−011 17000 1

INDICATES PARTS RECOMMENDED FOR STOCK

PART NAME

PART NUMBER

MAT’L CODE

MAINTENANCE & REPAIRPAGE E − 10

QTY

Page 38

PA SERIES

OM−06440

ILLUSTRATION

Figure 6. 46112−709 Priming Chamber Assembly

PARTS LIST

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 − 11

PART NAME

−ORIFICE BUTTON 26688−021 −−− 1

PART NUMBER

MAT’L CODE

QTY

Page 39

OM−06440 PA SERIES

ILLUSTRATION

Figure 7. 46181−907 Air Compressor Assembly

ITEM NO.

1 FLAT WASHER K#10 15991 4

2 MACH SCREW X#10−02 15991 4

3 LOCK WASHER J#10 15991 4

4 HEX NUT D#10 15991 4

5 AIR COMPRESSOR COVER 38354−043 15120 1

6 AIR COMPRESSOR 26813−112 −−− 1

7 90 ADAPTER 3/8" 25412−003 −−− 1

8 PIPE NIPPLE T0616 15079 1

9 PIPE CAP V06 15079 1 10 PULLEY ASSEMBLY 44112−003 −−− 1 11 A/C KNOB 38429−501 19220 1 12 PRESSURE RELIEF VALVE 26662−029 −−− 1 13 PIPE ELBOW R04 11999 1 14 SERVICE TEE US04 11999 1 15 VENTURI 26817−003 −−− 1 16 PIPE CPLG 1/2 AE08 15079 1 17 REDUCER PIPE BUSHING AP0804 15079 1 18 PIPE PLUG P08 15079 1 19 3/8" PIPE NIPPLE CLOSED T06 15079 1 20 3/8" PIPE COUPLING AE06 15079 1

NOT SHOWN:

PART NAME

KEY 24113−601 −−− 1

PART NUMBER

MAT’L CODE

QTY

MAINTENANCE & REPAIRPAGE E − 12

Page 40

PA SERIES

OM−06440

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Review all SAFETY information in Section A.

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

This pump requires little service due to its rugged, minimum-maintenance design. However, if it becomes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the Sectional Views (see Figures 1 through 7) and the corresponding Parts Lists. Maintenance and repair instructions for the air compressor are covered separately in the specific literature supplied by the manufacturers.

Some pump service functions may be performed without separating the pump end assembly from the power source. However, the priming chamber (3, Figure 3) and discharge check valve assembly (2, Figure 3) must be removed to service most pump components. The following instructions assume complete disassembly of the pump is required.

Before attempting to service the pump, lock out and tag out incoming power to the control box and take precautions to ensure that it will remain inoperative. Close all valves in the suction and discharge lines and drain the pump casing by removing the casing drain plug (13, Figure 4). Clean and reinstall the drain plug.

tenance procedures are used, and that any procedures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such practices.

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

2. Lock out and tag out incoming power to the control box to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

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

5. Close the suction and discharge valves.

6. Vent the pump slowly and cautiously.

7. Drain the pump.

This pump may be equipped with an optional automatic starting system, and therefore subject to automatic restart. Keep hands and clothing away from the unit to prevent injury during automatic operation. Lock out the power from the control box to ensure that the pump will remain inoperative. Failure to do so may result in serious personal injury.

Obtain the services of a qualified electrician to troubleshoot, test and/or service the electrical components of the control box.

MAINTENANCE & REPAIR PAGE E − 13

Page 41

Discharge Check Valve Removal and Disassembly

(Figure 2)

PA SERIESOM−06440

Use only replacement parts provided or approved by Gorman-Rupp. Use of nonauthorized parts may result in damage to the equipment and/or injury to personnel and will invalidate the warranty.

Priming Chamber Removal And Disassembly

(Figure 6)

Disconnect both the suction piping and the air discharge tubing from the priming chamber assembly (12, Figure 3). Support the priming chamber assembly using a sling and a suitable lifting device. Remove the hardware (6 and 7) and separate the priming chamber assembly, gasket (8) and baffle (9) from the suction spool (32, Figure 2).

(Figure 7)

Remove the hardware (not shown) securing the discharge check valve bracket to the base.

Support the discharge check valve assembly (26) using a sling and a suitable lifting device. Remove the hardware (not shown) and separate the discharge check valve assembly and gasket (not shown) from the pump assembly (1).

The flapper and cover O-ring are the only serviceable parts of the check valve. If the flapper requires replacement, remove the hardware securing the cover. Separate the cover and O-ring and remove the flapper.

Draining Oil From Seal Cavity

(Figure 3)

If any further disassembly is to be performed on the pump, the seal oil cavity must be drained to prevent the oil in the seal cavity from escaping as the pump casing is removed.

Remove the hardware (3 and 4) securing the priming valve (1) to the priming chamber (6). Carefully lift the valve components from the priming chamber. Remove the gasket (7) and clean the mating surfaces.

If the priming valve float is stuck or the strainer (5) is clogged, it can usually be cleaned without further disassembly.

The only serviceable part of the priming valve is the orifice button (2). If liquid continues to bypass through the priming chamber after adjusting the orifice button (see Priming Chamber Reassemb- ly and Installation for adjustment), the button 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 pivot pin. This will allow the linkage to be raised high enough to access the orifice button.

Position a, clean container (2 gallon [7,8 liter] minimum) under the seal cavity drain piping (16, 17 and

18). Remove the pipe cap (16) and drain the oil from the seal cavity into the container. For shorter drain time, remove the vented plug (10, Figure 5). Clean and reinstall the pipe cap and vent plug. Inspect the oil for water, dirt or a cloudy condition which could indicate seal failure.

Separating Pump End From Power Source

(Figure 1)

Further disassembly of the pump requires separating the pump end from the power source. Disconnect the discharge piping from the pump casing.

Remove the hardware (2 and 3) securing the guard (6) to the drive flange (18, Figure 4) and remove the guard. Disconnect the hardware securing the halves of the coupling (4) and separate the coupling halves.

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

Use lifting and moving equipment in

MAINTENANCE & REPAIRPAGE E − 14

Page 42

PA SERIES

OM−06440

good repair and with adequate capacity to prevent injuries to personnel or damage 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 discharge hoses and piping must be removed from the pump before lifting.

Remove the hardware (25, 26 and 27, Figure 1) securing the pump casing to the pump support assembly (28, Figure 1) and use a sling and suitable suitable lifting device to pull the pump end straight away from the power source. Remove the coupling half from the impeller shaft.

Loosening Impeller

Turn

Counterclockwise

Lathe Dog Arm

V" Notch

Heavy

Bar Stock

Figure 8. Loosening Impeller

Pump Casing and Wear Plate Removal

Shaft Key

Impeller Shaft

Lathe Dog

Setscrew

(Figure 4)

With the pump end separated from the power source, wedge a block of wood between the vanes of the impeller (1) and the pump casing (1, Figure

3) to prevent rotation.

Install one of the shaft keys (23) in the shaft keyway. Install a lathe dog on the drive end of the shaft (24) with the V" notch positioned over the shaft key.

With the impeller rotation still blocked, see Figure 8 and use a long piece of heavy bar stock to pry against the arm of the lathe dog in a counterclockwise direction (when facing the drive end of the shaft). Use caution not to damage the shaft or keyway. When the impeller breaks loose, remove the lathe dog, key and wood block.

(Figure 3)

Position the pump assembly on a flat work surface with the rotating assembly (8) positioned up. Support the pump casing (1) using wood blocks or other suitable material. Make sure the pump assembly is secure and stable before proceeding with pump disassembly.

Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or damage 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 discharge hoses and piping must be removed from the pump before lifting.

NOTE

Do not remove the impeller until the rotating assembly has been removed from the pump casing.

MAINTENANCE & REPAIR PAGE E − 15

Drain the oil from the seal cavity before removing the pump casing. See Draining Oil From Seal Cav- ity.

Page 43

PA SERIESOM−06440

(Figure 4)

Install a pair of S" hooks in two opposing holes in the moounting flange (18). Connect a sling and suitable lifting device to the S" hooks.

Remove the hardware (9 and 10) securing the pump casing (1) to the rotating assembly (2). Use the lifting device to pull the rotating assembly up out of the pump casing and position it on the work surface. Remove the shims (12) and clean the contacting surfaces. Tie and tag the shims or measure and record their thickness for ease of reassembly.

(Figure 3)

Inspect the wear plate assembly (7) for excessive wear or scoring and replace as required. If replacement of the wear plate assembly is required, position the pump casing horizontally on the work surface. Disengage the hardware (2 and 3) and pull the wear plate assembly out of the pump casing.

Impeller Removal

(Figure 4)

wooden dowel or other suitable tool to press on the back side of the stationary seat until the seat, Orings and stationary element can be removed.

Remove the shaft sleeve O-ring (26) and seal plate O-ring (27).

If no further disassembly is required, refer to Seal

Installation.

Shaft and Bearing Removal and Disassembly

(Figure 4)

When the pump is properly operated and maintained, the bearing housing should not require disassembly. 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.

With the rotating assembly removed from the pump casing, unscrew the impeller (1) in a counterclockwise direction (when facing the impeller). Use caution when unscrewing the impeller; tension on the shaft seal spring will be released as the impeller is removed. Inspect the impeller and replace it if cracked or badly worn.

Remove the impeller adjusting shims (2); tie and tag the shims, or measure and record their thickness for ease of reassembly.

Seal Removal

(Figures 4 and 9)

Slide the integral shaft sleeve and rotating portion of the seal off the shaft as a unit.

Use a pair of stiff wires with hooked ends to remove the stationary element and seat from the seal plate (4).

An alternate method of removing the stationary seal components is to remove the hardware (7 and

8) and separate the seal plate and gasket (3) from the bearing housing (11). Position the seal plate on a flat surface with the impeller side down. Use a

Remove the bearing housing drain plug (15A) and drain the lubricant. Clean and reinstall the drain plug.

Disengage the hardware (16 and 17) and remove the mounting flange (18), gasket (19) and oil seal (6A). Use a suitably sized dowel to press the oil seal from the mounting flange.

Place a block of wood against the impeller end of the shaft (24) and tap the shaft and assembled bearings (22 and 25) from the bearing housing. Press the oil seals (6) from the bearing housing.

Remove the bearing housing O-ring (29).

After removing the shaft and bearings, clean and inspect the bearings in place as follows.

To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place. It is strongly recommended that the bearings be replaced any time the shaft and bear- ings are removed.

MAINTENANCE & REPAIRPAGE E − 16

Page 44

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OM−06440

Clean the bearing housing, shaft 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 ventilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent containers.

Clean the bearings thoroughly in fresh cleaning solvent. Dry the bearings with filtered compressed air and coat with light oil.

Bearings must be kept free of all dirt and foreign material. Failure to do so will greatly shorten bearing life. Do not spin dry bearings. This may scratch the balls or races and cause premature bearing failure.

Rotate the bearings by hand to check for roughness or binding and inspect the bearing balls. If rotation is rough or the bearing balls are discolored, replace the bearings.

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

Clean and inspect the bearings as indicated in Shaft And Bearing Removal And Disassembly.

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. Bearings 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.

NOTE

Position the outboard bearing (22) on the shaft with the retaining ring on the bearing O.D. toward the drive end of the shaft.

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 continuous motion, to prevent the bearings from cooling and sticking on the shaft.

If bearing replacement is required, remove the snap ring (21) and use a bearing puller to remove the inboard and outboard bearings from the shaft.

Shaft and Bearing Reassembly and Installation

(Figure 4)

Inspect the shaft (24) for distortion, nicks or scratches, or for thread damage on the impeller end. Dress small nicks and burrs with a fine file or emery cloth. Replace the shaft if defective.

MAINTENANCE & REPAIR PAGE E − 17

Position the outboard bearing (8) on the shaft with the integral O.D. retaining ring positioned toward the drive end of the shaft.

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

NOTE

Page 45

PA SERIESOM−06440

If heating the bearings is not practical, use a suitably 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.

Secure the outboard bearing (22) to the shaft with the snap ring (21).

Apply a light coating of oil to the lip of the inboard oil seal (6A) and press it into the bearing housing bore with the lip positioned as shown in Figure 4. Press the oil seal into the housing until the face is just flush with the machined surface on the housing.

It is recommended that a sleeve be positioned against the inboard oil seal to prevent the lip of the oil seal from rolling as the shaft and bearings are installed in the bearing housing. The O.D. of the sleeve should be just smaller than the bearing housing bore, while the I.D. of the sleeve should be just larger than the O.D. of the lip seal area of the shaft.

With the lip seal sleeve in place, lubricate the lip seal area of the shaft and slide the shaft and assembled bearings into the bearing housing until the retaining ring on the outboard bearing seats against the bearing housing. Remove the lip seal sleeve.

oil seal into the housing until the face is just flush with the outer face of the mounting flange.

Install the drive flange gasket (19) and secure the drive flange to the bearing housing with the hardware (16 and 17). Be careful not to damage the lip of the oil seal (6A) on the shaft keyway. Torque the capscrews (16) to 40 ft. lbs. (480 in. lbs. or 5,5 m. kg.).

Lubricate a new bearing housing O-ring (29) with grease and install it in the groove in the bearing housing.

Lubricate the bearings as indicated in LUBRICA-

TION at the end of this section.

Seal Reassembly and Installation

(Figures 5 and 10)

Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent containers.

Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent. Inspect the stationary seat bore in the seal plate for dirt, nicks and burrs, and remove any that exist. The stationary seat bore must be completely clean before installing the seal.

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

Apply a light coating of oil to the lip of the outboard oil seal (6) and press it into thebearing housing with the lip positioned as shown in Figure 4. Press the oil seal into the housing until the face is just flush with the machined surface on the housing.

Apply a light coating of oil to the lip of the oil seal (6A) and press it into the mounting flange (18) with the lip positioned as shown in Figure 4. Press the

A new seal assembly should be installed any time the old seal is removed from the pump. Wear patterns on the finished faces cannot be realigned during reassembly. Reusing an old seal could result in premature failure.

The seal is not normally reused because wear patterns 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-

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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 leakage. Clean and polish the shaft sleeve, or replace it

RETAINER

SPRING

IMPELLER

if there are nicks or cuts on either end. If any components 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 shaft sleeve O-ring and the external stationary seat Oring with a very small amount of light lubricating oil. See Figure 9 for seal part identification.

SEAL PLATE

O-RINGS

IMPELLER

SHIMS

IMPELLER

SHAFT

BELLOWS

SPRING

CENTERING

WASHER

DRIVE BAND

ROTATING

ELEMENT

Figure 9. Seal Assembly

STATIONARY

ELEMENT

and secure it to the bearing housing with the hardware (7 and 8).

SLEEVE O-RING

INTEGRAL

SHAFT

SLEEVE

SHEAR

RING

(SHEARED)

STATIONARY

SEAT

This seal is not designed for operation at temperatures above 160F (71C). Do not use at higher operating temperatures.

If the seal plate was removed, install the seal plate gasket (5). Position the seal plate over the shaft

MAINTENANCE & REPAIR PAGE E − 19

To prevent damaging the shaft sleeve O-ring (26) on the shaft threads, cover the threads with electrical or duct tape. Slide the O-ring over the shaft until it seats against the shaft shoulder. Remove the tape covering the threads. Check to ensure that the shaft threads are free of any tape residue and

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clean as required before proceeding with seal installation.

Lubricate the external stationary seat O-ring with light oil. Slide the seal assembly onto the shaft until the external stationary seat O-ring engages the bore in the seal plate.

Clean and inspect the impeller as described in Im- peller Installation and Adjustment. Install half of the set of impeller shims (2) provided with the seal, and screw the impeller onto the shaft until it is seated against the seal (see Figure 10).

O-RING ENGAGED WITH SEAL PLATE

BORE

STATIONARY SEAT

FULLY SEATED IN

SEAL PLATE BORE

SHEAR RING

(SHEARED)

Figure 11. Seal Fully Installed

Measure the impeller-to-seal plate clearance, and add or remove impeller adjusting shims to obtain the proper clearance as described in Impeller In-

stallation and Adjustment.

If necessary to reuse an old seal in an emer-

gency, carefully separate the rotating and stationary seal faces from the bellows retainer and stationary seat.

SHEAR RING

(UNSHEARED)

Figure 10. Seal Partially Installed

Continue to screw the impeller onto the shaft. This will press the stationary seat into the seal plate bore.

NOTE

A firm resistance will be felt as the impeller presses the stationary seat into the seal plate bore.

As the stationary seat becomes fully seated, the seal spring compresses, and the shaft sleeve will break the nylon shear ring. This allows the sleeve to slide down the shaft until seated against the shaft shoulder. Continue to screw the impeller onto the shaft until the impeller, shims, and sleeve are fully seated against the shaft shoulder (see Figure

11).

Carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.

Do not attempt to separate the rotating portion of the seal from the shaft sleeve

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when reusing an old seal. The rubber bellows will adhere to the sleeve during use, and attempting to separate them could damage the bellows.

Inspect the seal components for wear, scoring, grooves, and other damage that might cause leakage. Inspect the integral shaft sleeve for nicks or cuts on either end. If any components are worn, or the sleeve is damaged, replace the complete seal; never mix old and new seal parts.

Install the stationary seal element in the stationary seat. Press this stationary subassembly into the seal plate bore until it seats squarely against the bore shoulder. A push tube made from a piece of plastic pipe would aid this installation. The I.D. of the pipe should be slightly larger than the O.D. of the shaft sleeve.

Slide the rotating portion of the seal (consisting of the integral shaft sleeve, spring centering washer, spring, bellows and retainer, and rotating element) onto the shaft until the seal faces contact.

Proceed with Impeller Installation and Adjust- ment.

the impeller off, and check the threads for dirt. Do not try to force the impeller onto the shaft.

A clearance of .025 to .040 inch (0,64 to 1,02 mm) between the impeller and the seal plate is necessary for maximum pump efficiency. Measure this clearance and add or remove impeller adjusting shims as required.

Pump Casing and Wear Plate Installation and Adjustment

(Figure 3)

If the wear plate assembly (7) was removed, position the pump casing (1) horizontally on the work surface. Position the replacement ring in the pump casing and secure it with the previously removed hardware (2 and 3).

Reposition the pump casing on a the work surface with the rotating assembly end positioned up. Support the pump casing using wood blocks or other suitable material. Make sure the pump assembly is secure and stable before proceeding with pump disassembly.

Impeller Installation And Adjustment

(Figure 4)

Inspect the impeller (1) and replace it if cracked or badly worn.

The shaft and impeller threads must be completely clean before reinstalling the impeller. Even the slightest amount of dirt on the threads can cause the impeller to seize to the shaft, making future removal difficult or impossible without damage to the impeller or shaft.

Install the same thickness of impeller adjusting shims (2) as previously removed and screw the impeller onto the shaft until tight.

NOTE

At the slightest sign of binding, immediately back

(Figure 4)

Install a pair of S" hooks in two opposing holes in the mounting flange (18). Connect a sling and suitable lifting device to the S" hooks.

Lubricate the O-rings (11 and 13) with light grease, and install them in the grooves in the bearing housing and seal plate. Use the lifting device to lower the rotating assembly (8) into the pump casing.

MAINTENANCE & REPAIR PAGE E − 21

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Align the holes in the bearing housing for the mounting hardware (9 and 10) with those in the pump casing.

Install the same thickness of adjusting shims (12) as previously removed, and secure the rotating assembly to the pump casing with the hardware (9 and 10). Do not fully tighten the capscrews until the impeller face clearance has been set.

A clearance of .010 to .020 inch (0,25 to 0,5 mm) between the impeller and the wear plate is also recommended for maximum pump efficiency. This clearance can be obtained by adding or removing an equal thickness of shims from each of the rotating assembly shim sets (12) until the impeller scrapes against the wear plate when the shaft is turned. After the impeller scrapes, add approximately .010 inch (0,25 mm) of shims to each shim set.

After the face clearance has been set, tighten the hardware securing the rotating assembly to the pump casing.

Securing Pump End to Power Source

(Figure 1)

Install the coupling half on the impeller shaft. Using a suitable lifting device, position the pump end assembly on the base. Align the coupling halves and reinstall the attaching hardware. Install the coupling guard (6) and secure the drive flange to the guard with the previously removed hardware (2 and 3).

Apply a small amount of light grease to the discharge flange gasket to hold it in place and position it against the pump casing flange. Support the discharge check valve assembly using a sling and a suitable lifting device. Using the previously removed hardware, secure the discharge check valve assembly and flange gasket to the pump assembly (1).

Priming Chamber Assembly And Installation

(Figure 6)

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).

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 orifice button fully seats against the orifice before the linkage bar on the float bottoms against the threads on the orifice button. When adjustment is complete, install and tighten the lock washer and hex nut securing the orifice button.

Reinstall any leveling shims used under the pump casing mounting feet and secure the pump assembly to the pump support assembly (28) with the previously removed hardware (25, 26 and 27).

Discharge Check Valve Reassembly And Installation

(Figure 2)

If the discharge check valve (26) was disassembled to replace the flapper or cover O-ring, position the flapper in the valve body and check to ensure free movement.

Install the valve cover O-ring and secure the cover to the body with the previously removed hardware.

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 removed hardware (2 and 3).

(Figure 5)

Install the baffle (9) and gasket (8) and use a sling and suitable lifting device to position the priming chamber assembly on the volute casing (1, Figure

2). Secure the priming chamber assembly with the hardware (6 and 7).

Reconnect the suction piping to the hopper spool and the air discharge tubing to the priming chamber assembly.

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LUBRICATION

(Figure 4)

Seal Assembly

Before starting the pump, remove the vented plug (10) and fill the seal cavity with approximately 5 quarts (4,7 liters) of SAE No. 30 non-detergent oil or to the center of the sight gauge (13). Clean and reinstall the vented plug. Maintain the oil level at the middle of the sight gauge.

Bearings

(Figure 4)

The bearing housing was fully lubricated when shipped from the factory. Check the oil level regularly through the sight gauge (13A) and maintain it at the midpoint of the gauge. When lubrication is required, remove the air vent (12) and add SAE No. 30 non-detergent oil through the opening. When lubricating a dry (overhauled) intermediate, fill the bearing cavity with approximately 28 ounces (0,8 liter). Clean and reinstall the air vent. Do not over-

lubricate. Over-lubrication can cause the bearings to over-heat, resulting in premature bearing failure.

NOTE

The white reflector in the sight gauge must be positioned horizontally to provide proper drainage.

Under normal conditions, drain the bearing housing once each year and refill with clean oil. Change the oil more frequently if the pump is operated continuously or installed in an environment with rapid temperature change.

Monitor the condition of the bearing lubricant regularly for evidence of rust or moisture condensation. This is especially important in areas where variable hot and cold temperatures are common.

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

MAINTENANCE & REPAIR PAGE E − 23

Page 51

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