Page 1
ACDEU
OM‐06168-OE01
July 24, 2008
Rev. B 06‐14‐13
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
PA SERIES PUMP
MODEL
PA4A60C-C2.2T
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A
www.grpumps.com.
2008 The Gorman‐Rupp Company
Page 2
Register your new
Gorman‐Rupp pump online at
www.grpumps.com
Valid serial number and e‐mail address required.
The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects or
other reproductive harm.
RECORD YOUR PUMP MODEL AND SERIAL NUMBER
Please record your pump model and serial number in the
spaces provided below. Your Gorman‐Rupp distributor
needs this information when you require parts or service.
Pump Model:
Serial Number:
Page 3
TABLE OF CONTENTS
INTRODUCTION PAGE I - 1.................................................
SAFETY ‐ SECTION A PAGE A - 1............................................
INSTALLATION - SECTION B PAGE B - 1....................................
Pump Dimensions PAGE B - 1.....................................................
PREINSTALLATION INSPECTION PAGE B - 1............................................
Battery Installation PAGE B - 2.....................................................
POSITIONING PUMP PAGE B - 2.......................................................
Lifting PAGE B - 2.................................................................
Mounting PAGE B - 2.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 3.........................................
Materials PAGE B - 3..............................................................
Line Configuration PAGE B - 3......................................................
Connections to Pump PAGE B - 3..................................................
Gauges PAGE B - 3...............................................................
SUCTION LINES PAGE B - 3...........................................................
Fittings PAGE B - 3...............................................................
Strainers PAGE B - 3..............................................................
Sealing PAGE B - 4...............................................................
Suction 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................................................................
ALIGNMENT PAGE B - 5..............................................................
AUTO‐START PAGE B - 5.............................................................
Float Switch Installation PAGE B - 6.................................................
OPERATION - SECTION C PAGE C - 1......................................
OPERATION PAGE C - 1..............................................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 1................................................................
Manual Starting PAGE C - 1........................................................
Automatic Starting PAGE C - 2.....................................................
Priming PAGE C - 2...............................................................
ROUTINE OPERATION PAGE C - 3.....................................................
OPERATION IN EXTREME HEAT PAGE C - 3............................................
OPERATIONAL CHECKS PAGE C - 3...................................................
Leakage PAGE C - 3..............................................................
Pump Vacuum Check PAGE C - 3..................................................
Liquid Temperature And Overheating PAGE C - 3.....................................
Strainer Check PAGE C - 4.........................................................
STOPPING PAGE C - 4................................................................
Manual Stopping PAGE C - 4.......................................................
Automatic Stopping PAGE C - 4....................................................
Safety Shutdown System PAGE C - 4...............................................
i
Page 4
TABLE OF CONTENTS
(continued)
PERIODIC CHECKS PAGE C - 5.......................................................
Seal Cavity and Bearing Lubrication PAGE C - 5......................................
Bearing Temperature Check PAGE C - 5.............................................
Engine Fuel Filter PAGE C - 5......................................................
Engine Oil PAGE C - 5.............................................................
Air Compressor PAGE C - 5........................................................
Air Compressor Drive Belt PAGE C - 5...............................................
COLD WEATHER PRESERVATION PAGE C - 5...........................................
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..........................................................
Power Unit Kit PAGE E - 5.........................................................
Pump Assembly PAGE E - 7.......................................................
Pump End Assembly PAGE E - 9...................................................
Repair Rotating Assembly PAGE E - 11...............................................
Priming Chamber Kit PAGE E - 12...................................................
Priming Chamber Assembly PAGE E - 13.............................................
Drive Assembly PAGE E - 14........................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 15.........................
Priming Chamber Removal And Disassembly PAGE C - 15..............................
Discharge Check Valve Removal and Disassembly PAGE C - 16.........................
Separating Pump And Drive Assembly From Engine PAGE C - 16........................
Draining Oil From Seal Cavity PAGE C - 17............................................
Loosening Impeller PAGE C - 17.....................................................
Pump Casing And Wear Plate Removal PAGE C - 17...................................
Impeller Removal PAGE C - 18......................................................
Seal Removal PAGE C - 18..........................................................
Shaft and Bearing Removal and Disassembly PAGE C - 18.............................
Shaft and Bearing Reassembly and Installation PAGE C - 19............................
Securing Bearing Housing And Drive Assembly To Engine PAGE C - 20..................
Seal Reassembly and Installation PAGE C - 21........................................
Impeller Installation And Adjustment PAGE C - 24......................................
Pump Casing And Wear Plate Installation PAGE C - 24.................................
Discharge Check Valve Reassembly And Installation PAGE C - 24.......................
Priming Chamber Assembly And Installation PAGE C - 24...............................
LUBRICATION PAGE C - 25.............................................................
Seal Assembly PAGE C - 25.........................................................
Bearings PAGE C - 25..............................................................
Engine PAGE C - 25................................................................
ii
Page 5
INTRODUCTION
OM-06168PA 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 Installation, Operation, and Mainte
nance manual is designed to help you achieve the
best performance and longest life from your Gor
man‐Rupp pump.
This pump is a PA Series, priming‐assisted centrif
ugal model. The unit is designed for handling non‐
volatile, non‐flammable liquids containing speci
fied entrained solids. The basic material of con
struction is ductile iron with stainless steel shaft
and ductile iron wearing parts.
Because pump installations are seldom identical,
this manual cannot possibly provide detailed in
structions and precautions for every aspect of
each specific application. Therefore, it is the re
sponsibility of the owner/installer of the pump to
ensure that applications not addressed in this
manual are performed only after establishing that
neither operator safety nor pump integrity are com
promised by the installation. Pumps and related
equipment must be installed and operated ac
cording to all national, local and industry stan
dards.
The following are used to alert personnel to proce
dures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel:
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure re
quired and the injury which will result
from failure to follow the procedure.
Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.
If there are any questions regarding the pump
which are not covered in this manual or in other lit
erature accompanying the unit, please contact
your Gorman‐Rupp distributor or the Gorman‐
Rupp Company:
The Gorman‐Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: (419) 755-1011
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-2870
For information or technical assistance on the en
gine, contact the engine manufacturer's local
dealer or representative.
Hazards or unsafe practices which COULD
result in minor personal injury or product or
property damage. These instructions de
scribe the requirements and the possible
damage which could result from failure to
follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
PAGE I - 1INTRODUCTION
Page 6
PA SERIES
SAFETY ‐ SECTION A
This information applies to Prime Aire
Series pumps. Refer to the manual ac
companying the engine or power
source before attempting to begin oper
ation.
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and pre
cautions for each specific application.
Therefore, it is the owner/installer's re
sponsibility to ensure that applications
not addressed in this manual are per
formed only after establishing that nei
ther operator safety nor pump integrity
are compromised by the installation.
r
the positive battery cable before per
forming any maintenance. Failure to do
so may result in serious personal injury.
Do not attempt to disengage any part of
an overheated pump unit. Vapor pres
sure within the pump casing can eject
these parts with great force when they
are disengaged. Allow the pump to
completely cool before servicing it.
OM-06168
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Shut down the engine and discon
nect the positive battery cable to
ensure that the pump will remain
inoperative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature and make
sure the pump is cool before open
ing any covers, plates, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau
tiously.
7. Drain the pump.
This pump is designed to handle most
non‐volatile, non‐flammable liquids
containing specified entrained solids.
Do not attempt to pump volatile, corro
sive, or flammable liquids which may
damage the pump or endanger person
nel as a result of pump failure.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment. Attach lifting equip
ment 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 pip
ing must be removed from the pump be
fore lifting.
This pump is equipped with an automat
ic starting system, and is subject to au
tomatic restart. Keep hands and cloth
ing away from the unit to prevent injury
during automatic operation. Disconnect
After the pump has been installed, make
certain that the pump and all piping or
PAGE A - 1SAFETY
Page 7
PA SERIESOM-06168
hose connections are tight, properly
supported and secure before operation.
Do not operate the pump against a
closed discharge valve. If operated
against a closed discharge valve, pump
components will deteriorate, and the
liquid could come to a boil, build pres
sure, and cause the pump casing to rup
ture or explode. Momentary closure of a
discharge valve is acceptable only
when required for startup or shutdown
procedures.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over
heated pump. Vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Al
low the pump to cool completely before
servicing.
This pump may be used to handle mate
rials which could cause illness through
direct exposure or emitted fumes. Wear
adequate protective clothing when
working on the pump or piping.
fingers or tools, causing severe injury to
personnel.
Make sure the pump is level. Lower jack
stands and chock the wheels, if so
equipped. Use caution when positioning
the skid‐mounted unit to prevent damage
to the fuel tank.
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating an internal combustion
engine in an enclosed area, make sure
exhaust fumes are piped to the outside.
These fumes contain carbon monoxide,
a deadly gas that is colorless, tasteless
and odorless.
Fuel used by internal combustion en
gines presents an extreme explosion
and fire hazard. Make certain that all
fuel lines are securely connected and
free of leaks. Never refuel a hot or run
ning engine. Avoid overfilling the fuel
tank. Always use the correct type of fuel.
Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
Do not operate the pump without guards
in place over the rotating parts. Ex
posed rotating parts can catch clothing,
PAGE A - 2 SAFETY
exceeded. The maximum continuous
operating speed for this pump is 1900
RPM.
Page 8
PA SERIES OM-06168
INSTALLATION - SECTION B
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this
section offers only general recommendations and
practices required to inspect, position, and ar
range the pump and piping.
Most of the information pertains to a standard
static lift application where the pump is positioned
above the free level of liquid to be pumped.
If installed in a flooded suction application where
the liquid is supplied to the pump under pressure,
some of the information such as mounting, line
OUTLINE DRAWING
configuration, and priming must be tailored to the
specific application. Since the pressure supplied
to the pump is critical to performance and safety,
be sure to limit the incoming pressure to 50% of the
maximum permissible operating pressure as
shown on the pump performance curve.
For further assistance, contact your Gorman‐Rupp
distributor or the Gorman‐Rupp Company.
Pump Dimensions
See Figure 1 for the approximate physical dimen
sions of this pump.
Figure 1. Pump Model PA4A60C-C2.2T
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be
fore shipment from the factory. Before installation,
inspect the pump for damage which may have oc
curred during shipment. Check as follows:
a. Inspect the pump for cracks, dents, damaged
threads, and other obvious damage.
b. Check for and tighten loose attaching hard
ware. Since gaskets tend to shrink after dry
ing, check for loose hardware at mating sur
faces.
PAGE B - 1INSTALLATION
Page 9
OM-06168 PA SERIES
c. Carefully read all tags, decals, and markings
on the pump assembly, and perform all duties
indicated. Note that the pump shaft rotates in
the required direction.
Only operate this pump in the direction in
dicated by the arrow on the pump body
and on the accompanying decal. Other
wise, the impeller could become loosened
from the shaft and seriously damage the
pump.
d. Check levels and lubricate as necessary. Re
fer to LUBRICATION in the Maintenance and
Repair Manual and perform duties as in
structed.
e. If the pump has been stored for more than 12
months, some of the components or lubri
cants may have exceeded their maximum
shelf life. These must be inspected or re
placed to ensure maximum pump service.
If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Gorman‐Rupp distributor or the factory to deter
mine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.
POSITIONING PUMP
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment. Attach lifting equip
ment 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 pip
ing must
be removed from the pump be
fore lifting.
Lifting
Pump unit weights will vary depending on the
mounting and drive provided. Check the shipping
tag on the unit packaging for the actual weight, and
use lifting equipment with appropriate capacity.
Drain the pump and remove all customer‐installed
equipment such as suction and discharge hoses
or piping before attempting to lift existing, installed
units.
Battery Installation
Unless otherwise specified on the pump order, the
engine battery is not included with engine driven
units.
Refer to the information accompanying the battery
and/or electrolyte solution for activation and charg
ing instructions.
Before installing the battery, clean the positive and
negative cable connectors, and the battery termi
nals. Secure the battery by tightening the
holddown brackets. The terminals and clamps
may be coated with petroleum jelly to retard corro
sion. Connect and tighten the positive cable first,
then the negative cable.
PAGE B - 2 INSTALLATION
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 mount
ing is essential for proper operation. The pump
may have to be supported or shimmed to provide
for level operation and eliminate vibration.
For engine driven units, the pump must be posi
tioned as level as possible to ensure sufficient lubri
cation and fuel supply to the engine.
If the pump has been mounted on a moveable
base, make certain the base is stationary by setting
Page 10
PA SERIES OM-06168
the brake and blocking the wheels before attempt
ing to operate the pump.
If the pump has been mounted on a mov
able base, do not attempt to operate the
pump unless the unit is level. Be sure
the leveling stands are positioned on a
solid surface, and the wheels are
chocked.
SUCTION AND DISCHARGE PIPING
Pump performance is adversely effected by in
creased suction lift, discharge elevation, and fric
tion losses. See the performance curve and oper
ating range shown on Page E‐1 to be sure your
overall application allows pump to operate within
the safe operation range.
Materials
Either pipe or hose maybe used for suction and
discharge lines; however, the materials must be
compatible with the liquid being pumped. If hose is
used in suction lines, it must be the rigid‐wall, rein
forced type to prevent collapse under suction. Us
ing piping couplings in suction lines is not recom
mended.
Line Configuration
Keep suction and discharge lines as straight as
possible to minimize friction losses. Make mini
mum use of elbows and fittings, which substan
tially increase friction loss. If elbows are necessary,
use the long‐radius type to minimize friction loss.
Connections to Pump
Before tightening a connecting flange, align it ex
actly with the pump port. Never pull a pipe line into
place by tightening the flange bolts and/or cou
plings.
Lines near the pump must be independently sup
ported to avoid strain on the pump which could
cause excessive vibration, decreased bearing life,
and increased shaft and seal wear. If hose‐type
lines are used, they should have adequate support
to secure them when filled with liquid and under
pressure.
Gauges
The pump is drilled and tapped for installing dis
charge pressure and vacuum suction gauges. It is
recommended that gauges be installed to monitor
pump performance. Seal the gauge threads with
pipe dope to ensure an airtight seal. Follow the
sealant manufacturer's recommendations when
selecting and applying the pipe dope. The pipe
dope should be compatible with the liquid being
pumped.
SUCTION LINES
To avoid air pockets which could affect pump prim
ing, the suction line must be as short and direct as
possible. When operation involves a suction lift, the
line must always slope upward to the pump from
the source of the liquid being pumped; if the line
slopes down to the pump at any point along the
suction run, air pockets will be created.
Fittings
Suction lines should be the same size as the pump
inlet. If reducers are used in suction lines, they
should be the eccentric type, and should be in
stalled with the flat part of the reducers uppermost
to avoid creating air pockets. Valves are not nor
mally used in suction lines, but if a valve is used,
install it with the stem horizontal to avoid air pock
ets.
Strainers
Be certain to use the strainer furnished with the
pump; any spherical solids which pass through the
strainer will also pass through the pump itself.
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 11
OM-06168 PA SERIES
Sealing
Since even a slight leak will affect priming, head,
and capacity, especially when operating with a
high suction lift, all connections in the suction line
should be sealed with pipe dope to ensure an air
tight seal. Follow the sealant manufacturer's rec
ommendations when selecting and applying the
pipe dope. The pipe dope should be compatible
with the liquid being pumped.
Suction Lines In Sumps
If a single suction line is installed in a sump, it
should be positioned away from the wall of the
sump at a distance equal to 1 1/2 times the diame
ter of the suction line.
If there is a liquid flow from an open pipe into the
sump, the flow should be kept away from the suc
tion inlet because the inflow will carry air down into
the sump, and air entering the suction line will re
duce pump efficiency.
If it is necessary to position inflow close to the suc
tion inlet, install a baffle between the inflow and the
suction inlet at a distance 1‐1/2 times the diameter
of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into
the suction inlet.
If two suction lines are installed in a single sump,
the flow paths may interact, reducing the efficiency
of one or both pumps. To avoid this, position the
suction inlets so that they are separated by a dis
tance equal to at least 3 times the diameter of the
suction pipe.
Suction Line Positioning
The depth of submergence of the suction line is
critical to efficient pump operation. Figure 2
shows recommended minimum submergence vs.
velocity.
Although not recommended, the vacuum assisted
priming feature allows the pump to be operated
temporarily in a “slurping” application with varying
water levels.
NOTE
The pipe submergence required may be reduced
by installing a standard pipe increaser fitting at the
end of the suction line. The larger opening size will
reduce the inlet velocity. Calculate the required
submergence using the following formula based
on the increased opening size (area or diameter).
PAGE B - 4 INSTALLATION
Page 12
PA SERIES OM-06168
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
DISCHARGE LINES
Siphoning
Do not terminate the discharge line at a level lower
than that of the liquid being pumped unless a si
phon breaker is used in the line. Otherwise, a si
phoning action causing damage to the pump
could result.
Valves
This pump is designed with a check valve in the
discharge line.
If a throttling valve is desired in the discharge line,
use a valve as large as the largest pipe to minimize
friction losses. Never install a throttling valve in a
suction line.
With high discharge heads, it is recommended that
a throttling valve be installed in the discharge line
to protect the pump from excessive shock pres
sure and reverse rotation when it is stopped.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
ALIGNMENT
The alignment of the pump, air compressor and
engine is critical for trouble‐free mechanical opera
tion. See Section E, Securing Intermediate And
Drive Assembly To Engine in MAINTENANCE
AND REPAIR, for details.
AUTO‐START
The standard pump is equipped with an auto‐start
control system which allows the pump to start and
stop as the liquid level in the wet well or sump rises
and falls.
Refer to the information which follows for installa
tion details for the liquid level sensing system pro
vided with your pump.
PAGE B - 5INSTALLATION
Page 13
OM-06168 PA SERIES
Float Switch Installation
The Float Switch autostart system employs either a
single or double float switch, where a bulb raises or
lowers (floats) with the liquid level, thus activating
an enclosed miniature switch. The floats are
equipped with a socket type connector that plugs
into a matching receptacle on the auto‐start control
box.
Standard floats are equipped with 50 feet (15,2 m)
of cable.
When installing the floats, note the following:
a. Be sure to provide sufficient room in the wet
well or sump so that floats do not get ob
structed or drawn into the suction line. If a flex
ible suction hose is used, it may be extended
to lay along the bottom of the wet well or sump
and the float can be attached to the hose
above the point where it bends along the bot
tom. Direct the suction line toward the flow,
and the float(s) away from the flow. If a stand
pipe is available, attach the float switch cable
to the standpipe in the sump at the approxi
mate desired liquid level.
b. In a single float system, the cable can be teth
ered to the suction line or standpipe approxi
mately 6 inches (152 mm) above the float.
This setting allows approximately 9 inches
(229 mm) of liquid rise between pump start/
stop. The start/stop interval may be increased
by extending the float end of the cable. The
liquid level in the sump will increase approxi
mately 8 inches (203 mm) between start/stop
intervals for every 6 inches (152 mm) of cable
increase.
c. If a double float switch system is used, posi
tion the “Start” float at the desired high water
level in the sump, and the “Stop” float at the
desired low water level in the pump.
d. Refer to Figure 3 for additional float switch
data.
ENGINE
CONTROL
BOX
CABLE
TETHER
POINT
1.25” Pipe
(Not Furnished)
ON
(Emptying)
OFF
(Filling)
OPERATING
RANGE
(See Table Below)
OFF
(Emptying)
ON
(Filling)
Figure 3. Float Switch Data
3.0
(0.9)
2.5
(.76)
2.0
(0.6)
1.5
(.46)
1.0
(0.3)
0.5
(.15)
1.0
(0.3)
APPROXIMATE FREE CORD LENGTH IN FT. (M)
2.0
(0.6)
3.0
(0.9)
4.0
(1.2)
PAGE B - 6 INSTALLATION
Page 14
PA SERIES
OM-06168
OPERATION - SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and
decals attached to the pump.
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating an internal combustion
engine in an enclosed area, make sure
exhaust fumes are piped to the outside.
These fumes contain carbon monoxide,
a deadly gas that is colorless, tasteless
and odorless.
OPERATION
cated (see LUBRICATION in MAINTENANCE
AND REPAIR).
The pump will begin to prime upon startup. The air
in the suction line will be discharged from the educ
tor discharge line. Complete priming is indicated
by a positive discharge pressure reading.
If full priming is not achieved, the discharge check
valve may be malfunctioning. If this occurs, shut
down the pump and consult Maintenance and
Repair, Section E for further details.
STARTING
Check the fuel level and oil levels in the engine, air
compressor, pump bearings and seal housing.
Make sure the pump is level. Lower the jack stands
and chock the wheels, if so equipped.
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 endan
ger personnel as a result of pump fail
ure.
Pump speed and operating condition
points must be within the continuous per
formance range shown on the perfor
mance curve in Section E on page E-1.
PRIMING
Install the pump and piping as described in IN
STALLATION. Make sure that the piping connec
tions are tight, and that the pump is securely
mounted. Check that the pump is properly lubri
Make sure the pump is level. Lower jack
stands and chock the wheels, if so
equipped. Use caution when positioning
the skid‐mounted unit to prevent damage
to the fuel tank.
This pump is equipped with automatic
liquid level controls, and is subject to
automatic restart. Keep hands and
clothing away from the unit to prevent
injury during automatic operation. Dis
connect the positive battery cable be
fore performing any maintenance. Fail
ure to do so may result in serious per
sonal injury.
Consult the engine operations manual before at
tempting to start the unit.
Manual Starting
On initial start‐up, set the engine speed at in the
half‐throttle position. Turn the keyswitch to `MANU
OPERATION PAGE C - 1
Page 15
OM-06168 PA SERIES
AL'. After the engine starts and the unit is fully
primed, adjust the engine RPM until the desired
flow rate is achieved.
Pump speed and operating condition
points must be within the continuous per
formance range shown on the curve on
Page E‐1.
Automatic Starting
With the float system installed, follow the proce
dures outlined for manual starting and throttle ad
justment. Switch the keyswitch to `OFF' until the
water level rises above the on point for the float sys
tem, then turn the keyswitch to the `AUTO' setting.
The unit will run until the float signals the control
that the water in the wet well is at the float off point,
at which time the unit will shut down automatically.
When the float signals the control that the water in
the wet well is at the float on point, the unit will re‐
start automatically, repeating the cycle.
Priming
These fumes contain carbon monoxide,
a deadly gas that is colorless, tasteless
and odorless.
Adjust the engine speed to achieve the desired
output. Do not exceed the factory set engine speed
and system operating pressure. Do not operate
below the recommended operating speed (if appli
cable).
Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. Refer to the Performance
Curve in the separate Parts List Manual
for the maximum continuous operating
speed for this pump.
Operation In Extreme Heat
The safety shutdown system will automatically
stop the unit if engine operating temperature ex
ceeds design limits. If engine over‐temperature
shutdown occurs, allow the unit to cool before re
starting.
The pump will begin to prime upon startup. The air
in the suction line will be discharged from the educ
tor discharge line. Complete priming is indicated
by a positive discharge pressure reading.
If full priming is not achieved, the discharge check
valve may be malfunctioning. If this occurs, shut
down the pump and consult the separate Mainte
nance and Repair manual for further details.
Routine Operation
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating an internal combustion
engine in an enclosed area, make sure
exhaust fumes are piped to the outside.
If engine overheating continues, check the engine
lubricant level and viscosity. Consult the engine
operation manual for the recommended lubricant
for operation in extreme heat.
If the unit is being operated in the automatic mode,
adjust the float(s) to allow shorter run and longer
cooling periods, if possible.
This pump is equipped with automatic
liquid level controls, and is subject to
automatic restart. Keep hands and
clothing away from the unit to prevent
injury during automatic operation. Dis
connect the battery before performing
any maintenance. Failure to do so may
result in serious personal injury.
OPERATIONPAGE C - 2
Page 16
PA SERIES
OM-06168
OPERATIONAL CHECKS
Leakage
Once the pump is fully primed, no leakage should
be visible at pump mating surfaces, or at pump
connections or fittings. Keep all line connections
and fittings tight to maintain maximum pump effi
ciency.
Pump Vacuum Check
Read the vacuum gauge with the pump primed
and at operation speed. Shut off the pump. The
vacuum gauge reading will immediately drop pro
portionate to static suction lift, and should then sta
bilize. If the vacuum reading falls off rapidly after
stabilization, an air leak exists. Before checking for
the source of the leak, check the point of installa
tion of the vacuum gauge.
Liquid Temperature And Overheating
plug to prevent injury to personnel from
hot liquid.
Strainer Check
Check the strainer regularly, and clean it as neces
sary. The strainer should also be checked if pump
flow rate begins to drop. Monitor and record the
vacuum suction gauge readings regularly to detect
strainer blockage.
Never introduce air or steam pressure into the
pump casing or piping to remove a blockage. This
could result in personal injury or damage to the
equipment. If backflushing is absolutely neces
sary, liquid pressure must be limited to 50% of the
maximum permissible operating pressure shown
on the pump performance curve.
STOPPING
Manual Stopping
The maximum liquid temperature for this pump is
160F (71C). Do not apply it at a higher operating
temperature.
Overheating can occur if operated with the valves
in the suction or discharge lines closed. Operating
against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to rup
ture or explode. If overheating occurs, stop the
pump immediately and allow it to completely cool
before servicing it. Approach any over‐heated
pump cautiously.
Allow an over‐heated pump to com
pletely cool before servicing. Do not re
move plates, covers, gauges, or fittings
from an overheated pump. Liquid within
the pump can reach boiling tempera
tures, and vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Af
ter the pump cools, drain the liquid from
the pump by removing the casing drain
plug. Use caution when removing the
Never halt the flow of liquid suddenly. If the liquid
being pumped is stopped abruptly, damaging
shock waves can be transmitted to the pump and
piping system. Close all connecting valves slowly.
Reduce the throttle speed slowly and allow the en
gine to idle briefly before stopping.
In the manual mode, reduce the throttle speed
slowly, and allow the engine to idle briefly before
switching the HAND‐OFF‐AUTO switch to `OFF'.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
After stopping the pump, switch off the engine igni
tion and remove the key to ensure that the pump
will remain inoperative.
Automatic Stopping
In the automatic mode, the pump will stop when
the liquid in the wet well or sump lowers and acti
vates the “Off” float switch(s). The pump will restart
OPERATION PAGE C - 3
Page 17
OM-06168 PA SERIES
automatically when the liquid rises and activates
the “On” float switch(s).
Safety Shutdown System
The unit is equipped with a safety system to auto
matically shut down the engine under certain con
ditions. The engine will automatically shut down:
1. If the engine exceeds its safe operating tem
perature.
2. If the engine oil pressure drops below design
limits.
3. If the engine fails to start within a pre‐set peri
od of time.
4. If the engine speed exceeds the safe operat
ing range.
5. If the engine fan belt breaks.
into service. Consult the factory for ad
ditional information.
PERIODIC CHECKS
Seal Cavity And Bearing Lubrication
Both the seal and bearing cavities were fully lubri
cated at the factory. Check the lubrication levels
before startup, and regularly thereafter as indi
cated in Section E, Maintenance and Repair.
When lubrication is required, use only SAE No. 30
non‐detergent oil.
Bearing Temperature Check
Bearings normally run at higher than ambient tem
peratures because of heat generated by friction.
Temperatures up to 160F (71C) are considered
normal for bearings, and they can operate safely to
at least 180F (82C).
Lights on the control panel will indicate which of the
safety features has caused the engine to shut
down.
Should any of the safety features cause the engine
to shut down, the cause must be determined and
corrected before putting the unit back into service.
The engine will not restart until the key switch has
been returned to the `OFF' position for at least 10
seconds.
All safety shutdown features are pre‐set at the fac
tory for optimum performance and safety; do not
attempt to adjust these settings.
Never disconnect any of the safety shut
down features; this will void the warran
ty and could result in serious damage to
the unit and/or injury to personnel. Safe
ty shutdown features are pre‐set at the
factory; do not attempt to adjust any of
the settings. Determine the cause of
shutdown before putting the unit back
Checking bearing temperatures by hand is inaccu
rate. Bearing temperatures can be measured ac
curately by placing a contact‐type thermometer
against the housing. Record this temperature for
future reference.
A sudden increase in bearing temperatures is a
warning that the bearings are at the point of failing
to operate properly. Make certain that the bearing
lubricant is of the proper viscosity and at the cor
rect level (see LUBRICATION in Section E, Main
tenance and Repair). Bearing overheating can
also be caused by shaft misalignment and/or ex
cessive vibration.
When pumps are first started, the bearings may
seem to run at temperatures above normal. Con
tinued operation should bring the temperatures
down to normal levels.
Engine Fuel Filter
Consult the manual accompanying the engine,
and change the fuel filter periodically as indicated.
If operated under extremely dusty and/or humid
conditions, change the filter more frequently. Irreg
ular performance and loss of power usually indi
cate a dirty fuel filter.
OPERATIONPAGE C - 4
Page 18
PA SERIES
OM-06168
Engine Oil
The engine was lubricated for test at the factory.
However, always check the lubrication level before
startup.
Consult the manual accompanying the engine,
and change the oil filter periodically as indicated. If
operated under extremely dusty conditions,
change the filter more frequently.
Air Compressor
The air compressor was lubricated for test at the
factory. However, always check the lubrication lev
el before startup.
Consult the manual accompanying the air com
pressor and preform all duties and checks as indi
cated.
COLD WEATHER PRESERVATION
In below freezing conditions, drain the pump to
prevent damage from freezing. Also, clean out any
solids by flushing with a hose. Operate the pump
for approximately one minute; this will remove any
remaining liquid that could freeze the pump rotat
ing parts. If the pump will be idle for more than a
few hours, or if it has been pumping liquids con
taining a large amount of solids, drain the pump,
and flush it thoroughly with clean water. To prevent
large solids from clogging the drain port and pre
venting the pump from completely draining, insert
a rod or stiff wire in the drain port, and agitate the
liquid during the draining process. Clean out any
remaining solids by flushing with a hose.
OPERATION PAGE C - 5
Page 19
PA SERIES
OM-06168
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Shut down the engine and discon
nect the positive battery cable to
ensure that the pump will remain
inoperative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau
tiously.
7. Drain the pump.
This pump is equipped with an automat
ic starting system, and is subject to au
tomatic restart. Keep hands and cloth
ing away from the unit to prevent injury
during automatic operation. Disconnect
the positive battery cable before per
forming any maintenance. Failure to do
so may result in serious personal injury.
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO
PRIME
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
Discharge check valve contami
nated, damaged, or unable to seat.
Air leak in suction line. Correct leak.
Lining of suction hose collapsed. Replace suction hose.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
Suction lift or discharge head too high. Check piping installation and install
Air compressor damaged or belts bro
ken.
Strainer clogged. Check strainer and clean if neces
Eductor clogged. Check and clean eductor.
Air leak in suction line. Correct leak.
Lining of suction hose collapsed. Replace suction hose.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
Clean or replace check valve.
leaking or worn seal or gasket.
bypass line if needed. See INSTAL
LATION.
Check and repair/replace.
sary.
leaking or worn seal or gasket.
TROUBLESHOOTING PAGE D - 1
Page 20
OM-06168
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PA SERIES
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE (cont.)
PUMP REQUIRES
TOO MUCH
POWER
Strainer clogged.
Discharge check valve clogged.
Suction intake not submerged at
proper level or sump too small.
Impeller or other wearing parts worn
or damaged.
Discharge head too high.
Suction lift too high.
Pump speed too slow. Check engine output; consult en
Belt or flexible coupling broken. Check and replace as necessary.
Pump speed too high. Check engine output.
Extreme ambient temperature. Reduce pump output.
Discharge head too low.
Fuel filter clogged. Check & replace often in extreme
Check strainer and clean if neces
sary.
Check and clean check valve.
Check installation and correct
submergence as needed.
Replace worn or damaged parts.
Check that impeller is properly
centered and rotates freely.
Free impeller of debris.Impeller clogged.
Install bypass line.
Measure lift w/vacuum gauge. Re
duce lift and/or friction losses in
suction line.
gine operation manual.
Adjust discharge valve.
operating conditions.
PUMP CLOGS
FREQUENTLY
EXCESSIVE NOISE
Dilute if possible.Liquid solution too thick.
Check and replace as required.Fuel contaminated.
Pump or jack shaft bearing(s) frozen. Disassemble, check and replace
bearing(s) as required..
Discharge flow too slow.
Suction check valve or foot valve
clogged or binding.
Liquid solution too thick.
Cavitation in pump. Reduce suction lift and/or friction
Pumping entrained air.
Impeller clogged or damaged.
Open discharge valve fully to in
crease flow rate, and run engine at
maximum governed speed.
Clean valve.
Dilute if possible.
losses in suction line. Record vac
uum and pressure gauge readings
and consult local representative or
factory.
Locate and eliminate source of air
bubble.
Secure mounting hardware.Pump or drive not securely mounted.
Clean out debris; replace damaged
parts.
TROUBLESHOOTINGPAGE D - 2
Page 21
PA SERIES
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
OM-06168
BEARINGS RUN
TOO HOT
Bearing temperature is high, but
within limits.
Low or incorrect lubricant.
Suction and discharge lines not prop
erly supported.
Excessive tension on drive belt.
PREVENTIVE MAINTENANCE
Since pump applications are seldom identical, and
pump wear is directly affected by such things as
the abrasive qualities, pressure and temperature
of the liquid being pumped, this section is intended
only to provide general recommendations and
practices for preventive maintenance. Regardless
of the application however, following a routine pre
ventive maintenance schedule will help assure
trouble‐free performance and long life from your
Gorman‐Rupp pump. For specific questions con
cerning your application, contact your Gorman‐
Rupp distributor or the Gorman‐Rupp Company.
Record keeping is an essential component of a
good preventive maintenance program. Changes
in suction and discharge gauge readings (if so
Check bearing temperature regu
larly to monitor any increase.
Check for proper type and level of
lubricant.
Check piping installation for proper
support.
Align drive properly.Drive misaligned.
Check belt tension. Adjust as
required.
equipped) between regularly scheduled inspec
tions can indicate problems that can be corrected
before system damage or catastrophic failure oc
curs. The appearance of wearing parts should also
be documented at each inspection for comparison
as well. Also, if records indicate that a certain part
(such as the seal) fails at approximately the same
duty cycle, the part can be checked and replaced
before failure occurs, reducing unscheduled down
time.
For new applications, a first inspection of wearing
parts at 250 hours will give insight into the wear rate
for your particular application. Subsequent inspec
tions should be performed at the intervals shown
on the chart below. Critical applications should be
inspected more frequently.
TROUBLESHOOTING PAGE D - 3
Page 22
OM-06168
PA SERIES
Preventive Maintenance Schedule
Service Interval*
Item
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.) I
Pump Performance (Gauges, Speed, Flow) I
Bearing Lubrication I R
Seal Lubrication (And Packing Adjustment,
If So Equipped) I R
V‐Belts (If So Equipped) I
Air Release Valve Plunger Rod (If So Equipped) I C
Front Impeller Clearance (Wear Plate) I
Rear Impeller Clearance (Seal Plate) I
Check Valve I
Pressure Relief Valve (If So Equipped) C
Pump and Driver Alignment I
Shaft Deflection I
Bearings I
Bearing Housing I
Piping I
Driver Lubrication - See Mfgr's Literature
Daily Weekly Monthly Semi‐
Annually
Annually
Legend:
I = Inspect, Clean, Adjust, Repair or Replace as Necessary
C = Clean
R = Replace
* Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually.
Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.
TROUBLESHOOTINGPAGE D - 4
Page 23
PA SERIES
OM-06168
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-C2.2T
Based on 70F (21C) clear water at sea level
with minimum suction lift. Since pump installations
are seldom identical, your performance may be dif
ferent due to such factors as viscosity, specific
gravity, elevation, temperature, and impeller trim.
Contact the Gorman‐Rupp Company to verify per
formance or part numbers.
Pump speed and operating condition
If your pump serial number is followed by an “N”,
your pump is NOT a standard production model.
MAINTENANCE & REPAIR PAGE E - 1
points must be within the continuous per
formance range shown on the curve.
Page 24
OM-06168 PA SERIES
PARTS PAGE
ILLUSTRATION
Figure 1. Pump Model PA4A60C-C2.2T
MAINTENANCE & REPAIRPAGE E - 2
Page 25
PA SERIES
OM-06168
Pump Model PA4A60C-C2.2T
PARTS LIST
(From S/N 1394774 Up)
ITEM
NO.
1 PUMP END PA4A60C-(SAE 4/10) --- 1
2 POWER UNIT KIT 46143-073 --- 1
3 BATTERY SEE OPTIONS --- REF
4 PUMP MOUNTING KIT 48157-026 --- 1
NOT SHOWN:
OPTIONAL:
PART NAME
G‐R DECAL GR-06 --- 3
PRIME AIRE DECAL 38812-078 --- 2
PAPER INSTRUCTION TAG 38817-085 --- 1
CAUTION DECAL 2613FJ --- 1
STRAINER 2690C 24000 1
WARNING DECAL 2613FE --- 1
BATTERY 29331-517 --- 1
WHEEL KIT GRP30-261 --- 1
PART
NUMBER
MAT'L
CODE
QTY
MAINTENANCE & REPAIR PAGE E - 3
Page 26
OM-06168 PA SERIES
ILLUSTRATION
Figure 2. 46143-073 Power Unit Kit
MAINTENANCE & REPAIRPAGE E - 4
Page 27
PA SERIES
OM-06168
PARTS LIST
46143-073 Power Unit Kit
ITEM
NO.
1 CATERPILLAR 2.2T ENGINE 29236-201 --- 1
2 BASE/FUEL TANK 41553-005 24150 1
3 LIFTING BAIL KIT 48274-803 --- 1
4 MUFFLER GUARD NOT REQUIRED
5 HOSE BARB FITTING 26523-386 --- 1
6 HOSE 11308G --- 2
7 HOSE CLAMP 26518-641 --- 1
8 CONTROL PANEL KIT 48122-543 --- 1
9 BATTERY BOX KIT 42432-005 --- 1
10 NEG. BATTERY CABLE 47311-134 --- 1
11 OIL DRAIN ASSY 46342-031 --- 1
12 POS. BATTERY CABLE 47311-113 --- 1
13 FUEL PICKUP 29332-145 --- 2
14 FUEL GAUGE 29332-135 --- 1
15 MALE ELBOW 26351-131 --- 2
16 CONNECTOR S1447 --- 1
17 HOSE ASSY 46341-789 --- 2
18 HEX HD CAPSCREW B1007 15991 4
19 HEX NUT D10 15991 4
20 LOCK WASHER J10 15991 4
21 FLAT WASHER K10 15991 4
NOT SHOWN:
PART NAME
FLOAT SWITCH KIT 48312-980 --- 1
ENGINE STARTUP TAG 38816-269 --- 1
INSTRUCTION DECAL 38818-144 --- 1
WARNING DECAL 38816-203 --- 4
PART
NUMBER
MAT'L
CODE
QTY
MAINTENANCE & REPAIR PAGE E - 5
Page 28
OM-06168 PA SERIES
ILLUSTRATION
Figure 3. PA4A60C-(SAE 4/10) Pump Assembly
MAINTENANCE & REPAIRPAGE E - 6
Page 29
PA SERIES
OM-06168
PA4A60C-(SAE 4/10) Pump Assembly
PARTS LIST
ITEM
NO.
1 PUMP END 64C60C-(SAE 4/10) --- 1
2 PRIMING CHAMBER KIT 48275-005 --- 1
3 CONNECTOR S1598 --- 1
4 HOSE BARB FITTING 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
10 BELT GUARD ASSY 42351-326 24150 1
11 HEX HD CAPSCREW 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 HD CAPSCREW 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 4” CHECK VALVE KIT 48274-003 --- 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 HOPPER SPOOL 38644-802 10000 1
33
34 COVER PLATE 38224-021 15080 1
35 LOCK WASHER J08 15991 2
36 HEX HD CAPSCREW B0804 15991 2
NOT SHOWN:
PART NAME
SYNCHRONOUS BELT 24186-008 --- 1
-CHECK VALVE 26642-124 --- 1
-FLAPPER 26688-005 --- 1
-COVER O‐RING 25152-366 --- 1
COVER PLATE GASKET 38689-037 18000 1
STRAINER 2690C 24000 1
G‐R DECAL GR-06 --- 1
PART
NUMBER
MAT'L
CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 7
Page 30
OM-06168 PA SERIES
ILLUSTRATION
Figure 4. 64C60C-(SAE 4/10) Pump End Assembly
MAINTENANCE & REPAIRPAGE E - 8
Page 31
PA SERIES
OM-06168
PARTS LIST
64C60C-(SAE 4/10) 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 44163-450 --- 1
9 HEX HD CAPSCREW B0806 15991 4
10 LOCK WASHER J08 15991 4
11 BEARING HOUSING O‐RING S1674 --- 1
12 ROTATING ASSY SHIM SET 13130 17040 4
13 SEAL PLATE O‐RING 25154-273 --- 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 PIPE 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
LUBE DECAL 11421A --- 1
DRIVE ASSEMBLY 44162-160 --- 1
PART
NUMBER
MAT'L
CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 9
Page 32
OM-06168 PA SERIES
ILLUSTRATION
SEAL AREA DETAIL
Figure 5. 44163-451 Repair Rotating Assembly
MAINTENANCE & REPAIRPAGE E - 10
Page 33
PA SERIES
OM-06168
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 ASSEMBLY 46513-151 --- 1
4 SEAL PLATE 38272-234 10010 1
5 SEAL PLATE GASKET 10959G 20000 1
6 OIL SEAL S1352 --- 1
6A OIL SEAL S1352 --- 1
6B OIL SEAL S1352 --- 1
7 LOCK WASHER J08 15991 4
8 HEX HD CAPSCREW 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 SIGHT GAUGE S1471 --- 1
13A SIGHT GAUGE S1471 --- 1
14 PIPE PLUG P12 15079 1
15 PIPE PLUG P04 15079 1
15A PIPE PLUG P04 15079 1
16 HEX HD CAPSCREW 21632-934 --- 8
17 LOCK WASHER J06 15991 8
18 MOUNTING FLANGE 38545-013 11010 1
19 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 1
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 ROTATING ASSY ADJ SHIM SET 13130 17040 4
29 BEARING HOUSING O‐RING S1674 --- 1
30 SHIPPING PLUG 11495B 15079 2
31 AIR COMPRESSOR DRIVE KEY N0607 15990 1
NOT SHOWN:
PART NAME
INSTRUCTION TAG 6588U --- 1
PART
NUMBER
MAT'L
CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 11
Page 34
OM-06168 PA SERIES
ILLUSTRATION
Figure 6. 46181-907 Air Compressor Assembly
MAINTENANCE & REPAIRPAGE E - 12
Page 35
PA SERIES
OM-06168
PARTS LIST
46181-907 Air Compressor Assembly
ITEM
NO.
1 FLAT WASHER K#10 15991 4
2 MACHINE 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
790 ADAPTOR 25412-003 --- 1
8 PIPE NIPPLE T0616 15079 1
9 PIPE CAP V06 15079 1
10 PULLEY ASSY 44112-003 --- 1
11 KNOB 38429-501 19550 1
12 PRESSURE RELIEF VALVE 26662-029 --- 1
13 PIPE ELBOW R04 11999 1
14 SERVICE TEE US04 119991 1
15 VENTURI 26817-003 --- 1
16 PIPE COUPLING AE08 15079 1
17 REDUCER PIPE BUSHING AP0804 15079 1
18 PIPE PLUG P08 15079 1
NOT SHOWN:
PART NAME
AIR COMPRESSOR DRIVE KEY 24113-601 --- REF
PART
NUMBER
MAT'L
CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 13
Page 36
OM-06168 PA SERIES
ILLUSTRATION
Figure 7. 48275-005 Priming Chamber Kit
ITEM
NO.
1 PRIMING CHAMBER ASSY 46112-709 --- 1
2 REDUCER 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 - 14
QTY
Page 37
PA SERIES
OM-06168
ILLUSTRATION
Figure 8. 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
6 PRIMING CHAMBER 38343-020 10000 1
6 STRAINER ASSY 46641-222 17000 1
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 15
PART NAME
-ORIFICE BUTTON 26688-021 --- 1
PART
NUMBER
MAT'L
CODE
QTY
Page 38
OM-06168 PA SERIES
ILLUSTRATION
Figure 9. 44162-160 Drive Assembly
ITEM
NO.
1 COUPLING KIT 48112-005 --- 1
2 -BUSHING 24131-496 --- 1
3 -COUPLING ASSEMBLY 24391-105 --- 1
4 LOCK WASHER 21171-536 --- 8
5 SOCKET HEAD CAPSCREW BD0606-1/2 15991 8
5 SOCKET HEAD CAPSCREW 22644-220 --- 8
6 HEX HD CAPSCREW B0605 15991 12
6 HEX HD CAPSCREW 22645-164 --- 12
7 HEX HD CAPSCREW 22645-164 --- 12
7 LOCK WASHER 21171-511 --- 12
PART NAME
USE FOR SAE APPLICATIONS
USE FOR METRIC APPLICATIONS
PART
NUMBER
MAT'L
CODE
MAINTENANCE & REPAIRPAGE E - 16
QTY
Page 39
PA SERIES
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and de
cals attached to the pump.
This pump requires little service due to its rugged,
minimum‐maintenance design. However, if it be
comes necessary to inspect or replace the wearing
parts, follow these instructions which are keyed to
the illustrations (see Figures 1 through 9) and the
corresponding Parts Lists. Maintenance and repair
instructions for the engine and air compressor are
covered separately in specific literature available
from the manufacturers.
This manual will alert personnel to known proce
dures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel. However,
this manual cannot possibly anticipate and provide
detailed precautions for every situation that might
occur during maintenance of the unit. Therefore, it
is the responsibility of the owner/maintenance per
sonnel to ensure that only safe, established main
tenance procedures are used, and that any proce
dures not addressed in this manual are performed
only after establishing that neither personal safety
nor pump integrity are compromised by such prac
tices.
Some pump service functions may be performed
without separating the pump end assembly from
the engine. However, the priming chamber (2, Fig
ure 3) and discharge check valve assembly (32,
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, shut down
the engine and take precautions to ensure that it
will remain inoperative. Close all valves in the suc
tion and discharge lines and drain the pump cas
ing by removing the casing drain plug (19, Figure
4). Clean and reinstall the drain plug.
OM-06168
This manual will alert personnel to
known procedures which require spe
cial attention, to those which could
damage equipment, and to those which
could be dangerous to personnel. How
ever, this manual cannot possibly antici
pate 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 main
tenance procedures are used, and that
any procedures not addressed in this
manual are performed only after estab
lishing 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 man
ual.
2. Shut down the engine and discon
nect the positive battery cable to
ensure that the pump will remain
inoperative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature and make
sure it is cool before opening any
covers, plates, gauges, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau
tiously.
7. Drain the pump.
Use only replacement parts provided or
approved by Gorman‐Rupp. Use of non‐
MAINTENANCE & REPAIR PAGE E - 17
Page 40
PA SERIESOM-05783
authorized parts may result in damage to
the equipment and/or injury to personnel
and will invalidate the warranty.
Priming Chamber Removal And Disassembly
(Figure 7)
Disconnect both the suction piping and the air dis
charge tubing from the priming chamber assembly
(1). 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 pump assembly.
(Figure 8)
Remove the hardware (2 and 3) securing the prim
ing valve (1) to the priming chamber (5). Carefully
lift the valve components from the priming cham
ber. Remove the gasket (4) and clean the mating
surfaces.
If the priming valve float is stuck or the strainer (6) is
clogged, it can usually be cleaned without further
disassembly.
The only serviceable part of the priming valve is the
orifice button (not shown). If liquid continues to by
pass through the priming chamber after adjusting
the orifice button (see Priming Chamber Reas
sembly and Installation for adjustment), the but
ton may require replacement. To replace the orifice
button, remove one of the “e‐clips” from the pivot
pin closest to the orifice button and remove the piv
ot pin. This will allow the linkage to be raised high
enough to access the orifice button.
Remove the hex nut and lock washer securing the
orifice button to the linkage bar and unscrew the
orifice button from the linkage bar.
Discharge Check Valve Removal and
Disassembly
(Figure 3)
Remove the hardware (not shown) securing the
discharge check valve bracket to the base.
charge check valve assembly and gasket (not
shown) from the pump assembly (1).
The flapper and cover O‐ring are the only service
able 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.
Separating Pump and Drive Assembly From
Engine
(Figure 3)
The pump and drive assembly must be separated
from the engine before further disassembly.
Disengage the hardware (11, 12 and 13) and re
move the belt guard assembly (10). Remove the
hardware (17, 18 and 19) securing the air com
pressor assembly (8) to the mounting flange (8,
Figure 5). Use a pry bar to raise the air compressor
high enough to remove the spacers (20). Remove
the belt (9) from the air compressor drive pulley
(not shown).
Disconnect all hoses and fittings from the air com
pressor and use a suitable hoist and sling to re
move the air compressor assembly.
(Figure 9)
Support the pump end using a hoist and sling, and
remove the hardware (not shown) securing the
pump casing to the base.
Remove the hardware (6 and 7) securing the
mounting flange (18, Figure 5) to the engine
bellhousing. Remove the intermediate guards (20,
Figure 5) and separate the assemblies by pulling
the intermediate straight away from the engine.
As the assemblies separate, the flexible portion of
the coupling assembly (3) will remain on the shaft.
To remove the coupling from the shaft, unscrew the
two allen head setscrews from the bushing (2).
Screw one of the setscrews into the puller hole on
the circumference of the bushing. As the coupling
and bushing separate, remove the bushing, and
slide the coupling off the shaft. Remove the shaft
key (23, Figure 5).
Support the discharge check valve assembly (26)
using a sling and a suitable lifting device. Remove
the hardware (not shown) and separate the dis
It is not necessary to remove the outer ring of the
coupling from the engine flywheel unless the cou
pling must be replaced. To remove the ring, disen
MAINTENANCE & REPAIRPAGE E - 18
Page 41
PA SERIES
OM-06168
gage the hardware (4 and 5) securing it to the fly
wheel.
Remove any leveling shims used under the casing
mounting feet. Tie and tag the shims for ease of
reassembly.
Move the pump end to a clean, well equipped shop
area for further disassembly.
(Figure 3)
Remove the belt (9). Remove the capscrews from
the center of the bushing (25). Reinstall the caps
crews in the tapped holes in the bushing and tight
en them in an alternating pattern until the bushing
is “jacked” out of the sprocket (24). Slide the bush
ing and sprocket off the shaft. Remove the key (31,
Figure 5).
Draining Oil From Seal Cavity
(Figure 5)
shaft). Use caution not to damage the shaft or key
way. When the impeller breaks loose, remove the
lathe dog, key and wood block.
Turn
Counterclockwise
Lathe Dog Arm
“V” Notch
Heavy
Bar Stock
Figure 10. Loosening Impeller
Shaft Key
Impeller Shaft
Lathe Dog
Setscrew
If any further disassembly is to be performed on the
pump, the seal oil cavity must be drained to pre
vent the oil in the seal cavity from escaping as the
pump casing is removed.
Position a clean container under the seal cavity
drain plug (15A). Remove the plug and drain the oil
from the seal cavity into the container. For shorter
drain time, remove the vented plug (10). Clean and
reinstall the drain plug and vent plug. Inspect the
oil for water, dirt or a cloudy condition which could
indicate seal failure.
Loosening Impeller
(Figure 5)
With the pump end separated from the engine,
wedge a block of wood between the vanes of the
impeller (1) and the pump casing (1, Figure 4) to
prevent rotation.
Install the shaft key (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.
Pump Casing And Wear Plate Removal
(Figure 4)
Support the pump casing using a suitable hoist
and sling.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment. If slings or chains are
used to move the pump or components,
make sure that the load is balanced;
otherwise serious personal injury or
death could result. Suction and dis
charge hoses and piping must be re
moved from the pump before lifting.
NOTE
Drain the oil from the seal cavity before removing
the pump casing. See Draining Oil From Seal Cav
ity.
With the impeller rotation still blocked, see Figure
10 and use a long piece of heavy bar stock to pry
against the arm of the lathe dog in a counterclock
wise direction (when facing the drive end of the
MAINTENANCE & REPAIR PAGE E - 19
Remove the hardware (9 and 10) securing the
pump casing (1) to the rotating assembly (8). Pull
the pump casing straight away from the rotating
Page 42
PA SERIESOM-05783
assembly to prevent binding on the impeller. Re
move the shims (12) and clean the contacting sur
faces. Tie and tag the shims or measure and re
cord their thickness for ease of reassembly.
Inspect the wear plate assembly (7) for excessive
wear or scoring. If replacement is required, remove
the hardware (2 and 3) and pull the wear plate out
of the pump casing.
Impeller Removal
(Figure 5)
With the rotating assembly removed from the
pump casing, unscrew the impeller (1) from the
shaft (24). Use caution when unscrewing the im
peller; tension on the shaft seal spring will be re
leased as the impeller is removed. Inspect the im
peller and replace if cracked or badly worn.
Remove the impeller adjusting shims (2); tie and
tag the shims, or measure and record their thick
ness for ease of reassembly.
Seal Removal
(Figures 5 and 12)
Slide the integral shaft sleeve and rotating portion
of the seal off the shaft as a unit.
Shaft and Bearing Removal and Disassembly
(Figure 5)
When the pump is properly operated and main
tained, the bearing housing should not require dis
assembly. Disassemble the shaft and bearings
only when there is evidence of wear or damage.
Shaft and bearing disassembly in the field
is not recommended. These operations
should be performed only in a properly
equipped shop by qualified personnel.
Remove the bearing housing drain plug (15) 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). 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 and 6B) from the bearing
housing.
After removing the shaft and bearings, clean and
inspect the bearings in place as follows.
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 (5) from
the bearing housing (9). Position the seal plate on a
flat surface with the impeller side down. Use a
wooden dowel or other suitable tool to press on the
back side of the stationary seat until the seat, O‐
rings, and stationary element can be removed.
Remove the shaft sleeve O‐ring (26) and seal plate
O‐ring (27).
If no further disassembly is required, refer to Seal
Installation.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and bear
ings are removed.
Clean the bearing housing, shaft and all compo
nent parts (except the bearings) with a soft cloth
soaked in cleaning solvent. Inspect the parts for
wear or damage and replace as necessary.
Most cleaning solvents are toxic and
MAINTENANCE & REPAIRPAGE E - 20
Page 43
PA SERIES
OM-06168
flammable. Use them only in a well ven
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.
Bearings must be kept free of all dirt and
foreign material. Failure to do so will great
ly shorten bearing life. Do not spin dry
bearings. This may scratch the balls or
races and cause premature bearing fail
ure.
Rotate the bearings by hand to check for rough
ness or binding and inspect the bearing balls. If ro
tation is rough or the bearing balls are discolored,
replace the bearings.
The bearing tolerances provide a tight press fit
onto the shaft and a snug slip fit into the bearing
housing. Replace the bearings, shaft, or bearing
housing if the proper bearing fit is not achieved.
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
strongly recommended that the bearings
be replaced any time the shaft and bear
ings are removed.
The bearings may be heated to ease installation.
An induction heater, hot oil bath, electric oven, or
hot plate may be used to heat the bearings. Bear
ings should never be heated with a direct flame or
directly on a hot plate.
NOTE
If a hot oil bath is used to heat the bearings, both the
oil and the container must be absolutely clean. If
the oil has been previously used, it must be thor
oughly filtered.
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 250F (120C), and slide the bearings
onto the shaft, one at a time, until they are fully
seated against the shaft shoulders. This should be
done quickly, in one continuous motion, to prevent
the bearings from cooling and sticking on 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.
(Figure 5)
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.
Clean and inspect the bearings as indicated in
Shaft And Bearing Removal And Disassembly.
If heating the bearings is not practical, use a suit
ably sized sleeve and an arbor (or hydraulic) press
to install the bearings on the shaft.
When installing the bearings onto the
shaft, never press or hit against the outer
race, balls, or ball cage. Press only on the
inner race.
Secure the outboard bearing to the shaft with the
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
MAINTENANCE & REPAIR PAGE E - 21
snap ring (21)
Apply a light coating of oil to the lip of the inboard oil
seal (6B) and press it into the bearing housing bore
Page 44
PA SERIESOM-05783
with the lip positioned as shown in Figure 5. 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 as
sembled bearings into the bearing housing until
the retaining ring on the outboard bearing seats
against the bearing housing. Remove the lip seal
sleeve.
drive key (23, Figure 5). Install the sprocket (24)
and bushing (25) on the shaft to the dimension
shown in Figure 11.
NOTE
When properly installed to the dimension shown in
Figure 11, the key (23, Figure 5) will not extend fully
through the bushing. This is an acceptable fit for
this application.
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 the bearing housing
with the lip positioned as shown in Figure 5. The
face of the oil seal should be just flush with the ma
chined face of the bearing 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 5. The face of
the oil seal should be flush with the chamfer on the
mounting flange bore.
Install the mounting flange gasket (19) and secure
the mounting flange to the bearing housing with
the hardware (16 and 17). Be careful not to dam
age the lip of the oil seal on the shaft keyway.
Lubricate the bearings as indicated in LUBRICA
TION at the end of this section.
Figure 11. Drive Sprocket Positioning
Secure the bushing and sheave to the shaft by
torqueing the bushing screws to 23.3 ft. lbs. (280
in. lbs. or 3,2 m. kg.). Install the belt (9) over the
sprocket and up through the slot in the mounting
flange (18, Figure 5).
(Figure 9)
Install the shaft key (23, Figure 5) in the shaft key
way. Position the flexible portion of the coupling as
sembly (3) on the shaft as shown in Figure 5.
NOTE
The flexible portion of the coupling must be proper
ly positioned on the shaft. The heads of the caps
crews in the center of the coupling must be posi
tioned away from the pump.
Securing Bearing Housing And Drive Assembly
To Engine
(Figure 3)
Install the key (31, Figure 5) in the shaft keyway,
making sure to leave room in the keyway for the
Align the keyway in the bushing (2) with the shaft
key, and slide it onto the shaft until the face of the
bushing is just flush with the end of the shaft. Ro
tate the flexible portion of the coupling until the
tapped holes for the two setscrews align with those
in the bushing, and install the setscrews.
MAINTENANCE & REPAIRPAGE E - 22
Page 45
PA SERIES
Make certain that the flexible portion of the
coupling is just flush with the end of the
shaft. This positioning is critical. If the
coupling is not properly positioned on the
shaft, the coupling parts may not fully en
gage, or a pre‐load condition can cause
premature bearing failure.
The end of the shaft must be just flush with
the face of the bushing. This will allow the
two portions of the coupling to fully engage
when the intermediate is secured to the en
gine bellhousing, without pre‐loading the
bearings.
OM-06168
ing with the previously removed hardware (6 and
7).
(Figure 3)
Use a suitable hoist and sling to position the air
compressor assembly (8) on the mounting flange
(18, Figure 5). Slide the belt (9) over the air com
pressor sprocket. Use a pry bar to raise the com
pressor high enough to install the spacers (20) be
tween the compressor and the mounting flange.
Secure the compressor to the mounting flange
with the hardware (17, 18 and 19). Reinstall the
guard (10) and secure it with the hardware (11, 12
and 13).
Seal Reassembly and Installation
(Figures 5, 12, 13 and 14)
With the flexible portion of the coupling and the
bushing properly positioned on the shaft, tighten
the two setscrews in an alternating sequence until
the bushing and coupling are fully secured. Torque
the setscrews to 23.3 ft. lbs. (280 in. lbs. or 3,2 m.
kg.).
If the complete coupling assembly is being re
placed, apply `Loctite Retaining Compound No.
242' or equivalent to the threads of the hardware (4
and 5), and secure the outer ring of the coupling to
the engine flywheel by torquing the hardware to 45
ft. lbs. (540 in. lbs. or 6,2 m. kg.).
Using a suitable lifting device, position the as
sembled drive and rotating assembly so the flex
ible portion of the coupling seats inside the outer
ring attached to the engine flywheel.
NOTE
To ease installation, lightly lubricate the rubber por
tion of the coupling with a non‐petroleum based
lubricant such as vegetable oil or glycerin, or a sili
con‐based lubricant such as “WD40” or equivalent.
Do not use petroleum‐based lubricants, or any oth
er substance which may soften or otherwise dam
age the rubber.
Install the intermediate guards (20, Figure 5) and
secure the mounting flange to the engine bellhous
Most cleaning solvents are toxic and
flammable. Use them only in a well ven
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
Clean the seal cavity and shaft with a cloth soaked
in fresh cleaning solvent. Inspect the stationary
seat bore in the seal plate for dirt, nicks and burrs,
and remove any that exist. The stationary seat bore
must be completely clean before installing the
seal.
A new seal assembly should be installed
any time the old seal is removed from the
pump. Wear patterns on the finished faces
cannot be realigned during reassembly.
Reusing an old seal could result in prema
ture failure.
To ease installation of the seal, lubricate the shaft
sleeve O‐ring and the external stationary seat O‐
ring with a very small amount of light lubricating oil.
See Figure 12 for seal part identification.
MAINTENANCE & REPAIR PAGE E - 23
Page 46
PA SERIESOM-05783
SPRING
IMPELLER
IMPELLER
SHIMS
IMPELLER
SHAFT
BELLOWS
SPRING
CENTERING
WASHER
RETAINER
DRIVE BAND
ROTATING
ELEMENT
STATIONARY
ELEMENT
SEAL PLATE
O‐RINGS
SLEEVE
O‐RING
INTEGRAL
SHAFT
SLEEVE
SHEAR
RING
(SHEARED)
STATIONARY
SEAT
Figure 12. 46513-151 Cartridge Seal Assembly
This seal is not designed for operation at
temperatures above 160F (71C). Do not
use at higher operating temperatures.
If the seal plate was removed, install the seal plate
gasket (5). Position the seal plate over the shaft
and secure it to the bearing housing with the hard
ware (7 and 8).
To prevent damaging the shaft sleeve O‐ring (26)
on the shaft threads, stretch the O‐ring over a piece
of tubing. The I.D. of the tubing must be slightly
larger than the O.D. of the shaft. To ease installation
the tubing wall should be as thin as possible. The
length should be long enough to cover the threads
on the end of the shaft. Slide the tube over the shaft
threads, then slide the O‐ring off the tube and onto
the shaft. Remove the tube, and continue to slide
the O‐ring down the shaft until it seats against the
shaft shoulder.
When installing a new cartridge seal assembly,
remove the seal from the container, and remove
the mylar storage tabs from between the seal
faces.
New cartridge seal assemblies may be
equipped with mylar storage tabs between
the seal faces. These storage tabs must be
removed before installing the seal.
Lubricate the external stationary seat O‐ring with
light oil. Slide the seal assembly onto the shaft until
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 13).
MAINTENANCE & REPAIRPAGE E - 24
Page 47
PA SERIES
OM-06168
O‐RING ENGAGED
WITH SEAL PLATE
BORE
SHEAR RING
(UNSHEARED)
Figure 13. 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.
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 station
ary seal faces from the bellows retainer and sta
tionary seat.
A new seal assembly should be installed
any time the old seal is removed from the
pump. Wear patterns on the finished faces
cannot be realigned during reassembly.
Reusing an old seal could result in prema
ture failure.
Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate precision
finished faces; even fingerprints on the faces can
shorten seal life. If necessary, clean the faces with a
non‐oil based solvent and a clean, lint‐free tissue.
Wipe lightly in a concentric pattern to avoid
scratching the faces.
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
14).
STATIONARY SEAT
FULLY SEATED IN
SEAL PLATE BORE
SHEAR RING
(SHEARED)
Figure 14. Seal Fully Installed
Measure the impeller‐to‐seal plate clearance, and
add or remove impeller adjusting shims to obtain
Carefully wash all metallic parts in fresh cleaning
solvent and allow to dry thoroughly.
Do not attempt to separate the rotating
portion of the seal from the shaft sleeve
when reusing an old seal. The rubber bel
lows will adhere to the sleeve during use,
and attempting to separate them could
damage the bellows.
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leak
age. Inspect the integral shaft sleeve for nicks or
cuts on either end. If any components are worn, or
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.
MAINTENANCE & REPAIR PAGE E - 25
Page 48
PA SERIESOM-05783
Slide the rotating portion of the seal (consisting of
the integral shaft sleeve, spring centering washer,
spring, bellows and retainer, and rotating element)
onto the shaft until the seal faces contact.
Proceed with Impeller Installation and Adjust
ment.
Impeller Installation And Adjustment
(Figure 5)
Inspect the impeller (1) and replace it if cracked or
badly worn.
The shaft and impeller threads must be
completely clean before reinstalling the im
peller. Even the slightest amount of dirt on
the threads can cause the impeller to seize
to the shaft, making future removal difficult
or impossible without damage to the im
peller or shaft.
Apply a small amount of `Never‐Seez' or equivalent
anti‐lock compound on the shaft threads. Screw
the impeller onto the shaft until tight.
NOTE
At the slightest sign of binding, immediately back
the impeller off, and check the threads for dirt. Do
not try to force the impeller onto the shaft.
Install the same thickness of adjusting shims (12)
as previously removed, and secure the rotating as
sembly 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 rec
ommended for maximum pump efficiency. This
clearance can be obtained by adding or removing
an equal thickness of shims from each rotating as
sembly shim sets (12) until the impeller scrapes
against the wear plate when the shaft is turned. Af
ter 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.
Reinstall any leveling shims used under the pump
casing mounting feet and secure the casing (1) to
the base with the previously removed hardware.
Discharge Check Valve Reassembly And
Installation
(Figure 3)
If the discharge check valve (26) was disas
sembled 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.
A clearance of .025 to .040 inch (0,64 to 1,02 mm)
between the impeller and the seal plate is neces
sary for maximum pump efficiency. Measure this
clearance, and add or remove impeller adjusting
shims as required.
Pump Casing And Wear Plate Installation
(Figure 4)
If the wear plate (7) was removed, position the re
placement wear plate in the casing and secure it
with the hardware (2 and 3).
Lubricate the O‐rings (11 and 13) with light grease,
and install them in the grooves in the bearing hous
ing and seal plate. Ease the rotating assembly into
the pump casing. Be careful not to damage the O‐
rings.
Apply a small amount of light grease to the dis
charge flange gasket to hold it in place and posi
tion it against the pump casing flange. Support the
discharge check valve assembly using a sling and
a suitable lifting device. Using the previously re
moved hardware, secure the discharge check
valve assembly and flange gasket to the pump as
sembly (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 (not shown) squarely engages the valve
seat. Replace the orifice button if required (see
Priming Chamber Removal and Disassembly
for orifice button removal).
MAINTENANCE & REPAIRPAGE E - 26
Page 49
PA SERIES
OM-06168
If the orifice button was removed, screw the new
orifice button into the linkage bar until fully seated.
Align the hole in the linkage bar with the holes in the
bracket and reinstall the pivot pin. Secure the pivot
pin with the previously removed “e‐clip”.
Adjust the orifice button seating as necessary by
screwing the orifice button into or out of the linkage
bar. Proper adjustment is achieved when the ori
fice button fully seats against the orifice before the
linkage bar on the float bottoms against the
threads on the orifice button. When adjustment is
complete, install and tighten the lock washer and
hex nut securing the orifice button.
Install the strainer (6) and priming valve gasket (4).
Lower the float into the priming chamber (5) and
secure the priming valve with the previously re
moved hardware (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 hopper spool (32, Fig
ure 3). Secure the priming chamber assembly with
the hardware (6 and 7).
Bearings
(Figure 5)
The bearing housing was fully lubricated when
shipped from the factory. Check the oil level regu
larly through the sight gauge (13) and maintain it at
the midpoint of the gauge. When lubrication is re
quired, 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 posi
tioned horizontally to provide proper drainage.
Under normal conditions, drain the bearing hous
ing once each year and refill with clean oil. Change
the oil more frequently if the pump is operated con
tinuously or installed in an environment with rapid
temperature change.
Reconnect the suction piping to the hopper spool
and the air discharge tubing to the priming cham
ber assembly.
LUBRICATION
Seal Assembly
(Figure 5)
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 (4, Figure 4).
Clean and reinstall the vented plug. Maintain the oil
level at the middle of the sight gauge.
Monitor the condition of the bearing lubri
cant regularly for evidence of rust or mois
ture condensation. This is especially im
portant in areas where variable hot and
cold temperatures are common.
For cold weather operation, consult the factory or a
lubricant supplier for the recommended grade of
oil.
Engine
Consult the literature supplied with the engine, or
contact your local engine representative.
MAINTENANCE & REPAIR PAGE E - 27
Page 50
For U.S. and International Warranty Information,
Please Visit www.grpumps.com/warranty
or call:
U.S.: 419-755-1280
International: +1-419-755-1352
For Canadian Warranty Information,
Please Visit www.grcanada.com/warranty
or call:
519-631-2870
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA
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