GORMAN-RUPP PUMPS PA Series, PA4E71C-3TNV88F FT4-ESP Installation, Operation, And Maintenance Manual With Parts List

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Page 1

OM-07138-01

October 18, 2017

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

PA SERIES PUMP

MODEL

PA4E71C-3TNV88F FT4-ESP

GORMAN‐RUPP PUMPS

www.grpumps.com

2017 Gorman‐Rupp Pumps Printed in U.S.A.

Page 2

Gorman‐Rupp pump online at

www.grpumps.com

Valid serial number and e‐mail address required.

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

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

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

Pump Model:

Serial Number:

Page 3

TABLE OF CONTENTS

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

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

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

Pump Dimensions PAGE B - 1.....................................................

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Suction 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..............................................................

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

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

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

OPERATION IN EXTREME HEAT PAGE C - 2............................................

OPERATIONAL CHECKS PAGE C - 2...................................................

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

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

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

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

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

Manual Stopping PAGE C - 3.......................................................

Automatic Stopping PAGE C - 3....................................................

Safety Shutdown System PAGE C - 3...............................................

PERIODIC CHECKS PAGE C - 3.......................................................

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

Bearing Temperature Check PAGE C - 3.............................................

Engine Fuel Filter PAGE C - 4......................................................

Page 4

TABLE OF CONTENTS

(continued)

Engine Oil 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 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........................................................

Seal and Bearing Cavity Drains PAGE E - 15..........................................

Air Compressor Assembly PAGE E - 17...............................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 18.........................

Priming Chamber Removal And Disassembly PAGE E - 19..............................

Discharge Check Valve Removal and Disassembly PAGE E - 19.........................

Suction Adaptor and Wear Plate Removal PAGE E - 19.................................

Separating Pump and Drive Assembly From Engine PAGE E - 20........................

Loosening Impeller PAGE E - 20.....................................................

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

Impeller Removal PAGE E - 21......................................................

Seal Removal PAGE E - 21..........................................................

Shaft and Bearing Removal and Disassembly PAGE E - 21.............................

Shaft and Bearing Reassembly and Installation PAGE E - 22............................

Securing Bearing Housing and Drive Assembly To Engine PAGE E - 23..................

Seal Reassembly and Installation PAGE E - 24........................................

Impeller Installation And Adjustment PAGE E - 27......................................

Pump Casing Installation PAGE E - 27................................................

Wear Plate and Suction Adaptor Installation PAGE E - 27...............................

Discharge Check Valve Reassembly and Installation PAGE E - 28.......................

Priming Chamber Assembly And Installation PAGE E - 28...............................

Final Pump Assembly PAGE E - 29..................................................

LUBRICATION PAGE E - 29.............................................................

Seal Assembly PAGE E - 29.........................................................

Bearings PAGE E - 29..............................................................

Engine PAGE E - 29................................................................

Page 5

PA SERIES

OM-07138

INTRODUCTION

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

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

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

If there are any questions regarding the pump or its application which are not covered in this man ual or in other literature accompanying this unit, please contact your Gorman‐Rupp distributor, or The Gorman‐Rupp Company:

HAZARD AND INSTRUCTION DEFINITIONS

The following are used to alert maintenance per sonnel to procedures which require special atten tion, to those which could damage equipment, and to those which could be dangerous to personnel:

Immediate hazards which WILL result in severe personal injury or death. These instructions describe the procedure re quired and the injury which will result from failure to follow the procedure.

Hazards or unsafe practices which COULD result in severe personal injury or death. These instructions describe the procedure required and the injury which could result from failure to follow the procedure.

The Gorman‐Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901-1217

Phone: (419) 755-1011

or:

Gorman‐Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631-2870

For information or technical assistance on the power source, contact the power source manufac turer's local dealer or representative.

Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. These instructions describe the requirements and the possi ble damage which could result from failure to follow the procedure.

NOTE

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

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 before attempt ing to begin operation.

Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and pre cautions for each specific application. Therefore, it is the owner/installer's re sponsibility to ensure that applications not addressed in this manual are per formed only after establishing that nei ther operator safety nor pump integrity are compromised by the installation.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. 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 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.

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.

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.

Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.

After the pump has been installed, make certain that the pump and all piping or

OM-07138

PAGE A - 1SAFETY

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PA SERIESOM-07138

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 2200

RPM.

Page 8

PA SERIES OM-07138

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

62.12

[ 1578,0 ]

APPROX

39.25

[ 997,0 ]

EQUALLY SPACED AS SHOWN

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.

DISCHARGE:

(OPPOSITE SIDE)

4.00 NOMINAL WITH

8 HOLES .69/[17,5] DIA THRU

ON A 7.50/[190,5] DIA B.C.

25.75

[ 654,0 ]

104.04 [ 2642,6 ] APPROX

(OPEN)

SUCTION

(OPPOSITE SIDE)

DISCHARGE

24.81

[ 630,2 ]

APPROX

4.49

29.70

[ 754,4 ]

[ 789,0 ]

31.06

58.90 [ 1496,1 ] APPROX

[ 114,2 ]

57.06

[ 1449,2 ]

APPROX

Figure 1. Pump Model PA4E71C-3TNV88F FT4-ESP

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested be fore shipment from the factory. Before installation, inspect the pump for damage which may have oc curred during shipment. Check as follows:

3.00/[76,2] I D PINTLE EYE

56.20 [ 1427,4 ] APPROX

10°

13.76 [ 349,5 ] APPROX

SUCTION:

120.05

[ 3049,4 ]

4.00 NOMINAL WITH

8 HOLES .75/[19,0] DIA THRU

EQUALLY SPACED AS SHOWN

APPROX

ON A 7.50/[190,5] DIA B.C.

21.81

[ 554,0 ]

APPROX SUCTION CENTER

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-07138 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.

Battery Installation

sion. Connect and tighten the positive cable first, then the negative cable.

POSITIONING PUMP

Lifting

Pump unit weights will vary depending on the mounting and drive provided. Check the shipping tag on the unit packaging for the actual weight, and use lifting equipment with appropriate capacity. Drain the pump and remove all customer‐installed equipment such as suction and discharge hoses or piping before attempting to lift existing, installed units.

Unless otherwise specified on the pump order, the engine battery was not included with the unit. When selecting a battery, refer to the specifications on the paper tag attached to the battery box in or der to ensure the proper size and electrical charac teristics of the battery.

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

PAGE B - 2 INSTALLATION

Mounting

Locate the pump in an accessible place as close as practical to the liquid being pumped. Level mount ing is essential for proper operation. The pump may have to be supported or shimmed to provide for level operation and eliminate vibration.

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

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

Page 10

PA SERIES OM-07138

to secure them when filled with liquid and under pressure.

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

SUCTION AND DISCHARGE PIPING

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

Materials

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

Line Configuration

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

Connections to Pump

Gauges

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

SUCTION LINES

To avoid air pockets which could affect pump prim ing, the suction line must be as short and direct as possible. When operation involves a suction lift, the line must always slope upward to the pump from the source of the liquid being pumped; if the line slopes down to the pump at any point along the suction run, air pockets will be created.

Fittings

Suction lines should be the same size as the pump inlet. If reducers are used in suction lines, they should be the eccentric type, and should be in stalled with the flat part of the reducers uppermost to avoid creating air pockets. Valves are not nor mally used in suction lines, but if a valve is used, install it with the stem horizontal to avoid air pock ets.

Strainers

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

Before tightening a connecting flange, align it ex actly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or cou plings.

Lines near the pump must be independently sup ported to avoid strain on the pump which could cause excessive vibration, decreased bearing life, and increased shaft and seal wear. If hose‐type lines are used, they should have adequate support

If a strainer not furnished with the pump is installed by the pump user, make certain that the total area of the openings in the strainer is at least three or four times the cross section of the suction line, and that the openings will not permit passage of solids larger than the solids handling capability of the pump.

This pump is designed to handle up to 3 inch (76,2 mm) diameter spherical solids.

PAGE B - 3INSTALLATION

Page 11

OM-07138 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-07138

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 Bearing Housing

and Drive Assembly To Engine in MAINTE NANCE 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-07138 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

(Emptying)

OFF

(Filling)

OPERATING

CABLE

TETHER

RANGE

(See Table Below)

POINT

OFF

(Emptying)

1.25” Pipe (Not Furnished)

(Filling)

Figure 3. Float Switch Data

COLD WEATHER INSTALLATION

If the pump is to be installed in an environment where sub‐freezing temperatures will occur during operation, consideration must be given to prevent the pump and components from freezing when the pump is idle between pumping cycles. With Gor man‐Rupp priming assisted pumps, there are two methods of accomplishing this.

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)

One method is through the use of an optional heat ed priming chamber, which is available as a facto ry‐installed option or as a retrofit kit for most mod els (consult the factory). This method pumps heat ed liquid from the engine cooling system through the priming chamber to heat the chamber and its contents. This method is particularly effective where pumping cycles are short enough to ensure

PAGE B - 6 INSTALLATION

Page 14

PA SERIES OM-07138

that the liquid in the priming chamber never fully freezes.

The second method involves configuring the pumping system to drain both the priming cham ber and pump casing after each pumping cycle. With no liquid remaining in the system, freezing cannot occur.

To configure the pump to drain between pumping cycles, the first step is to remove the check valve from the line that runs between the top of the prim ing hopper and the priming venturi. This check valve is located close to the venturi end of the line. Remove the check valve, then reconnect the line directly to the venturi. This will allow air to enter the pump through the top of the priming hopper when the pump shuts off, providing for complete drainage of the pump and priming hopper.

Next, install a drain line between the pump drain and the wet well or sump. This line must remain submerged in the liquid below the pump down lev el of the liquid level control device; otherwise, the pump may not prime. If the application involves liq uids that could clog the drain line, make sure to check the line periodically to ensure it remains open; otherwise, liquid could remain in the casing, resulting in freezing and potential damage to the pumping system.

Configuring the system to drain between cycles will help ensure that the pump will not freeze during cold weather applications. However, it should be

noted that the time required for the pump to be gin to discharge liquid will increase, as the pump will have to fully re‐prime at the beginning of each pumping cycle.

PAGE B - 7INSTALLATION

Page 15

PA SERIES

OPERATION - SECTION C

OPERATION

Review all SAFETY information in Section A.

OM-07138

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

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.

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.

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

Consult the manual accompanying the engine control box and start the pump.

PRIMING

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

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

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.

OPERATION PAGE C - 1

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.

ROUTINE OPERATION

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).

Page 16

OM-07138 PA SERIES

and fittings tight to maintain maximum pump effi ciency.

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 Section E 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.

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 liquid level device(s) to allow shorter run and longer cooling periods, if possible.

Pump Vacuum Check

Read the vacuum gauge with the pump primed and at operation speed. Shut off the pump. The vacuum gauge reading will immediately drop pro portionate to static suction lift, and should then sta bilize. If the vacuum reading falls off rapidly after stabilization, an air leak exists. Before checking for the source of the leak, check the point of installa tion of the vacuum gauge.

Liquid Temperature And Overheating

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

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

pump cautiously.

OPERATIONAL CHECKS

The engine powering this unit may be equipped with an EPA‐compliant Exhaust After‐Treatment (EAT) system, which is de signed to reduce the amount of polutants expelled into the atmosphere during oper ation. Refer to the manual accompanying the engine for a detailed explanation of the engine EAT and follow all instructions in the engine manual to ensure uninterrupted op eration of the unit.

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

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 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

OPERATIONPAGE C - 2

Page 17

PA SERIES

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

OM-07138

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 into service. Consult the factory for ad ditional information.

In the manual mode, reduce the throttle speed slowly, and allow the engine to idle briefly before turning the keyswitch to `OFF'.

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

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” liquid level device(s). The pump will restart automatically when the liquid rises and acti vates the “On” liquid level device(s).

Safety Shutdown System

The unit is equipped with a safety system to auto matically shut down the engine under certain con ditions.

Displays 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.

All safety shutdown features are pre‐set at the fac tory for optimum performance and safety; do not attempt to adjust these settings.

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 160F (71C) are considered normal for bearings, and they can operate safely to at least 180F (82C).

Checking bearing temperatures by hand is inaccu rate. Bearing temperatures can be measured ac curately by placing a contact‐type thermometer against the housing. Record this temperature for future reference.

A sudden increase in bearing temperatures is a warning that the bearings are at the point of failing to operate properly. Make certain that the bearing lubricant is of the proper viscosity and at the cor rect level (see LUBRICATION in 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.

OPERATION PAGE C - 3

Page 18

OM-07138 PA SERIES

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.

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.

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.

COLD WEATHER INSTALLATION in the Installa tion section of this manual for details.

OPERATIONPAGE C - 4

Page 19

PA SERIES

OM-07138

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.

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-07138

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-07138

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-07138

PA SERIES

Preventive Maintenance Schedule

Service Interval*

Item

General Condition (Temperature, Unusual

Noises or Vibrations, Cracks, Leaks,

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

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

Daily Weekly Monthly Semi‐

Annually

Legend: I = Inspect, Clean, Adjust, Repair or Replace as Necessary C = Clean R = Replace

* Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually.

Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.

TROUBLESHOOTINGPAGE D - 4

Page 23

PA SERIES

OM-07138

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 PA4E71C-3TNV88F FT4-ESP

Based on 70F (21C) clear water at sea level with minimum suction lift. Since pump installations are seldom identical, your performance may be dif ferent due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.

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

Pump speed and operating condition

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

MAINTENANCE & REPAIR PAGE E - 1

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

Page 24

OM-07138 PA SERIES

PARTS PAGE

ILLUSTRATION

5537 36

37 36

Figure 1. Pump Model PA4E71C-3TNV88F FT4-ESP

MAINTENANCE & REPAIRPAGE E - 2

Page 25

PA SERIES

OM-07138

Pump Model PA4E71C-3TNV88F FT4-ESP

PARTS LIST

(From S/N1689600 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 performance or part numbers.

ITEM

PART NAME PART

NO.

NUMBER

QTY ITEM

NO.

PART NAME PART

NUMBER

QTY

1 PUMP END ASSY 46133-447 1 2 YANMAR 3TNV88F FT4 29239-064 1 3 BASE/FUEL TANK ASSY 41553-043 24150 1 4 WHEEL KIT GRP30-265 1 5 LIFTING BAIL ASSY 44715-065 24150 1 6 SAFETY CABLE BRKT 34268-020 13000 1 7 SUCT SPOOL BRKT 34165-008 15080 1 8 FLAT WASHER K08 15991 1

9 LOCK WASHER J08 15991 4 10 HEX HEAD CAP SCREW B0806 15991 1 11 FLAT WASHER K10 15991 6 12 HEX HEAD CAP SCREW B1006-1/2 15991 6 13 LOCK WASHER J10 15991 14 14 HEX NUT D10 15991 8 15 HEX HEAD CAP SCREW B1007 15991 2 16 LOCKING FUEL CAP 29332-111 1 17 FUEL GAUGE 29332-173 1 18 SOCKET HD CAP SCREW BD#10-03S 15991 5 19 CONTROL PANEL BRCT 34518-052 15080 1 20 CNTRL PNL INSTALL KIT 48122-544 1 21 HEX HEAD CAP SCREW B0605-1/2 15991 4 22 LOCK WASHER J06 15991 11 23 HEX NUT D06 15991 10 24 HEX HEAD CAP SCREW B1006S 15991 4 25 TOP SEAL 33311-054 19460 2 26 BATTERY BOX ASSY 42432-005 1 27 FRNT PNL MOUNT BRKT 34268-021 15120 1 28 FLAT WASHER K06 15991 3 29 THREADED INSERT 21769-159 13 30 1/0 NEG. CABLE ASSY 47311-177 1 31 1/0 POS. CABLE ASSY 47311-118 1 32 HEX HEAD CAP SCREW B0504 15991 13 33 LOCK WASHER J05 15991 23 34 FLAT WASHER K05 15991 21 35 AIR INTAKE COVER ASSY 46823-029 1 36 HEX NUT D04 15991 16 37 LOCK WASHER J04 15991 16 38 HEX HEAD CAP SCREW B0403-1/2 15991 12 39 FLAT WASHER K04 15991 12 40 HEX HEAD CAP SCREW B0807 15991 3 41 EDUCTOR HOSE ASSY 46341-030 1 42 FUEL TANK VENT ASSY 46341-819 1 43 FUEL LINE ASSY 46341-818 1 44 RADIATOR DRAIN ASSY 46342-044 1 45 OIL DRAIN 46342-051 1

46 PUMP DRAIN ASSY 46346-322 1 47 BATTERY 12V SEE OPTIONS 1 48 ENCLOSURE ASSY 42164-021 1 49 GAS LIFTING STRUT 29337-524 2 50 HEX NUT D05 15991 2 51 SAFETY CABLE 41158-846 2 52 STRIKER PLT ASSY 41145-014 24150 2 53 DOUBLE SIDED TAPE 4" 18666-205 1 54 PIPE PLUG P08 15079 5 55 ISOLATION MOUNT 24631-014 4

NOT SHOWN:

WARNING DECAL 38816-345 2 OIL DRAIN LABEL 38816-323 1 RADIATOR DRAIN LABEL 38816-322 1 WARNING DECAL 38816-203 4 PUMP DRAIN LABEL 38816-320 1 CAUTION DECAL 38816-140 1 BASE DRAIN LABEL 38816-351 1 FUEL TANK DRAIN LABEL 38816-321 2 BRG/SEAL DRAIN LABEL 38816-346 1 INSTRUCTION DECAL 38818-144 1 ENG OPERATING DECAL 38816-347 1 G‐R DECAL 6 IN GR-06 2 ENGINE START-UP TAG 38816-269 1 PRIME AIRE DECAL 38812-078 2 CABLE TIE 27111-229 1 CABLE TIE 27111-205 10 FUEL DECAL 38816-196 1 394" LG SPNG RUB SEAL 18668-008 1 WIRING INSTRUCTION KIT 47381-042 1 FLOOR MAT/FRONT 33137-024 19460 1 FOAM RS/FRONT 33621-005 19460 1 FOAM RS/REAR 33621-006 19460 1 FLOOR MAT/REAR 33642-016 19460 1 FLOOR MAT/MIDDLE 33137-023 19460 1 BASE SIDE FOAM 33641-226 19460 1 4" STRAINER ASSY 2690C 24000 1 FLOAT SWITCH 48312-980 1 DECAL KIT/SILENT PUMP 48154-810 1 WARNING DECAL 38817-101 2 WARNING DECAL 2613FE 1 DISCHARGE STICKER 6588BJ 1

OPTIONAL:

BATTERY 12V 29331-527 1

MAINTENANCE & REPAIR PAGE E - 3

Page 26

OM-07138 PA SERIES

ILLUSTRATION

11 13 14

1511

1314

8 9 10

11 12

21 22 23

32 22

38 37 36

50 33

Figure 2. Pump Model PA4E71C-3TNV88F FT4-ESP (Cont'd)

MAINTENANCE & REPAIRPAGE E - 4

Page 27

PA SERIES

9ump Model PA4E71C-3TNV88F FT4-ESP (Cont'd)

ITEM

PART NAME PART

NO.

NUMBER

PARTS LIST

QTY ITEM

NO.

PART NAME PART

NUMBER

OM-07138

QTY

1 PUMP END ASSY 46133-447 1

2 YANMAR 3TNV88F FT4 29239-064 1

3 BASE/FUEL TANK ASSY 41553-043 24150 1

4 WHEEL KIT GRP30-265 1

5 LIFTING BAIL ASSY 44715-065 24150 1

6 SAFETY CABLE BRKT 34268-020 13000 1

7 SUCT SPOOL BRKT 34165-008 15080 1

8 FLAT WASHER K08 15991 1

NOT SHOWN:

OPTIONAL:

BATTERY 12V 29331-527 1

MAINTENANCE & REPAIR PAGE E - 5

Page 28

OM-07138 PA SERIES

ILLUSTRATION

15 52 51 50

2825

15 15

46 43 40

Figure 3. Pump Assembly

4245 45

MAINTENANCE & REPAIRPAGE E - 6

Page 29

PA SERIES

ITEM

PART NAME PART

NO.

NUMBER

Pump Assembly

PARTS LIST

QTY ITEM

NO.

PART NAME PART

NUMBER

OM-07138

QTY

1 PUMP END ASSEMBLY 46133-382 1

2 PRIMING CHAMBER KIT 48275-005 1

3 STREET ELBOW RS08 11999 1

4 PIPE NIPPLE T0836 15079 1

5 BELT GUARD FRONT 34718-015 15120 1

6 AIR COMPRESSOR ASS'Y 46181-911 1

7 LOCK WASHER J06 15991 10

8 HEX HEAD CAP SCREW B0605 15991 4

9 HEX NUT D06 15991 6 10 HEX HEAD CAP SCREW B0604-1/2 15991 2 11 FLAT WASHER K06 15991 14

12 COG BELT 24186-010 1 13 FAN GUARD 42381-510 2415X 1 14 GUARD BRACKET 34127-110 15120 2 15 HEX NUT D10 15991 20 16 HEX HEAD CAP SCREW B0603-1/2 15991 4 17 HEX HEAD CAP SCREW B0404 15991 2 18 LOCK WASHER J04 15991 4 19 FLAT WASHER K04 15991 2 20 BUSHING 1610 X 1-1/2 24131-317 1 21 HEX HEAD CAP SCREW B1007 15991 4

22 KEY N0605 15990 1 23 PUMP SPROCKET 24271-115 1 24 PIPE PLUG P08 15079 3 25 PIPE ELBOW 45° AG08 11999 1 26 PIPE NIPPLE T0818 15079 1 27 ST ELBOW 26381-448 1 28 REDUCER PIPE BUSHING AP1208 15079 1 29 VENTED PIPE PLUG 4823A 15079 1 30 PIPE ELBOW R08 11999 1 31 HEX NUT D#10 15991 2 32 FLAT WASHER K#10 15991 2 33 RD HEAD MACH SCREW X#10-06 15991 2 34 LOCK WASHER J#10 15991 2 35 HEX HEAD CAP SCREW B0402-1/2 15991 2

36 VALVE BRACKET 34518-028 13000 1 37 SEAL/BRG CAVITY DRAIN 46342-045 1 38 HEX NUT D04 15991 2 39 LOCK WASHER J10 15991 16 40 CHECK VALVE KIT 4" 48274-003 1 41 FLAT WASHER K10 15991 6 42 STUD C1009 15991 2

43 GASKET 25113-034 1 44 ECC. REDUCER SPOOL 38642-508 10000 1 45 STUD C1010 15991 10

46 GASKET 25113-033 1 47 4" NPT FLANGE 1756 10010 1 48 PIPE NIPPLE T6444 15079 1 49 HEX HEAD CAP SCREW B1011 15991 8 50 4" NPT FLANGE 1756 10010 1 51 GASKET 1676GB 20000 1 52 4" HOPPER SPOOL 38644-802 10000 1 53 HEX HEAD CAP SCREW B0804 15991 2 54 LOCK WASHER J08 15991 2 55 COVER PLATE 38244-021 15080 1

56 GASKET 38689-037 18000 1 57 DRIVE ASSEMBLY 44162-182 1 58 PIPE PLUG P04 15079 1

NOT SHOWN:

SUCTION STICKER 6588AG 1 DISCHARGE STICKER 6588BJ 1 WARNING DECAL 2613FE 1 DRAIN VALVE DECAL 38817-090 1 NAMEPLATE BLANK 38819-004 13000 1 DRIVE SCREW BM#04-03 17000 4 LUBRICATION DECAL 11421A 1 INSTRUCTION DECAL 38817-085 1 G‐R DECAL 3 IN GR-03 1 WARNING DECAL 38817-102 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 7

Page 30

OM-07138 PA SERIES

ILLUSTRATION

Figure 4. Pump End Assembly

MAINTENANCE & REPAIRPAGE E - 8

Page 31

PA SERIES

OM-07138

Pump End Assembly

PARTS LIST

ITEM NO.

 1 PUMP CASING SEE NOTE BELOW 1

2 REPAIR ROTATING ASSY 44163-475 1

 3 PIPE PLUG P12 15079 3  4 PIPE PLUG P08 15079 3

5 O‐RING 25152-273 1 6 SHIM SET 13130-3 17040 8 7 O‐RING S1674 1 8 LOCK WASHER J08 15991 8

9 HEX HEAD CAP SCREW B0806 15991 4 10 O‐RING 25152-178 1 11 WEAR PLATE ASSY 46451-762 1 12 SUCTION SUPPORT 34266-052 15080 1 13 FLAT WASHER K06 15991 3 14 LOCK WASHER J06 15991 7 15 HEX HEAD CAP SCREW B0606-1/2 15991 3 16 HEX NUT D10 15991 4 17 HEX HEAD CAP SCREW B0803 15991 4 18 LOCK COLLAR 38115-551 15001 4 19 ADJUSTING SCREW 31871-070 1500G 4 20 O‐RING 25152-246 1 21 HEX HEAD CAP SCREW B0604-1/2 15991 4 22 SUCTION ADAPTER 38641-736 10000 1 23 O‐RING 25152-277 1 24 O‐RING 25152-158 1

PART NAME

PART NUMBER

QTY

 INCLUDED W/REPAIR PUMP CASING ASSY 46474-360 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 9

Page 32

OM-07138 PA SERIES

ILLUSTRATION

Figure 5. Repair Rotating Assembly

MAINTENANCE & REPAIRPAGE E - 10

Page 33

PA SERIES

OM-07138

PARTS LIST

Repair Rotating Assembly

ITEM NO.

1 IMPELLER 38615-108 1102H 1

2 CARTRIDGE SEAL ASSEMBLY 46513-151 1

3 IMPELLER ADJ SHIM SET 37J 17090 REF

4 SHAFT SLEEVE O‐RING 25154-022 REF

5 SEAL PLATE 38272-234 1102H 1

6 SEAL PLATE GASKET 10959G 20000 1

7 OIL SEAL S1352 1

7A OIL SEAL S1352 1 7B OIL SEAL S1352 1

8 LOCK WASHER J08 15991 4

9 HEX HD CAPSCREW B0805-1/2 15991 4 10 BEARING HOUSING 38251-415 10000 1 11 BEARING CAVITY DRAIN PLUG P04 15079 1

11A SEAL CAVITY DRAIN PLUG P04 15079 1

12 VENTED PLUG 4823A 15079 1 13 RED PIPE BUSHING AP0802 15079 1 14 AIR VENT S1530 1 15 SEAL CAVITY SIGHT GAUGE S1471 1

15A BEARING CAVITY SIGHT GAUGE S1471 1

16 PIPE PLUG P12 15079 1 17 INTERMEDIATE GUARD 42381-509 24152 2 18 HEX HD CAPSCREW 21632-934 8 19 LOCK WASHER J06 15991 8 20 MOUNTING FLANGE 38545-013 11010 1 21 MOUNTING FLANGE GASKET 38683-275 18000 1 22 SNAP RING S442 1 23 BALL BEARING S375 1 24 SHAFT KEY N0604 15990 1 25 IMPELLER SHAFT 38514-829 1706H 1 26 BALL BEARING S1088 1 27 PIPE PLUG PC20 10009 1 28 SEAL PLATE O‐RING 25152-273 1 29 ROTATING ASSEMBLY ADJ SHIM SET 13130 -3 17040 4 30 BEARING HOUSING O‐RING S1674 1 31 SHIPPING PLUG 11495B 15079 2

NOT SHOWN:

PART NAME

INSTRUCTION TAG 6588U 1 WARNING DECAL 38817-102 2

PART NUMBER

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 11

Page 34

OM-07138 PA SERIES

ILLUSTRATION

Figure 6. Priming Chamber Kit

PARTS LIST

ITEM NO.

1 PRIMING CHAMBER ASSY 46112-709 1

2 PIPE BUSHING AP1608 15070 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

MAINTENANCE & REPAIRPAGE E - 12

QTY

Page 35

PA SERIES

OM-07138

ILLUSTRATION

Figure 7. 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 - 13

PART NAME

-ORIFICE BUTTON 26688-021 1

PART NUMBER

QTY

Page 36

OM-07138 PA SERIES

ILLUSTRATION

Figure 8. Drive Assembly

PARTS LIST

ITEM NO.

1 SPROCKET 24271-122 1

2 COUPLING ASSY 24391-114 1

3 LOCK WASHER 21171-511 10

4 CAPSCREW 22645-164 10

5 SOC HD CAPSCR EW 22644-211 8

6 KEY N0604 15990 1

7 BUSHING 24131-595 1

8 BUSHING 24131-039 1

PART NAME

PART NUMBER

MAINTENANCE & REPAIRPAGE E - 14

QTY

Page 37

PA SERIES

OM-07138

ILLUSTRATION

Figure 9. Seal and Bearing Cavity Drains

ITEM NO.

190 SWIVEL ELBOW 26571-042 2

2 SWIVEL 26523-042 2

3 HOSE CLAMP 26518-642 6

4 3/8” ID x 10-1/2” LG. HOSE 18513-054 1

5 SHUTOFF VALVE 26661-407 1

6 STREET ELBOW RS06 11999 2

7 STREET ELBOW AGS06 11999 1

8 HOSE BARB FITTING 26523-389 3

9 REDDUCER PIPE BUSHING AP0604 14100 1 10 CONNECTOR S1447 1 11 HOSE BARB FITTING 26523-015 1 12 3/8” ID x 20” LG. HOSE 18513-054 1 13 REDUCER PIPE BUSHING AP0806 14990 1 14 3/8” ID x 9” LG. HOSE 18513-054 1

MAINTENANCE & REPAIR PAGE E - 15

PART NAME

PART NUMBER

QTY

Page 38

OM-07138 PA SERIES

ILLUSTRATION

Figure 10. Air Compressor Assembly

9 19 18

1318

MAINTENANCE & REPAIRPAGE E - 16

Page 39

PA SERIES

OM-07138

Air Compressor Assembly

PARTS LIST

ITEM NO.

1 CURTIS TOLEDO COMPRESSOR 26813-113 1 2 PIPE CAP V04 15079 1 3 PIPE NIPPLE T0428 15079 1 4 STREET ELBOW RS04 11999 1 5 HYDRAULIC HOSE ADAPTER 26813-952 1 6 GROMMET 27135-101 1 7 FAN GUARD ASSEMBLY 34851-513 15120 2 8 FAN 26761-013 1

9 HEX NUT METRIC 22647-006 4 10 HEX NUT D06 15991 4 11 LOCK WASHER J06 15991 4 12 HEX HD CAP SCREW 22645-036 4 13 HEX HEAD CAP SCREW B0403-1/2 15991 2 14 HEX HEAD CAP SCREW B0606-1/2 15991 4 15 CLAMP W/CUSHION 27111-347 1 16 FLAT WASHER K06 15991 4 17 COMPRESSOR BASE 33659-064 15080 1 18 FLAT WASHER K04 15991 8 19 LOCK WASHER J04 15991 9 20 HEX NUT D04 15991 2 21 MOUNT PLATE 33541-078 15080 1 22 HEX NUT D10 15991 6

22A HEX NUT D10 15991 6

23 LOCK WASHER J10 15991 4 24 THREADED ROD 31345-092 1500G 4 25 HEX JAM NUT AT10 15991 4 26 HEX HEAD CAP SCREW B0406 15991 3 27 HEX HEAD CAP SCREW 22645-135 1 28 LOCK WASHER J05 15991 1 29 SPROCKET 24271-005 1 30 COMPRESSOR BUSHING 31531-022 1

NOT SHOWN:

PART NAME

WARNING DECAL 38817-101 1 WARNING DECAL 38817-102 2

PART NUMBER

QTY

MAINTENANCE & REPAIR PAGE E - 17

Page 40

PA SERIESOM-07138

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 10) 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.

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 (40, Figure 3) must be removed to service most pump components. The following instructions assume complete disassembly of the pump is required.

No instructions for removal and/or disassembly of the enclosure or its components are provided in this manual. If removal of the enclosure is required for pump service, be sure to use safe shop practic es so as not to endanger personnel, and use cau tion to prevent damage to the enclosure.

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 (4, Figure 4). Clean and reinstall the drain plug.

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.

This pump is designed to handle materi al which could cause illness through di rect exposure or emitted fumes. Wear adequate protective clothing when working on the pump or piping.

Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in

MAINTENANCE & REPAIRPAGE E - 18

Page 41

PA SERIES

OM-07138

good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.

separate the priming chamber assembly, gasket (8) and baffle (9) from the spool (52, Figure 3).

(Figure 7)

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.

Use Only Genuine Gorman-Rupp re placement parts. Failure to do so may cre ate a hazard and damage the pump or di minish optimal pump performance. Any such hazard, damage or diminished per formance is not covered by the warranty.

NOTE

When appropriate recycling facilities are available, the user should recycle components and fluids when doing any routine maintenance / repairs and also at the end of the pump’s useful life. All other components and fluids shall be disposed of ac cording to all applicable codes and regulations.

Priming Chamber Removal and Disassembly

(Figure 6)

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)

Support the discharge check valve assembly (40) using a sling and a suitable lifting device. Remove the hardware (15, 39 and 41) and separate the dis charge check valve assembly and gasket (43) from the eccentric spool (44).

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.

Suction Adaptor and Wear Plate Removal

(Figure 4)

Disconnect the air discharge tubing from the prim ing chamber assembly (1). Support the priming chamber assembly using a sling and a suitable lift ing device. Remove the hardware (6 and 7) and

MAINTENANCE & REPAIR PAGE E - 19

The wear plate (11) is easily accessible and may be serviced by removing the suction adaptor (22). Be fore attempting to service the pump, remove the lowermost pipe plug (3) and drain the pump cas

Page 42

PA SERIESOM-07138

ing. When the casing is fully drained, clean and re install the pipe plug.

It is not necessary to remove the hopper spool (52, Figure 3) or suction extension to remove the suc tion adaptor. Remove the hardware (13, 14 and 15) securing the suction adaptor to the suction sup port bracket (12).

Install two 3/8-16 UNC 2B capscrews (not sup plied) in the jacking holes in the suction adaptor, and use the screws to “jack” the suction adaptor and assembled wear plate from the pump casing (1). Remove the jacking screws from the suction adaptor.

Inspect the wear plate and replace it if badly scored or worn. To remove the wear plate, remove the nuts (16) and adjusting screws (19) and separate the wear plate from the suction adaptor.

Inspect the O‐rings (20, 23 and 24) and replace them if damaged or worn.

See Figure 1 and remove the air intake cover as sembly (35) from the base (3). Support the pump end using a hoist and sling,and remove the hard ware securing the suction support bracket (12, Fig ure 4) to the base.

See Figure 3 and place a clean drip pan under the outlet for the drain assembly (37). Open the drain assembly shutoff valve and drain the oil from the seal and bearing cavities. Inspect the seal oil for water, dirt or a cloudy condition which could indi cate seal failure.

After draining the bearing and seal cavities, dis connect the lines for the drain assembly from the bearing housing (10, Figure 5).

See Figure 8 and remove the hardware (3 and 4) securing the intermediate to the engine bellhou sing. Remove the intermediate guards (17, Figure

5) and separate the assemblies by pulling the pump assembly straight away from the engine.

(Figure 8)

Separating Pump and Drive Assembly From Engine

(Figure 3)

The pump and drive assembly must be separated from the engine before further disassembly.

Removing the pump and drive assembly first re quires separating the air compressor (5) from the pump assembly.

Disengage the hardware (7, 9, 11 and 16) and re move the guard (13).

See Figure 10 and loosen the nuts (22A) on the threaded rods (24) enough to be able to remove the belt (12, Figure 3) from the sprocket (29).

Remove the hardware (10 and 11) securing the mounting plate (21, Figure 10) to the rotating as sembly mounting flange (20, Figure 5).

Disengage the piping running from the air com pressor to the pump. Use a sling and suitable lifting device to reposition the compressor to allow room for pump end removal and secure it to prevent movement.

As the assemblies separate, the flexible portion of the coupling assembly (2) will remain on the shaft. To remove the coupling from the shaft, unscrew the capscrews from the bushing (7). Screw one of the capscrews into the puller hole in the circumference of the bushing. As the coupling and bushing sepa rate, remove the bushing and slide the coupling off the shaft. Remove the bushing key.

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 gage the hardware (5) securing it to the flywheel.

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 cog belt (12). Remove the setscrews from the center of the bushing (20). Reinstall one of the setscrews in the tapped hole in the bushing and tighten it to “jack” the bushing out of the drive sprocket (23). Slide the bushing and drive sprock et off the shaft. Remove the key (22).

MAINTENANCE & REPAIRPAGE E - 20

Page 43

PA SERIES

OM-07138

Loosening Impeller

(Figure 4)

With the pump end separated from the engine, wedge a block of wood between the vanes of the impeller (1, Figure 5) and the pump casing (1) to prevent rotation.

Install the shaft key (24, Figure 5) in the shaft key way. Install a lathe dog on the drive end of the shaft (25, Figure 5) with the “V” notch positioned over the shaft key.

With the impeller rotation still blocked, see Figure 11 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 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

Shaft Key

Impeller Shaft

Impeller Removal

(Figure 5)

With the rotating assembly removed from the pump casing, unscrew the impeller (1) from the shaft (25). 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 (3); 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.

Use a pair of stiff wires with hooked ends to remove the stationary element and seat.

An alternate method of removing the stationary seal components is to remove the hardware (8 and

9) and separate the seal plate (5) and gasket (6) from the bearing housing (10). 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 re moved.

Remove the shaft sleeve O‐ring (4) and seal plate O‐ring (28).

Lathe Dog

Setscrew

Figure 11. Loosening Impeller

Pump Casing Removal

(Figure 4)

Support the pump casing using a suitable hoist and sling.

Remove the hardware (8 and 9) securing the pump casing (1) to the rotating assembly (2). Pull the pump casing straight away from the rotating as sembly to prevent binding on the impeller. Remove the shims (6) and clean the contacting surfaces.

MAINTENANCE & REPAIR PAGE E - 21

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

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

Page 44

PA SERIESOM-07138

should be performed only in a properly equipped shop by qualified personnel.

Disengage the hardware (18 and 19) and remove the mounting flange (20), gasket (21) and oil seal (7B). Press the oil seal from the mounting flange.

Place a block of wood against the impeller end of the shaft (25) and tap the shaft and assembled bearings (23 and 26) from the bearing housing. Press the oil seals (7 and 7A) from the bearing housing.

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.

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.

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 (22) and use a bearing puller to remove the inboard and outboard bearings from the shaft.

Shaft and Bearing Reassembly and Installation

(Figure 5)

Inspect the shaft (25) 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.

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

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

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

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 inboard bearing (26) on the shaft with

MAINTENANCE & REPAIRPAGE E - 22

Page 45

PA SERIES

OM-07138

the shield facing toward the impeller end of the shaft. Position the outboard bearing (23) on the shaft with the retaining ring on the bearing O.D. to ward 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 con tinuous motion, to prevent the bearings from cool ing 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.

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.

sembled bearings into the bearing housing until the retaining ring on the outboard bearing seats against the bearing housing. Remove the lip seal sleeve.

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 (7) and press it into the bearing housing with the lip positioned as shown in Figure 5, Detail C. The face of the oil seal should be just flush with the machined face of the bearing housing.

Apply a light coating of oil to the lip of the oil seal (7B) and press it into the mounting flange (20) with the lip positioned as shown in Figure 5, Detail B. The face of the oil seal should be flush with the chamfer on the mounting flange bore.

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 (23) to the shaft with the snap ring (22)

Apply a light coating of oil to the lip of the inboard oil seal (7A) and press it into the bearing housing bore with the lip positioned as shown in Figure 5, Detail C. Press the oil seal into the housing until the face is just flush with the machined surface on the hous ing.

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.

Install the drive flange gasket (21) and secure the drive flange to the bearing housing with the hard ware (18 and 19). Be careful not to damage the lip of the oil seal on the shaft keyway.

Lubricate the bearings as indicated in LUBRICA

TION at the end of this section.

Securing Bearing Housing and Drive Assembly to Engine

(Figure 8)

Install the key (6) in the shaft keyway, making sure to leave room in the keyway for the coupling key. Install the drive sprocket (1) and bushing (8) on the shaft to the dimension shown in Figure 8.

Make certain that the drive sprocket is mounted as shown in Figure 8. This di mension is critical. If the drive sprocket is not properly positioned on the shaft, it will not align properly with the driven sprocket on the air compressor, which can cause premature cog belt failure.

With the lip seal sleeve in place, lubricate the lip seal area of the shaft, and slide the shaft and as

MAINTENANCE & REPAIR PAGE E - 23

Secure the bushing and sprocket to the shaft by torqueing the bushing setscrews to 14.6 ft. lbs.

Page 46

PA SERIESOM-07138

(175 in. lbs. or 2 m. kg.). Install the cog belt (12, Fig ure 3) over the sprocket and slide it up through the slot in the mounting flange (20, Figure 5).

Install the key (6) for the bushing (7) in the shaft keyway. Position the flexible portion of the coupling assembly (2) on the shaft as shown in Figure 8.

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.

Align the keyway in the bushing (7) with the bush ing key, and slide it onto the shaft to the dimension shown in Figure 8. Rotate the flexible portion of the coupling until the tapped holes for the two set screws align with those in the bushing, and install the capscrews.

Make certain that the flexible portion of the coupling is mounted as shown in Figure

10. This dimension is critical. If the cou pling 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.

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 (17, Figure 5) and secure the mounting flange to the engine bellhous ing with the previously removed hardware (3 and

4).

(Figure 3)

Use a suitable hoist and sling to position the air compressor (6) on the mounting flange (20, Figure

5) and secure it to the mounting flange with the pre viously removed hardware (10 and 11).

Slide the cog belt (12) over the air compressor driv en sprocket (29, Figure 10). Turn the uppermost nuts (25, Figure 10) on the threaded rods (24, Fig ure 10) evenly in a cross pattern to tighten the cog belt on the sprockets. Do not over‐tighten the cog belt.

The end of the shaft must extend 1.22 inches (31 mm) from the face of the cou pling. This will allow the two portions of the coupling to fully engage when the interme diate is secured to the engine bellhousing, without pre‐loading the bearings.

With the flexible portion of the coupling and the bushing properly positioned on the shaft, tighten the capscrews in an alternating sequence until the bushing and coupling are fully secured. Torque the capscrews to 9 ft. lbs. (108 in. lbs. or 1,2 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 (5), and secure the outer ring of the coupling to the engine flywheel by torquing the hardware to 16 ft. lbs. (192 in. lbs. or 2,2 m. kg.).

NOTE

Tension on the cog belt should be enough so the belt feels snug or taut. Avoid over‐tensioning the belt. To check belt tension, finish reassembling the pump, then start the unit. A belt that is too loose will “jump teeth” under load. If this occurs, gradually in crease the belt tension until satisfactory operation is achieved.

Reinstall the guard (13) and secure it with the previ ously removed hardware.

(Figure 3)

Re‐connect the lines for the drain assembly (37) to the drain ports in the bearing housing (10, Figure

5). Be sure to connect the correct drain line to the corresponding drain port (seal or bearing cavity).

MAINTENANCE & REPAIRPAGE E - 24

Page 47

PA SERIES

OM-07138

Seal Reassembly and Installation

(Figures 5, 12, 13 and 14)

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

RETAINER

SPRING

IMPELLER

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.

SEAL PLATE

O‐RINGS

IMPELLER

SHIMS

IMPELLER

SHAFT

BELLOWS

SPRING

CENTERING

WASHER

DRIVE BAND

ROTATING

ELEMENT

Figure 12. Cartridge Seal Assembly

STATIONARY

ELEMENT

If the seal plate (5) was removed, install the seal plate gasket (6). Position the seal plate over the shaft and secure it to the bearing housing with the hardware (8 and 9).

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.

MAINTENANCE & REPAIR PAGE E - 25

To prevent damaging the shaft sleeve O‐ring (4) on the shaft threads, stretch the O‐ring over a piece of tubing. The I.D. of the tubing must be slightly larger

Page 48

PA SERIESOM-07138

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 (if so equipped) from be tween 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.

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

14).

STATIONARY SEAT

FULLY SEATED IN

SEAL PLATE BORE

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 (3) provided with the seal, and screw the impeller onto the shaft until it is seated against the seal (see Figure

13).

O‐RING ENGAGED WITH 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 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.

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.

MAINTENANCE & REPAIRPAGE E - 26

Page 49

PA SERIES

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.

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

OM-07138

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.

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.

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.

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.

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 Installation

(Figure 4)

Lubricate the O‐rings (5 and 7) with light grease and install them in the grooves in the seal plate and bearing housing. Slide the pump casing over the rotating assembly. Be careful not to damage the O‐ring.

Install the adjusting shims (6) and secure the pump casing to the rotating assembly with the hardware (8 and 9).

Wear Plate and Suction Adaptor Installation

(Figure 4)

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.

MAINTENANCE & REPAIR PAGE E - 27

If the wear plate (11) was removed for replace ment, install new O‐rings (10 and 24) on the wear plate and lubricate them with light grease. Slide the wear plate studs through the holes in the suction adaptor (22). Press the wear plate into the suction adaptor until fully seated. Secure the wear plate to the suction adaptor with the nuts (16).

Install new O‐rings (20 and 23) in the grooves in the suction adaptor and lubricate them with light

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PA SERIESOM-07138

grease. Clean any scale or debris from the contact ing surfaces in the pump casing that might inter fere or prevent a good seal with the suction adap tor.

Slide the suction adaptor and wear plate into the pump casing. Secure the suction adaptor to the suction support bracket (12) and pump casing with the hardware (13, 14 and 15). Reinstall the re maining suction adaptor hardware (14 and 21). Se cure the suction adaptor bracket to the base with the previously removed hardware.

Screw the four adjusting screws (19) into the tapped holes in the suction adaptor until they touch the wear plate. Use the lock collars (18) to turn the adjusting screws in an alternating se quence until the wear plate just touches the impel ler.

Position the lock collars over the adjusting screws so the holes in the collars for the locking screws (17) align approximately with the corresponding holes in the suction cover. Use the lock collars to index the adjusting screws three detents counter clockwise. Remove the lock collars, index them clockwise until the holes in the collars for the lock ing screws realign with the corresponding holes in the suction adaptor and reinstall them on the ad justing screws.

Secure the locking collars to the back cover plate with the hardware (8 and 17).

Be sure the wear plate does not scrape against the impeller.

Over time it may be necessary to repeat the adjust ment process to compensate for normal wear be tween the impeller and wear plate. When all of the adjustment has been used on the suction side of the pump, an additional 0.125 inch (3,2 mm) of ad justment may be obtained by removing the rotat ing assembly adjusting shims (6).

Discharge Check Valve Reassembly and Installation

(Figure 3)

If the discharge check valve (40) 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.

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 (43) to the ec centric reducer spool (44).

Priming Chamber Assembly and Installation

(Figure 7)

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).

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.

Allow an installed pump to completely cool before draining liquid from the pump casing. Disengage the hardware (8 and 9), remove the rotating as sembly adjusting shims, then reinstall the hard ware securing the rotating assembly to the pump casing. Perform the suction adaptor adjustment procedure described above to obtain the proper face clearance.

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 6)

Install the baffle (9) and gasket (8) and use a sling and suitable lifting device to position the priming

MAINTENANCE & REPAIRPAGE E - 28

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PA SERIES

OM-07138

chamber assembly on the hopper spool (not shown). 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 cham ber assembly.

Final Pump Assembly

(Figure 2)

Secure the suction spool bracket (7) to the base with the previously removed hardware.

Reinstall the air intake cover assembly (35) and se cure it with the previously removed hardware.

LUBRICATION

(Figure 5)

Seal Assembly

Before starting the pump, remove the vented plug (12) and fill the seal cavity with approximately 2 quarts (1,9 liters) of SAE No. 30 non‐detergent oil to the center of the sight gauge (15). Clean and re install the vented plug. Maintain the oil level at the middle of the sight gauge.

Bearings

(Figure 5)

larly through the sight gauge (15A) at the midpoint of the gauge. When lubrication is required, remove the air vent and bushing (13 and

14) and add SAE No. 30 non‐detergent oil through the opening. When lubricating a dry (overhauled) intermediate, fill the bearing cavity with approxi mately 10 ounces (0,3 liter) to the midpoint of the sight gauge. Clean and reinstall the air vent. Do not over‐lubricate. Over‐lubrication can cause the bearings to over‐heat, resulting in premature bear ing failure.

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.

and maintain it

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

The bearing housing was fully lubricated when shipped from the factory. Check the oil level regu

MAINTENANCE & REPAIR PAGE E - 29

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

Page 52

For Warranty Information, Please Visit

www.grpumps.com/warranty

or call:

U.S.: 419-755-1280

Canada: 519-631-2870

International: +1-419-755-1352

GORMAN‐RUPP PUMPS