Gorman-Rupp Pumps PA6A60-4045D User Manual
ACDE
PUBLICATION NUMBER OM−04402
January 29, 1996
Rev. F 01-11-05
PRIME-AIRER
SERIES PUMPS
(Including 60-Series Pump End)
THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
www.gormanrupp.com
ECopyright by the Gorman-Rupp Company
The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects or
other reproductive harm.
OM−04402 PA SERIES PUMPS
INTRODUCTION
Thank You for purchasing a Gorman-Rupp Prime-
AireT priming-assisted 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.
A set of manuals accompanies your pump. Each
set consists of three parts; the Installation/Operation Manual contains essential information on installing and operating the pump. However, since
pump installations are seldom identical, some of
the information only summarizes general recommendations and practices required to inspect, position, and arrange the pump and piping.
The Parts List Manual provides a performance
curve, pump model cross-section drawing, and
parts list for your pump.
The Maintenance and Repair Manual provides
troubleshooting and maintenance instructions required to properly diagnose operational problems,
and to service the pump components.
This pump is a PA Series, priming-assisted centrifugal model. The unit is designed for handling nonvolatile, non-flammable liquids containing specified entrained solids.
Because pump installations are seldom identical,
this manual cannot possibly provide detailed instructions and precautions for every aspect of
each specific application. Therefore, it is the responsibility of the owner/installer of the pump to
ensure that applications not addressed in this
manual are performed only after establishing that
neither operator safety nor pump integrity are compromised by the installation. Pumps and related
equipment must be installed and operated according to all national, local and industry standards.
If there are any questions regarding the pump
which are not covered in this manual or in other literature accompanying the unit, please contact
your Gorman-Rupp distributor or the GormanRupp Company:
The 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
CONTENTS
SAFETY − SECTION A
INSTALLATION − SECTION B
PREINSTALLATION INSPECTION PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POSITIONING PUMP PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUCTION AND DISCHARGE PIPING PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUCTION LINES PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGE LINES PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALIGNMENT PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION − SECTION C
OPERATION OF MOTOR DRIVEN UNITS PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION OF ENGINE DRIVEN UNITS PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATIONAL CHECKS (All Models) PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOPPING (Motor Driven Units) PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOPPING (Non-Auto-Start Engine Driven Units) PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOPPING (Auto-Start Engine Driven Units) PAGE C − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC CHECKS (All Models) PAGE C − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC CHECKS (Engine Driven Units) PAGE C − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COLD WEATHER PRESERVATION (All Models) PAGE C − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE I − 1INTRODUCTION
OM−04402PA SERIES PUMPS
RECORDING MODEL AND
WARRANTY INFORMATION
SERIAL NUMBERS
Please record the model and serial number for
your Gorman-Rupp Prime-AireT priming-assisted
pump in the spaces provided below. Your GormanRupp distributor needs this information when you
require parts or service.
Model:
Serial Number:
The following are used to alert personnel to procedures which require special attention, to those which
could damage equipment, and to those which could be dangerous to personnel:
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure required and the injury which will result
from failure to follow the procedure.
The warranty provided with your Prime-AireT priming-assisted pump is part of Gorman-Rupp’s
support program for customers who operate and
maintain their equipment as described in this and
the other accompanying literature. Please note
that should the equipment be abused or modified
to change its performance beyond the original factory specifications, the warranty will become void
and any claim will be denied.
Hazards or unsafe practices which COULD
result in minor personal injury or product or
property damage. These instructions describe the requirements and the possible
damage which could result from failure to
follow the procedure.
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.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
PAGE I − 2 INTRODUCTION
PA SERIES PUMPS
OM−04402
SAFETY - SECTION A
This information applies to Prime AireR
Series pumps. Refer to the manual accompanying the engine or power
source before attempting to begin operation.
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and precautions for each specific application.
Therefore, it is the owner/installer’s responsibility to ensure that applications
not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity
are compromised by the installation.
Before attempting to open or service the
pump:
1. Familiarize yourself with this manual.
2. Shut down the engine and disconnect the positive battery cable, or
lock out incoming power to the motor and take precautions 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 opening any covers, plates, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.
ing away from the unit to prevent injury
during automatic operation. Disconnect
the positive battery cable before performing any maintenance. Failure to do
so may result in serious personal injury.
This pump is designed to handle most
non-volatile, non-flammable liquids
containing specified entrained solids.
Do not attempt to pump volatile, corrosive, or flammable liquids which may
damage the pump or endanger personnel as a result of pump failure.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or damage to equipment. Attach lifting equipment to the lifting device fitted to the
pump. If chains or cable are wrapped
around the pump to lift it, make certain
that they are positioned so as not to
damage the pump, and so that the load
will be balanced. The bail is intended for
use in lifting the pump assembly only.
Suction and discharge hoses and piping must be removed from the pump before lifting.
After the pump has been installed, make
certain that the pump and all piping or
hose connections are tight, properly
supported and secure before operation.
If the pump is equipped with the automatic starting system, it is subject to automatic restart. Keep hands and cloth-
Do not operate the pump against a
closed discharge valve. If operated
PAGE A − 1SAFETY
against a closed discharge valve, pump
components will deteriorate, and the
liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode. Momentary closure of a
discharge valve is acceptable only
when required for startup or shutdown
procedures.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an overheated pump. Vapor pressure within the
pump can cause parts being disengaged to be ejected with great force. Allow the pump to cool completely before
servicing.
PA SERIES PUMPSOM−04402
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.
This pump is may be used to handle materials which could cause illness
through direct exposure or emitted
fumes. Wear adequate protective clothing when working on the pump or piping.
Do not operate the pump without guards
in place over the rotating parts. Exposed rotating parts can catch clothing,
fingers or tools, causing severe injury to
personnel.
Fuel used by internal combustion engines 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 running 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
exceeded. Refer to the Performance
Curve in the Parts List Manual for the
maximum continuous operating speed
for this pump.
PAGE A − 2 SAFETY
PA SERIES PUMPS OM−04402
INSTALLATION − SECTION B
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this
section offers only general recommendations and
practices required to inspect, position, and arrange the pump and piping.
Most of the information pertains to a standard
static lift application where the pump is positioned
above the free level of liquid to be pumped.
If installed in a flooded suction application where
the liquid is supplied to the pump under pressure,
some of the information such as mounting, line
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.
Only operate this pump in the direction indicated by the arrow on the pump body
and on the accompanying decal. Otherwise, the impeller could become loosened
from the shaft and seriously damage the
pump.
d. Check levels and lubricate as necessary. Re-
fer to LUBRICATION in the Maintenance and
Repair Manual and perform duties as instructed.
e. If the pump has been stored for more than 12
months, some of the components or lubricants may have exceeded their maximum
shelf life. These must be inspected or re-
placed to ensure maximum pump service.
For further assistance, contact your Gorman-Rupp
distributor or the Gorman-Rupp Company.
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested before shipment from the factory. Before installation,
inspect the pump for damage which may have occurred during shipment. Check as follows:
a. Inspect the pump for cracks, dents, damaged
threads, and other obvious damage.
b. Check for and tighten loose attaching hard-
ware. Since gaskets tend to shrink after drying, check for loose hardware at mating surfaces.
c. 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.
If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Gorman-Rupp distributor or the factory to determine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.
Battery Installation (Engine Driven Units)
Unless otherwise specified on the pump order, the
engine battery is not included with engine driven
units.
Refer to the information accompanying the battery
and/or electrolyte solution for activation and charging instructions.
Before installing the battery, clean the positive and
negative cable connectors, and the battery terminals. Secure the battery by tightening the
holddown brackets. The terminals and clamps
may be coated with petroleum jelly to retard corrosion. Connect and tighten the positive cable first,
then the negative cable.
PAGE B − 1INSTALLATION
OM−04402 PA SERIES PUMPS
POSITIONING PUMP
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or damage to equipment. Attach lifting equipment to the lifting device fitted to the
pump. If chains or cable are wrapped
around the pump to lift it, make certain
that they are positioned so as not to
damage the pump, and so that the load
will be balanced. The bail is intended for
use in lifting the pump assembly only.
Suction and discharge hoses and piping must be removed from the pump before lifting.
Lifting
Use lifting and moving equipment with a capacity
of at least 5 times the weight of the pump, not including the weight of any customer installed accessories. Customer-installed equipment such as
suction and discharge piping must be removed
before attempting to lift. Contact the factory or the
Pump Specification Data Sheet for the approximate weight of your pump.
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 attempting to operate the pump.
If the pump has been mounted on a movable base, do not attempt to operate the
pump unless the unit is level. Be sure
the leveling stands are positioned on a
solid surface, and the wheels are
chocked.
SUCTION AND DISCHARGE PIPING
Pump performance is adversely effected by increased suction lift, discharge elevation, and friction losses. See the Performance Curve in the Parts
List Manual to be sure your overall application allows pump to operate within the safe operation
range.
Materials
Either pipe or hose maybe used for suction and
discharge lines; however, the materials must be
compatible with the liquid being pumped. If hose is
used in suction lines, it must be the rigid-wall, reinforced type to prevent collapse under suction. Using piping couplings in suction lines is not recommended.
Line Configuration
The pump assembly can be seriously
damaged if the chains or cables used to lift
and move the unit are improperly wrapped
around the pump.
Mounting
Locate the pump in an accessible place as close as
practical to the liquid being pumped. Level mounting is essential for proper operation. The pump
may have to be supported or shimmed to provide
for level operation and eliminate vibration.
For engine driven units, the pump must be posi-
tioned as level as possible to ensure sufficient lubrication and fuel supply to the engine.
PAGE B − 2 INSTALLATION
Keep suction and discharge lines as straight as
possible to minimize friction losses. Make minimum use of elbows and fittings, which substantially increase friction loss. If elbows are necessary,
use the long-radius type to minimize friction loss.
Connections to Pump
Before tightening a connecting flange, align it exactly with the pump port. Never pull a pipe line into
place by tightening the flange bolts and/or couplings.
Lines near the pump must be independently supported to avoid strain on the pump which could
PA SERIES PUMPS OM−04402
cause excessive vibration, decreased bearing life,
and increased shaft and seal wear. If hose-type
lines are used, they should have adequate support
to secure them when filled with liquid and under
pressure.
Gauges
The pump is drilled and tapped for installing discharge pressure and vacuum suction gauges. It is
recommended that gauges be installed to monitor
pump performance. Seal the gauge threads with
pipe dope to ensure an airtight seal. Follow the
sealant manufacturer’s recommendations when
selecting and applying the pipe dope. The pipe
dope should be compatible with the liquid being
pumped.
SUCTION LINES
To avoid air pockets which could affect pump priming, the suction line must be as short and direct as
possible. When operation involves a suction lift, the
line must always slope upward to the pump from
the source of the liquid being pumped; if the line
slopes down to the pump at any point along the
suction run, air pockets will be created.
larger than the solids handling capability of the
pump.
Consult the pump Specification Data Sheet or the
factory for the solids handling capabilities of your
pump.
Sealing
Since even a slight leak will affect priming, head,
and capacity, especially when operating with a
high suction lift, all connections in the suction line
should be sealed with pipe dope to ensure an airtight seal. Follow the sealant manufacturer’s recommendations when selecting and applying the
pipe dope. The pipe dope should be compatible
with the liquid being pumped.
Suction Lines In Sumps
If a single suction line is installed in a sump, it
should be positioned away from the wall of the
sump at a distance equal to 1 1/2 times the diameter of the suction line.
If there is a liquid flow from an open pipe into the
sump, the flow should be kept away from the suction inlet because the inflow will carry air down into
the sump, and air entering the suction line will reduce pump efficiency.
Fittings
Suction lines should be the same size as the pump
inlet. If reducers are used in suction lines, they
should be the eccentric type, and should be installed with the flat part of the reducers uppermost
to avoid creating air pockets. Valves are not normally used in suction lines, but if a valve is used,
install it with the stem horizontal to avoid air pockets.
Strainers
Be certain to use the strainer furnished with the
pump; any spherical solids which pass through the
strainer will also pass through the pump itself.
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
If it is necessary to position inflow close to the suction inlet, install a baffle between the inflow and the
suction inlet at a distance 1-1/2 times the diameter
of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into
the suction inlet.
If two suction lines are installed in a single sump,
the flow paths may interact, reducing the efficiency
of one or both pumps. To avoid this, position the
suction inlets so that they are separated by a distance equal to at least 3 times the diameter of the
suction pipe.
Suction Line Positioning
The depth of submergence of the suction line is
critical to efficient pump operation. Figure B−1
shows recommended minimum submergence vs.
velocity.
Although not recommended, the vacuum assisted
priming feature allows the pump to be operated
PAGE B − 3INSTALLATION
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