Gorman-Rupp Pumps PA6C60-4045T User Manual

ACDEU

OM-06199-03

September 25, 2008

Rev. E 03‐09‐12

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

PA SERIES PUMP

MODEL

PA6C60-4045T

THE GORMAN‐RUPP COMPANY  MANSFIELD, OHIO

www.grpumps.com

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

2008 The Gorman‐Rupp Company

Register your new

Gorman‐Rupp pump online at

www.grpumps.com

Valid serial number and e‐mail address required.

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

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

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

Pump Model:

Serial Number:

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Leakage PAGE C - 1..............................................................

Pump Vacuum Check PAGE C - 1..................................................

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

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

STOPPING PAGE C - 2................................................................

BEARING TEMPERATURE CHECK PAGE C - 2..........................................

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

TROUBLESHOOTING - SECTION D PAGE D - 1..............................

PREVENTIVE MAINTENANCE PAGE D - 3...............................................

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

STANDARD PERFORMANCE CURVE PAGE E - 1........................................

i

TABLE OF CONTENTS

(continued)

PARTS LIST:

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

Pump Assembly PAGE E - 5.......................................................

Pump End Assembly PAGE E - 7...................................................

Repair Rotating Assembly PAGE E - 9...............................................

Priming Chamber Assembly PAGE E - 10.............................................

Drive Assembly PAGE E - 11........................................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 12.........................

Priming Chamber Removal And Disassembly PAGE E - 12..............................

Discharge Check Valve Removal and Disassembly PAGE E - 13.........................

Draining Oil From Seal Cavity PAGE E - 13............................................

Separating Pump And Drive Assembly From Engine PAGE E - 13........................

Impeller Loosening PAGE E - 13.....................................................

Pump Casing And Wear Plate Removal PAGE E - 14...................................

Impeller Removal PAGE E - 14......................................................

Seal Removal PAGE E - 14..........................................................

Shaft and Bearing Removal and Disassembly PAGE E - 15.............................

Shaft and Bearing Reassembly and Installation PAGE E - 15............................

Securing Intermediate And Drive Assembly To Engine PAGE E - 16......................

Seal Reassembly and Installation PAGE E - 17........................................

Impeller Installation And Adjustment PAGE E - 20......................................

Pump Casing And Wear Plate Installation PAGE E - 20.................................

Discharge Check Valve Reassembly And Installation PAGE E - 20.......................

Priming Chamber Assembly And Installation PAGE E - 21...............................

LUBRICATION PAGE E - 21.............................................................

Seal Assembly PAGE E - 21.........................................................

Bearings PAGE E - 21..............................................................

Engine PAGE E - 21................................................................

ii

INTRODUCTION

OM-06199PA SERIES

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

install and operate your pump. Failure to do so
could result in personal injury or damage to the
pump. This Installation, Operation, and Mainte
nance manual is designed to help you achieve the
best performance and longest life from your Gor
man‐Rupp pump.

This pump is a PA Series, priming‐assisted centrif
ugal model. The unit is designed for handling non‐
volatile, non‐flammable liquids containing speci
fied entrained solids. The basic material of con
struction is ductile iron, with stainless steel shaft
and ductile iron wearing parts.

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

The following are used to alert personnel to proce
dures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel:

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

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

If there are any questions regarding the pump
which are not covered in this manual or in other lit
erature accompanying the unit, please contact
your Gorman‐Rupp distributor or the Gorman‐
Rupp Company:

The Gorman‐Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901-1217

Phone: [phone]

or:

Gorman‐Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: [phone]

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

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

NOTE

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

PAGE I - 1INTRODUCTION

PA SERIES

SAFETY ‐ SECTION A

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



OM-06199

damage the pump or endanger person
nel as a result of pump failure.

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, disconnect
the positive battery cable 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 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.

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

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.

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.

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

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

PAGE A - 1SAFETY

heated pump. Vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Al
low the pump to cool completely before
servicing.

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

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

PA SERIESOM-06199

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.

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.

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, Page E‐1 for the maxi
mum continuous operating speed for
this pump.

PAGE A - 2 SAFETY

PA SERIES OM-06199

INSTALLATION - SECTION B

Review all SAFETY information in Section A.

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

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

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

OUTLINE DRAWING

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

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

Pump Dimensions

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

Figure 1. Pump Model PA6C60-4045T

PREINSTALLATION INSPECTION

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

a. Inspect the pump for cracks, dents, damaged

threads, and other obvious damage.

b. Check for and tighten loose attaching hard

ware. Since gaskets tend to shrink after dry
ing, check for loose hardware at mating sur
faces.

PAGE B - 1INSTALLATION

OM-06199 PA SERIES

c. Carefully read all tags, decals, and markings

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

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

d. Check levels and lubricate as necessary. Re

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

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

months, some of the components or lubri
cants may have exceeded their maximum
shelf life. These must be inspected or re
placed to ensure maximum pump service.

If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Gorman‐Rupp distributor or the factory to deter
mine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.

POSITIONING PUMP

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

be removed from the pump be

fore lifting.

Lifting

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

Battery Installation

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

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

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

PAGE B - 2 INSTALLATION

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

Mounting

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

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

If the pump has been mounted on a moveable
base, make certain the base is stationary by setting

PA SERIES OM-06199

the brake and blocking the wheels before attempt
ing to operate the pump.

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

SUCTION AND DISCHARGE PIPING

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

Materials

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

Line Configuration

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

Connections to Pump

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

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

lines are used, they should have adequate support
to secure them when filled with liquid and under
pressure.

Gauges

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

SUCTION LINES

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

Fittings

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

Strainers

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

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

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

PAGE B - 3INSTALLATION

OM-06199 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

PA SERIES OM-06199

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

DISCHARGE LINES

Siphoning

Do not terminate the discharge line at a level lower
than that of the liquid being pumped unless a si
phon breaker is used in the line. Otherwise, a si
phoning action causing damage to the pump
could result.

Valves

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

If a throttling valve is desired in the discharge line,
use a valve as large as the largest pipe to minimize
friction losses. Never install a throttling valve in a
suction line.

With high discharge heads, it is recommended that
a throttling valve be installed in the discharge line
to protect the pump from excessive shock pres
sure and reverse rotation when it is stopped.

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

ALIGNMENT

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

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

AUTO‐START

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

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

PAGE B - 5INSTALLATION

OM-06199 PA SERIES

Float Switch Installation

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

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

When installing the floats, note the following:

a. Be sure to provide sufficient room in the wet

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

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

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

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

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

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

d. Refer to Figure 3 for additional float switch

data.

ENGINE

CONTROL

BOX

CABLE

TETHER

POINT

1.25” Pipe
(Not Furnished)

ON

(Emptying)

OFF

(Filling)

OPERATING

RANGE

(See Table Below)

OFF

(Emptying)

ON

(Filling)

Figure 3. Float Switch Data

3.0

(0.9)

2.5

(.76)

2.0

(0.6)

1.5

(.46)

1.0

(0.3)

0.5

(.15)

1.0

(0.3)

APPROXIMATE FREE CORD LENGTH IN FT. (M)

2.0

(0.6)

3.0

(0.9)

4.0

(1.2)

PAGE B - 6 INSTALLATION

PA SERIES

OM-06199

OPERATION - SECTION C

Review all SAFETY information in Section A.

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

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

OPERATION

cated (see LUBRICATION in MAINTENANCE
AND REPAIR).

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

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

Repair, Section E for further details.

STARTING

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

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

This pump is designed to handle most
non‐volatile, non‐flammable liquids
containing specified entrained solids
and corrosives. Do not attempt to pump
volatile, corrosive, or flammable liquids
which may damage the pump or endan
ger personnel as a result of pump fail
ure.

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

PRIMING

Install the pump and piping as described in IN
STALLATION. Make sure that the piping connec

tions are tight, and that the pump is securely
mounted. Check that the pump is properly lubri

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

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

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

Manual Starting

On initial start‐up, set the engine speed at in the
half‐throttle position. Turn the keyswitch to `MANU

OPERATION PAGE C - 1