GORMAN-RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADAPrinted in U.S.A.
2010 The Gorman-Rupp Company
Page 2
Register your new
Gorman-Rupp pump online at
www.grpumps.com
Valid serial number and e-mail address required.
The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects or
other reproductive harm.
RECORD YOUR PUMP MODEL AND SERIAL NUMBER
Please record your pump model and serial number in the
spaces provided below. Your Gorman-Rupp distributor
needs this information when you require parts or service.
Thank You for purchasing a Gorman-Rupp pump.
Read this manual carefully to learn how to safely
install and operate your pump. Failure to do so
could result in personal injury or damage to the
pump.
This pump is a PA Series, priming-assisted centrifugal model. The unit is designed for handling nonvolatile, non-flammable liquids containing specified entrained solids. The basic material of construction is ductile iron, with stainless steel shaft
and ductile iron wearing parts. The pump is surrounded by a sound-attenuating enclosure.
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.
The following are used to alert personnel to procedures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel:
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure required and the injury which will result
from failure to follow the procedure.
Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.
For information or technical assistance on the engine, contact the engine manufacturer’s local
dealer or representative.
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
Hazards or unsafe practices which COULD
result in minor personal injury or product or
property damage. These instructions describe the requirements and the possible
damage which could result from failure to
follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
PAGE I − 1INTRODUCTION
Page 6
PA SERIES
SAFETY - SECTION A
This information applies to Prime Aire
Series pumps. Refer to the manual accompanying the engine or power
source before attempting to begin operation.
OM−06341
damage the pump or endanger personnel as a result of pump failure.
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, 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 opening any covers, plates, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the 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.
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 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.
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
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over-
PAGE A − 1SAFETY
Page 7
heated 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.
This pump 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.
PA SERIESOM−06341
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 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.
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 maximum continuous operating speed for
this pump.
PAGE A − 2SAFETY
Page 8
PA SERIESOM−06341
INSTALLATION − SECTION B
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this
section offers only general recommendations and
practices required to inspect, position, and arrange the pump and piping.
Most of the information pertains to a standard
static lift application where the pump is positioned
above the free level of liquid to be pumped.
If installed in a flooded suction application where
the liquid is supplied to the pump under pressure,
some of the information such as mounting, line
OUTLINE DRAWING
configuration, and priming must be tailored to the
specific application. Since the pressure supplied
to the pump is critical to performance and safety,
be sure to limit the incoming pressure to 50% of the
maximum permissible operating pressure as
shown on the pump performance curve.
For further assistance, contact your Gorman-Rupp
distributor or the Gorman-Rupp Company.
Pump Dimensions
See Figure 1 for the approximate physical dimensions of this pump.
Figure 1. Pump Model PA6C60−4045T−ESP
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.
PAGE B − 1INSTALLATION
Page 9
OM−06341PA 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 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 andRepair 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.
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.
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 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 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 − 2INSTALLATION
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.
If the pump has been mounted on a moveable
base, make certain the base is stationary by setting
Page 10
PA SERIESOM−06341
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 and operating range shown on Page E-1 to be sure your
overall application allows pump to operate within
the safe operation range.
Materials
Either pipe or hose maybe used for suction and
discharge lines; however, the materials must be
compatible with the liquid being pumped. If hose is
used in suction lines, it must be the rigid-wall, reinforced type to prevent collapse under suction. Using piping couplings in suction lines is not recommended.
Line Configuration
Keep suction and discharge lines as straight as
possible to minimize friction losses. Make minimum use of elbows and fittings, which substantially increase friction loss. If elbows are necessary,
use the long-radius type to minimize friction loss.
Connections to Pump
Before tightening a connecting flange, align it exactly with the pump port. Never pull a pipe line into
place by tightening the flange bolts and/or couplings.
Lines near the pump must be independently supported to avoid strain on the pump which could
cause excessive vibration, decreased bearing life,
and increased shaft and seal wear. If hose-type
lines are used, they should have adequate support
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.
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
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−06341PA SERIES
Sealing
Since even a slight leak will affect priming, head,
and capacity, especially when operating with a
high suction lift, all connections in the suction line
should be sealed with pipe dope to ensure an airtight seal. Follow the sealant manufacturer’s recommendations when selecting and applying the
pipe dope. The pipe dope should be compatible
with the liquid being pumped.
Suction Lines In Sumps
If a single suction line is installed in a sump, it
should be positioned away from the wall of the
sump at a distance equal to 1 1/2 times the diameter of the suction line.
If there is a liquid flow from an open pipe into the
sump, the flow should be kept away from the suction inlet because the inflow will carry air down into
the sump, and air entering the suction line will reduce pump efficiency.
If it is necessary to position inflow close to the suction inlet, install a baffle between the inflow and the
suction inlet at a distance 1-1/2 times the diameter
of the suction pipe. The baffle will allow entrained
air to escape from the liquid before it is drawn into
the suction inlet.
If two suction lines are installed in a single sump,
the flow paths may interact, reducing the efficiency
of one or both pumps. To avoid this, position the
suction inlets so that they are separated by a distance equal to at least 3 times the diameter of the
suction pipe.
Suction Line Positioning
The depth of submergence of the suction line is
critical to efficient pump operation. Figure 2
shows recommended minimum submergence vs.
velocity.
Although not recommended, the vacuum assisted
priming feature allows the pump to be operated
temporarily in a slurping" application with varying
water levels.
NOTE
The pipe submergence required may be reduced
by installing a standard pipe increaser fitting at the
end of the suction line. The larger opening size will
reduce the inlet velocity. Calculate the required
submergence using the following formula based
on the increased opening size (area or diameter).
PAGE B − 4INSTALLATION
Page 12
PA SERIESOM−06341
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
DISCHARGE LINES
Siphoning
Do not terminate the discharge line at a level lower
than that of the liquid being pumped unless a siphon breaker is used in the line. Otherwise, a siphoning action causing damage to the pump
could result.
Valves
This pump is designed with a check valve in the
discharge line.
If a throttling valve is desired in the discharge line,
use a valve as large as the largest pipe to minimize
friction losses. Never install a throttling valve in a
suction line.
With high discharge heads, it is recommended that
a throttling valve be installed in the discharge line
to protect the pump from excessive shock pressure and reverse rotation when it is stopped.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
ALIGNMENT
The alignment of the pump, air compressor and
engine is critical for trouble-free mechanical operation. 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 installation details for the liquid level sensing system provided with your pump.
PAGE B − 5INSTALLATION
Page 13
OM−06341PA 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 obstructed or drawn into the suction line. If a flexible suction hose is used, it may be extended
to lay along the bottom of the wet well or sump
and the float can be attached to the hose
above the point where it bends along the bottom. Direct the suction line toward the flow,
and the float(s) away from the flow. If a stand-
pipe is available, attach the float switch cable
to the standpipe in the sump at the approximate desired liquid level.
b. In a single float system, the cable can be teth-
ered to the suction line or standpipe approximately 6 inches (152 mm) above the float.
This setting allows approximately 9 inches
(229 mm) of liquid rise between pump start/
stop. The start/stop interval may be increased
by extending the float end of the cable. The
liquid level in the sump will increase approximately 8 inches (203 mm) between start/stop
intervals for every 6 inches (152 mm) of cable
increase.
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 − 6INSTALLATION
Page 14
PA SERIES
OM−06341
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 eductor 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 Efor 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 endanger personnel as a result of pump failure.
Pump speed and operating condition
points must be within the continuous performance range shown on the performance curve in Section E on page E−1.
PRIMING
Install the pump and piping as described in INSTALLATION. 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. Disconnect the positive battery cable before performing any maintenance. Failure to do so may result in serious personal injury.
Consult the engine operations manual before attempting 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-
OPERATIONPAGE C − 1
Page 15
OM−06341PA SERIES
AL’. After the engine starts and the unit is fully
primed, adjust the engine RPM until the desired
flow rate is achieved.
Pump speed and operating condition
points must be within the continuous performance range shown on the curve on
Page E-1.
Automatic Starting
With the float system installed, follow the procedures outlined for manual starting and throttle adjustment. Switch the keyswitch to ‘OFF’ until the
water level rises above the on point for the float system, then turn the keyswitch to the ‘AUTO’ setting.
The unit will run until the float signals the control
that the water in the wet well is at the float off point,
at which time the unit will shut down automatically.
When the float signals the control that the water in
the wet well is at the float on point, the unit will restart automatically, repeating the cycle.
Priming
The pump will begin to prime upon startup. The air
in the suction line will be discharged from the eductor discharge line. Complete priming is indicated
by a positive discharge pressure reading.
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 applicable).
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 Maintenance and Repair, 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 exceeds design limits. If engine over-temperature
shutdown occurs, allow the unit to cool before restarting.
If engine overheating continues, check the engine
lubricant level and viscosity. Consult the engine
operation manual for the recommended lubricant
for operation in extreme heat.
If the unit is being operated in the automatic mode,
adjust the float(s) to allow shorter run and longer
cooling periods, if possible.
If full priming is not achieved, the discharge check
valve may be malfunctioning. If this occurs, shut
down the pump and consult the separate Mainte-
nance and Repair manual for further details.
Routine Operation
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating an internal combustion
engine in an enclosed area, make sure
exhaust fumes are piped to the outside.
These fumes contain carbon monoxide,
a deadly gas that is colorless, tasteless
and odorless.
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. Disconnect the battery before performing
any maintenance. Failure to do so may
result in serious personal injury.
OPERATIONAL CHECKS
Leakage
Once the pump is fully primed, no leakage should
be visible at pump mating surfaces, or at pump
OPERATIONPAGE C − 2
Page 16
PA SERIES
OM−06341
connections or fittings. Keep all line connections
and fittings tight to maintain maximum pump efficiency.
Pump Vacuum Check
Read the vacuum gauge with the pump primed
and at operation speed. Shut off the pump. The
vacuum gauge reading will immediately drop proportionate to static suction lift, and should then stabilize. If the vacuum reading falls off rapidly after
stabilization, an air leak exists. Before checking for
the source of the leak, check the point of installation of the vacuum gauge.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
160 F (71C). Do not apply it at a higher operating
temperature.
Overheating can occur if operated with the valves
in the suction or discharge lines closed. Operating
against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to rupture or explode. If overheating occurs, stop the
pump immediately and allow it to completely cool
before servicing it. Approach any over-heated
pump cautiously.
Strainer Check
Check the strainer regularly, and clean it as necessary. The strainer should also be checked if pump
flow rate begins to drop. Monitor and record the
vacuum suction gauge readings regularly to detect
strainer blockage.
Never introduce air or steam pressure into the
pump casing or piping to remove a blockage. This
could result in personal injury or damage to the
equipment. If backflushing is absolutely necessary, liquid pressure must be limited to 50% of the
maximum permissible operating pressure shown
on the pump performance curve.
STOPPING
Manual Stopping
Never halt the flow of liquid suddenly. If the liquid
being pumped is stopped abruptly, damaging
shock waves can be transmitted to the pump and
piping system. Close all connecting valves slowly.
Reduce the throttle speed slowly and allow the engine to idle briefly before stopping.
In the manual mode, reduce the throttle speed
slowly, and allow the engine to idle briefly before
switching the HAND-OFF-AUTO switch to ‘OFF’.
If the application involves a high discharge
head, gradually close the discharge
Allow an over-heated pump to completely cool before servicing. Do not remove plates, covers, gauges, or fittings
from an overheated pump. Liquid within
the pump can reach boiling tempera-
throttling valve before stopping the pump.
After stopping the pump, switch off the engine ignition and remove the key to ensure that the pump
will remain inoperative.
tures, and vapor pressure within the
pump can cause parts being disen-
Automatic Stopping
gaged to be ejected with great force. After 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.
OPERATIONPAGE C − 3
In the automatic mode, the pump will stop when
the liquid in the wet well or sump lowers and activates the Off" float switch(s). The pump will restart
automatically when the liquid rises and activates
the On" float switch(s).
Page 17
OM−06341PA SERIES
Safety Shutdown System
The unit is equipped with a safety system to automatically shut down the engine under certain conditions. The engine will automatically shut down:
1. If the engine exceeds its safe operating temperature.
2. If the engine oil pressure drops below design
limits.
3. If the engine fails to start within a pre-set period of time.
4. If the engine speed exceeds the safe operating range.
5. If the engine fan belt breaks.
Lights on the control panel will indicate which of the
safety features has caused the engine to shut
down.
Should any of the safety features cause the engine
to shut down, the cause must be determined andcorrected before putting the unit back into service.
The engine will not restart until the key switch has
been returned to the ‘OFF’ position for at least 10
seconds.
PERIODIC CHECKS
Seal Cavity And Bearing Lubrication
Both the seal and bearing cavities were fully lubricated at the factory. Check the lubrication levels
before startup, and regularly thereafter as indicated in 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 temperatures because of heat generated by friction.
Temperatures up to 160F (71C) are considered
normal for bearings, and they can operate safely to
at least 180F (82C).
Checking bearing temperatures by hand is inaccurate. Bearing temperatures can be measured accurately by placing a contact-type thermometer
against the housing. Record this temperature for
future reference.
A sudden increase in bearing temperatures is a
warning that the bearings are at the point of failing
to operate properly. Make certain that the bearing
lubricant is of the proper viscosity and at the correct level (see LUBRICATION in Section E, Main-tenance and Repair). Bearing overheating can
also be caused by shaft misalignment and/or excessive vibration.
All safety shutdown features are pre-set at the factory for optimum performance and safety; do not
attempt to adjust these settings.
Never disconnect any of the safety shutdown features; this will void the warranty and could result in serious damage to
the unit and/or injury to personnel. Safety 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 additional information.
When pumps are first started, the bearings may
seem to run at temperatures above normal. Continued operation should bring the temperatures
down to normal levels.
Air Compressor
The air compressor was lubricated for test at the
factory. However, always check the lubrication level before startup.
Additional Checks
See Page D−4 and perform all recommended preventive maintenance checks applicable to your
particular unit.
Consult the manual accompanying the engine and
perform any and all routine checks recommended
by the engine manufacturer.
OPERATIONPAGE C − 4
Page 18
PA SERIES
OM−06341
COLD WEATHER PRESERVATION
In below freezing conditions, drain the pump to
prevent damage from freezing. Also, clean out any
solids by flushing with a hose. Operate the pump
for approximately one minute; this will remove any
remaining liquid that could freeze the pump rotating parts. If the pump will be idle for more than a
few hours, or if it has been pumping liquids containing a large amount of solids, drain the pump,
and flush it thoroughly with clean water. To prevent
large solids from clogging the drain port and preventing the pump from completely draining, insert
a rod or stiff wire in the drain port, and agitate the
liquid during the draining process. Clean out any
remaining solids by flushing with a hose.
OPERATIONPAGE C − 5
Page 19
PA SERIES
TROUBLESHOOTING − SECTION D
Review all SAFETY information in Section A.
Before attempting to open or service the
pump:
1. Familiarize yourself with this manual.
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 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.
OM−06341
TROUBLEPOSSIBLE CAUSEPROBABLE REMEDY
PUMP FAILS TO
PRIME
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
Discharge check valve contaminated, damaged, or unable to seat.
Air compressor head 180 out.Consult factory.
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 broken.
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.
TROUBLESHOOTINGPAGE D − 1
Page 20
OM−06341
TROUBLEPOSSIBLE CAUSEPROBABLE REMEDY
PA SERIES
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE (cont.)
PUMP REQUIRES
TOO MUCH
POWER
Strainer clogged.
Discharge check valve clogged.
Suction intake not submerged at
proper level or sump too small.
Impeller or other wearing parts worn
or damaged.
Discharge head too high.
Suction lift too high.
Pump speed too slow.Check engine output; consult en-
Belt or flexible coupling broken.Check and replace as necessary.
Pump speed too high.Check engine output.
Extreme ambient temperature.Reduce pump output.
Discharge head too low.
Fuel filter clogged.Check & replace often in extreme
Check strainer and clean if necessary.
Check and clean check valve.
Check installation and correct
submergence as needed.
Replace worn or damaged parts.
Check that impeller is properly
centered and rotates freely.
Pump or jack shaft bearing(s) frozen.Disassemble, check and replace
bearing(s) as required..
Discharge flow too slow.
Suction check valve or foot valve
clogged or binding.
Liquid solution too thick.
Cavitation in pump.Reduce suction lift and/or friction
Pumping entrained air.
Impeller clogged or damaged.
Open discharge valve fully to increase flow rate, and run engine at
maximum governed speed.
Clean valve.
Dilute if possible.
losses in suction line. Record vacuum and pressure gauge readings
and consult local representative or
factory.
Locate and eliminate source of air
bubble.
Secure mounting hardware.Pump or drive not securely mounted.
Clean out debris; replace damaged
parts.
TROUBLESHOOTINGPAGE D − 2
Page 21
PA SERIES
TROUBLEPOSSIBLE CAUSEPROBABLE REMEDY
OM−06341
BEARINGS RUN
TOO HOT
Bearing temperature is high, but
within limits.
Low or incorrect lubricant.
Suction and discharge lines not properly supported.
Excessive tension on drive belt.
PREVENTIVE MAINTENANCE
Since pump applications are seldom identical, and
pump wear is directly affected by such things as
the abrasive qualities, pressure and temperature
of the liquid being pumped, this section is intended
only to provide general recommendations and
practices for preventive maintenance. Regardless
of the application however, following a routine preventive maintenance schedule will help assure
trouble-free performance and long life from your
Gorman-Rupp pump. For specific questions concerning your application, contact your GormanRupp distributor or the Gorman-Rupp Company.
Record keeping is an essential component of a
good preventive maintenance program. Changes
in suction and discharge gauge readings (if so
Check bearing temperature regularly to monitor any increase.
Check for proper type and level of
lubricant.
Check piping installation for proper
support.
Align drive properly.Drive misaligned.
Check belt tension. Adjust as
required.
equipped) between regularly scheduled inspections can indicate problems that can be corrected
before system damage or catastrophic failure occurs. The appearance of wearing parts should also
be documented at each inspection for comparison
as well. Also, if records indicate that a certain part
(such as the seal) fails at approximately the same
duty cycle, the part can be checked and replaced
before failure occurs, reducing unscheduled down
time.
For new applications, a first inspection of wearing
parts at 250 hours will give insight into the wear rate
for your particular application. Subsequent inspections should be performed at the intervals shown
on the chart below. Critical applications should be
inspected more frequently.
If So Equipped)IR
V-Belts (If So Equipped)I
Air Release Valve Plunger Rod (If So Equipped)IC
Front Impeller Clearance (Wear Plate)I
Rear Impeller Clearance (Seal Plate)I
Check ValveI
Pressure Relief Valve (If So Equipped)C
Pump and Driver AlignmentI
Shaft DeflectionI
BearingsI
Bearing HousingI
PipingI
Driver Lubrication − See Mfgr’s Literature
DailyWeeklyMonthlySemi-
Annually
Annually
Legend:
I = Inspect, Clean, Adjust, Repair or Replace as Necessary
C = Clean
R = Replace
* Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually.
Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.
TROUBLESHOOTINGPAGE D − 4
Page 23
PA SERIES
OM−06341
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 PA6C60−4045T−ESP
Based on 70F (21C) clear water at sea level
with minimum suction lift. Since pump installations
are seldom identical, your performance may be different due to such factors as viscosity, specific
gravity, elevation, temperature, and impeller trim.
Pump speed and operating condition
points must be within the continuous performance range shown on the curve.
1COUPLING KIT44165−016−−−1
2BUSHING24131−498−−−1
3−KEY24113−603−−−REF
4DRIVE FLANGE38545−00410000REF
5IMPELLER SHAFT38515−5861706HREF
6LOCKWASHER21171−536−−−8
7SOC HD CAPSCREWBD0606 1/2159918
7SOC HD CAPSCREW22644−220−−−8
8HEX HD CAPSCREWB0605159918
8HEX HD CAPSCREW22645−164−−−8
9LOCKWASHERJ06159918
9LOCKWASHER21171−511−−−8
PART NAME
USE FOR SAE APPLICATIONS
USE FOR METRIC APPLICATIONS
PART
NUMBER
MAT’L
CODE
QTY
MAINTENANCE & REPAIRPAGE E − 18
Page 41
PA SERIES
PUMP AND SEAL DISASSEMBLY
AND REASSEMBLY
OM−06341
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and decals attached to the pump.
This pump requires little service due to its rugged,
minimum-maintenance design. However, if it becomes necessary to inspect or replace the wearing
parts, follow these instructions which are keyed to
the Sectional Views (see Figures 1 through and 10)
and the corresponding Parts Lists. Maintenance
and repair instructions for the engine is covered
separately in the specific literature supplied by the
manufacturer.
This manual will alert personnel to known procedures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel. However,
this manual cannot possibly anticipate and provide
detailed 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 establishing that neither personal safety
nor pump integrity are compromised by such practices.
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 practices so as not to endanger personnel and use caution to prevent damage to the enclosure.
Many pump service functions may be performed
without separating the pump end assembly from
the engine. However, the priming chamber assembly and discharge check valve assembly must be
removed to service most pump components. The
following instructions assume complete disassembly of the pump is required.
This manual will alert personnel to
known procedures which require special attention, to those which could
damage equipment, and to those which
could be dangerous to personnel. However, this manual cannot possibly anticipate and provide detailed instructions
and precautions for every situation that
might occur during maintenance of the
unit. Therefore, it is the responsibility of
the owner/maintenance personnel to
ensure that only safe, established maintenance procedures are used, and that
any procedures not addressed in this
manual are performed only after establishing that neither personal safety nor
pump integrity are compromised by
such practices.
Before attempting to open or service the
pump:
1. Familiarize yourself with this manual.
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 it is cool before opening any
covers, plates, gauges, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.
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 suction and discharge lines and drain the pump casing.
MAINTENANCE & REPAIRPAGE E − 19
This pump may be used to handle materials which could cause illness through
Page 42
PA SERIESOM−06341
direct exposure or emitted fumes. Wear
adequate protective clothing when
working on the pump or piping.
Use only replacement parts provided or
approved by Gorman-Rupp. Use of nonauthorized parts may result in damage to
the equipment and/or injury to personnel
and will invalidate the warranty.
Priming Chamber Removal And Disassembly
(Figure 8)
Disconnect both the suction piping and the air discharge tubing from the priming chamber assembly
(1). Support the priming chamber assembly using
a sling and a suitable lifting device. Remove the
hardware (6 and 7) and separate the priming
chamber assembly, baffle (9) and gasket (8) from
the pump assembly.
(Figure 9)
Discharge Check Valve Removal and
Disassembly
(Figure 5)
Remove the hardware (not shown) securing the
discharge check valve bracket to the base.
Support the discharge check valve (2) using a sling
and a suitable lifting device. Remove the hardware
(not shown) and separate the discharge check
valve assembly and gasket from the pump assembly (1).
The flapper and cover O-ring are the only serviceable parts of the check valve. If the flapper requires
replacement, remove the hardware securing the
cover and O-ring. Separate the valve cover and remove the flapper.
Back Cover Plate and Wear Plate Removal
(Figure 6)
The wear plate (24) is easily accessible and may be
serviced by removing the back cover plate (32).
Before attempting to service the pump, remove the
pump casing drain plug (10B) and drain the pump.
Clean and reinstall the drain plug.
Remove the hardware (2 and 3) securing the priming valve (1) to the priming chamber (5). Carefully
lift the valve components from the priming chamber. 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 bypass through the priming chamber after adjusting
the orifice button (see Priming Chamber Reas-sembly and Installation for adjustment), the button may require replacement. To replace the orifice
button, remove one of the e-clips" from the pivot
pin closest to the orifice button and remove the pivot pin. This will allow the linkage to be raised high
enough to access the orifice button.
Remove the hex nut and lockwasher securing the
orifice button to the linkage bar and unscrew the
orifice button from the linkage bar.
Remove the back cover nuts (31) and pry the back
cover and assembled wear plate from the pump
casing (1).
NOTE
An alternate method of removing the back cover
from the pump casing is to remove the back cover
nuts (31) and two diagonally opposing locking collars (28). Use the adjusting screws (30) to press the
back cover out of the pump casing.
Remove and discard the O-rings (16 and 25).
Inspect the wear plate and, if replacement is required, remove the hardware (26 and 27) securing
it to the back cover plate.
Separating Pump And Drive Assembly From
Engine
(Figure 10)
Further disassembly of the pump requires separating the pump end and drive assembly from the en-
MAINTENANCE & REPAIRPAGE E − 20
Page 43
PA SERIES
OM−06341
gine. Disconnect the discharge piping from the
pump casing.
Remove the hardware (8 and 9) securing the drive
flange (4) to the engine bellhousing. Separate the
assemblies by pulling the pump end straight away
from the engine.
As the assemblies separate, the flexible portion of
the coupling assembly (1) will remain on the shaft.
To remove the coupling from the shaft, unscrew the
two allen head setscrews from the bushing (2).
Screw one of the setscrews into the puller hole on
the circumference of the bushing. As the coupling
and bushing separate, remove the bushing, and
slide the coupling off the shaft. Remove the shaft
key (3).
It is not necessary to remove the outer ring of the
coupling from the engine flywheel unless the coupling must be replaced. To remove the ring, disengage the hardware (6 and 7) securing it to the flywheel.
Remove the impeller capscrew and washer (26
and 27).
Install the shaft key (22) in the shaft keyway. Install
a lathe dog on the drive end of the shaft (23) 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 counterclockwise direction (when facing the drive end of the
shaft). Use caution not to damage the shaft or keyway. When the impeller breaks loose, remove the
lathe dog, key and wood block.
Turn
Counterclockwise
Lathe Dog Arm
Move the pump end to a clean, well equipped shop
area for further disassembly.
Draining Oil From Seal Cavity
(Figure 7)
If any further disassembly is to be performed on the
pump, the seal oil cavity must be drained to prevent the oil in the seal cavity from escaping as the
pump casing is removed.
Position a clean container (3 gallons [11,4 liters]
minimum capacity) under the seal cavity drain
plugs (10A, Figure 6 and 7B, Figure 7). Remove the
plug and drain the oil from the seal cavity into the
container. For shorter drain time, remove the
vented plugs (14, Figure 6 and 8, Figure 7). Clean
and reinstall the drain and vent plugs. Inspect the
oil for water, dirt or a cloudy condition which could
indicate seal failure.
Loosening Impeller
(Figure 7)
With the pump end separated from the engine,
wedge a block of wood between the vanes of the
impeller and the pump casing to prevent rotation.
V" Notch
Heavy
Bar Stock
Figure 11. Loosening Impeller
Shaft Key
Impeller Shaft
Lathe Dog
Setscrew
NOTE
Do not remove the impeller until the rotating assembly has been removed from the pump casing.
Pump Casing Removal
(Figure 6)
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or damage to equipment. If slings or chains are
used to move the pump or components,
make sure that the load is balanced;
otherwise serious personal injury or
MAINTENANCE & REPAIRPAGE E − 21
Page 44
PA SERIESOM−06341
death could result. Suction and discharge hoses and piping must be removed from the pump before lifting.
Support the pump casing using a suitable hoist
and sling, and remove the hardware (18 and 19).
Install four 1/2−13 UNC x 2-inch long jacking
screws in the tapped holes in the bearing housing
(6, Figure 7). Tighten the jacking screws in an alternating pattern until the pump casing is pushed off
of the bearing housing. Remove the jacking
screws and shims (17).
Impeller Removal
(Figure 7)
With the rotating assembly removed from the
pump casing, unscrew the impeller (1) in a counterclockwise direction (when facing the impeller).
Use caution when unscrewing the impeller; tension on the shaft seal spring will be released as the
impeller is removed. Inspect the impeller and replace if cracked or badly worn.
Remove the impeller adjusting shims (29); tie and
tag the shims, or measure and record their thickness for ease of reassembly.
Seal Removal
(Figures 7 and 12)
Remove the spring centering washer and seal
spring. Slide the shaft sleeve (24) and rotating portion of the seal (consisting of the bellows, retainer,
and rotating element) off the shaft as a unit.
Apply oil to the sleeve and work it up under the rubber bellows. Slide the rotating portion of the seal off
the sleeve.
side of the stationary seat until the seat and O-ring
can be removed.
Remove the seal plate O-ring (30).
Remove the shaft sleeve O-ring (28).
If no further disassembly is required, refer to Seal
Installation.
Shaft and Bearing Removal and Disassembly
(Figure 7)
When the pump is properly operated and maintained, the bearing housing should not require disassembly. Disassemble the shaft and bearings
only when there is evidence of wear or damage.
Shaft and bearing disassembly in the field
is not recommended. These operations
should be performed only in a properlyequipped shop by qualified personnel.
Remove the bearing housing drain plug (7A) and
drain the lubricant. Clean and reinstall the drain
plug.
Disengage the hardware (13 and 14) and remove
the drive flange (16), gasket (18) and oil seal (15).
Use a suitably sized dowel to press the oil seal from
the drive flange.
Place a block of wood against the impeller end of
the shaft (23) and tap the shaft and assembled
bearings from the intermediate. Press the inboard
oil seal (4) out of the bearing housing.
Remove the bearing housing O-ring (31).
Slide a pair of stiff wires with hooked ends along
the shaft and hook the stationary seat from the
back side. Pull the stationary seat and O-ring from
the seal plate.
An alternate method of removing the stationary
seal components is to remove the hardware (11
and 12) and separate the seal plate from the bearing housing (6). 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
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
MAINTENANCE & REPAIRPAGE E − 22
Page 45
PA SERIES
OM−06341
be replaced any time the shaft and bear-
ings are removed.
Clean the bearing housing, shaft and all component parts (except the bearings) with a soft cloth
soaked in cleaning solvent. Inspect the parts for
wear or damage and replace as necessary.
Most cleaning solvents are toxic and
flammable. Use them only in a well ventilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent containers.
Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.
Shaft and Bearing Reassembly and Installation
(Figure 6)
Inspect the shaft 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.
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.
NOTE
The inboard bearing (25) comes from the manufacturer with a retaining ring installed on the bearing
O.D. This retaining ring must be removed prior to
installation. Position the outboard bearing (21) on
the shaft with the integral retaining ring toward the
drive end of the shaft.
Bearings must be kept free of all dirt and
foreign material. Failure to do so will greatly shorten bearing life. Do not spin dry
bearings. This may scratch the balls or
races and cause premature bearing failure.
Rotate the bearings by hand to check for roughness or binding and inspect the bearing balls. If rotation is rough or the bearing balls are discolored,
replace the bearings.
The bearing tolerances provide a tight press fit
onto the shaft and a snug slip fit into the bearing
housing. Replace the bearings, shaft, or bearing
housing if the proper bearing fit is not achieved.
If bearing replacement is required, remove the
snap ring and thrust washer (19 and 20) and use a
bearing puller to remove the inboard and outboard
bearings (21 and 25) from the shaft.
The bearings may be heated to ease installation.
An induction heater, hot oil bath, electric oven, or
hot plate may be used to heat the bearings. Bearings should never be heated with a direct flame or
directly on a hot plate.
NOTE
If a hot oil bath is used to heat the bearings, both the
oil and the container must be absolutely clean. If
the oil has been previously used, it must be thor-oughly filtered.
Heat the bearings to a uniform temperature no
higher than 250F (120C), and slide the bearings
onto the shaft, one at a time, until they are fully
seated. This should be done quickly, in one continuous motion, to prevent the bearings from cooling and sticking on the shaft.
After the bearings have been installed and allowed
to cool, check to ensure that they have not moved
away from the shaft shoulders in shrinking. If
MAINTENANCE & REPAIRPAGE E − 23
Page 46
PA SERIESOM−06341
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 suitably sized sleeve, and an arbor (or hydraulic) press
to install the bearings on the shaft.
When installing the bearings onto the
shaft, never press or hit against the outer
race, balls, or ball cage. Press only on the
inner race.
Install the thrust washer (20) and secure the outboard bearing (21) to the shaft with the snap ring
(19).
Apply a light coating of oil to the lip of the inboard oil
seal (4) and press it into the bearing housing with
the lip positioned as shown in Figure 4. Press the
oil seal into the housing until the face is just flush
with the machined surface on the housing.
Lubricate a new bearing housing O-ring (31) with
grease and install it in the groove in the bearing
housing.
Lubricate the bearings as indicated in LUBRICA-
TION at the end of this section.
Securing Bearing Housing And Drive
Assembly To Engine
(Figure 10)
Install the shaft key (22, Figure 7) in the shaft keyway. Position the flexible portion of the coupling assembly (1) on the shaft as shown in Figure 10.
NOTE
The flexible portion of the coupling must be properly positioned on the shaft. The heads of the capscrews in the center of the coupling must be posi-tioned toward the drive end of the shaft.
Align the keyway in the bushing (2) with the shaft
key, and slide it onto the shaft to the dimension
shown in Figure 10. Rotate the flexible portion of
the coupling until the tapped holes for the two setscrews align with those in the bushing, and install
the setscrews.
Slide the shaft and assembled bearings into the intermediate bore until the integral retaining ring on
the O.D. of the outboard bearing is fully seated
against the bearing housing shoulder. Use caution
not to damage the lip seal (4) on the shaft threads.
When installing the shaft and bearings into
the bearing bore, push against the outer
race. Never hit the balls or ball cage.
Install the drive flange gasket (18) and secure the
drive flange (16) to the bearing housing with the
hardware (13 and 14).
Apply a light coating of oil to the lip of the oil seal
(15) and press it into the drive flange with the lip positioned as shown in Figure 7. Be careful not to
damage the lip of the oil seal (12) on the shaft keyway. The face of the oil seal should be just flush
with the outer face of the drive flange.
Make certain that the flexible portion of the
coupling is mounted as shown in Figure
10. This is critical. If the coupling is not
properly positioned on the shaft, the
coupling parts may not fully engage, or a
pre-load condition can cause premature
bearing failure.
The coupling must be positioned 1.44inches (37 mm) from the end of the shaft.
This will allow the two portions of the coupling to fully engage when the drive flange
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 two setscrews in an alternating sequence until
the bushing and coupling are fully secured. Torque
the setscrews to 14.6 ft. lbs. (175 in. lbs. or 2 m.
kg.).
MAINTENANCE & REPAIRPAGE E − 24
Page 47
PA SERIES
OM−06341
If the complete coupling assembly is being replaced, apply ‘Loctite Retaining Compound No.
242’ or equivalent to the threads of the hardware (6
and 7), and secure the outer ring of the coupling to
the engine flywheel by torquing the hardware to 45
ft. lbs. (540 in. lbs. or 6,2 m. kg.).
Using a suitable lifting device, position the assembled rotating assembly and coupling so the
flexible portion of the coupling seats inside the outer ring attached to the engine flywheel.
NOTE
To ease installation, lightly lubricate the rubber portion of the coupling with a non-petroleum basedlubricant such as vegetable oil or glycerin, or a silicon-based lubricant such as WD40" or equivalent.
Do not use petroleum-based lubricants, or any other substance which may soften or otherwise damage the rubber.
Install the intermediate guards (17, Figure 7), and
secure the drive flange (4) to the engine bellhousing with the previously removed hardware (8 and
9).
Seal Reassembly and Installation
(Figures 7 and 12)
Clean the seal cavity and shaft with a cloth soaked
in fresh cleaning solvent. Inspect the stationary
seat bore in the seal plate for dirt, nicks and burrs,
and remove any that exist. The stationary seat bore
must be completely clean before installing the
seal.
The seal is not normally reused because wear patterns on the finished faces cannot be realigned
during reassembly. This could result in premature
failure. If necessary to reuse an old seal in an emergency, carefully wash all metallic parts in fresh
cleaning solvent and allow to dry thoroughly.
Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate precision
finished faces; even fingerprints on the faces can
shorten seal life. If necessary, clean the faces with a
non-oil based solvent and a clean, lint-free tissue.
Wipe lightly in a concentric pattern to avoid
scratching the faces.
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leakage. Clean and polish the shaft sleeve, or replace it
if there are nicks or cuts on either end. If any components are worn, replace the complete seal;
never mix old and new seal parts.
Most cleaning solvents are toxic and
flammable. Use them only in a well ventilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent containers.
If a replacement seal is being used, remove it from
the container and inspect the precision finished
faces to ensure that they are free of any foreign
matter.
To ease installation of the seal, lubricate the Orings and bellows with water or a very small
amount of oil, and apply a drop of light lubricating
oil on the finished faces. Assemble the seal as follows (see Figure 12).
MAINTENANCE & REPAIRPAGE E − 25
Page 48
PA SERIESOM−06341
IMPELLER
IMPELLER
SHAFT
BELLOWS
CENTERING
SPRING
IMPELLER
SHIMS
SPRING
WASHER
RETAINER
DRIVE BAND
ROTATING
ELEMENT
SEAL PLATE
O-RINGS
SLEEVE
O-RING
INTEGRAL
SHAFT
SLEEVE
STATIONARY
SEAT
Figure 12. Seal Assembly
This seal is not designed for operation at
temperatures above 160F (71C). Do not
use at higher operating temperatures.
Lubricate the stationary seat O-ring with water or
light oil. Press the stationary seat into the seal plate
(3) until fully seated.
Position the seal plate over the shaft and secure it
to the bearing housing (6) with the hardware (11
and 12). Be careful not to damage the stationary
seat on the shaft threads.
Lubricate a new seal plate O-ring (30) with grease
and install it in the groove in the seal plate.
To prevent damaging the shaft sleeve O-ring (28)
on the shaft threads, stretch the O-ring over a piece
of tubing 1-1/4 I.D. x 1-1/2 O.D. x 2-inches long (32
mm x 38 mm x 51 mm). 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.
Lubricate the shaft sleeve (24) with a small amount
of light oil and slide the rotating subassembly (consisting of rotating element, bellows and retainer),
onto the sleeve until the rotating element is justflush with the undercut end of the sleeve.
Slide the shaft sleeve and subassembled seal onto
the shaft until the seal faces contact. Continue to
push the sleeve through the seal until the undercut
end seats over the O-ring and against the shaft
shoulder.
Install the seal spring and spring centering washer.
Lubricate the seal as indicated in LUBRICATION
after the impeller is installed.
Impeller Installation And Adjustment
(Figure 7)
Inspect the impeller (1) and replace it if cracked or
badly worn.
MAINTENANCE & REPAIRPAGE E − 26
Page 49
PA SERIES
OM−06341
Lubricate the O-rings (16 and 25) with light grease
and install them in the grooves in the wear plate
and back cover.
The shaft and impeller threads must be
completely clean before reinstalling the impeller. Even the slightest amount of dirt on
the threads can cause the impeller to seize
to the shaft, making future removal difficult
or impossible without damage to the impeller or shaft.
Install the same thickness of impeller adjusting
shims (29) as previously removed and screw the
impeller assembly onto the shaft until tight.
NOTE
At the slightest sign of binding, immediately back
the impeller off, and check the threads for dirt. Do
not try to force the impeller onto the shaft.
A clearance of .025 to .040 inch (0,64 to 1,02 mm)
between the impeller and the seal plate is necessary for maximum pump efficiency. Measure this
clearance, and add or remove impeller adjusting
shims as required.
Clearance between the impeller and wear plate is
adjusted using the four back cover nuts (31) and
locking collars (28). There are 18 detents on the
I.D. of each locking collar. Indexing the collars one
detent on the adjusting screws represents approximately .005 inch (0,13 mm) of wear plate clearance. The recommended clearance between the
wear plate and the impeller is .010 to .020 inch
(0,25 to 0,50 mm).
USE TWO REMAINING
ADJUSTING SCREWS AND
LOCKING COLLARS TO SET
FACE CLEARANCE
USE TWO
OPPOSING
BACK COVER
NUTS TO PRESS
BACK COVER
INTO PUMP
CASING
Secure the impeller to the shaft with the impeller
washer and capscrew (26 and 27).
Pump Casing Installation
(Figure 6)
Lubricate the rotating assembly O-rings (15 and
16) with a light coating of grease. Use a suitable
hoist and sling to slide the pump casing (1) over the
rotating assembly.
Install two shims (17) at each mounting location
and secure the casing to the rotating assembly (2)
with the hardware (18 and 19).
Wear Plate And Back Cover Plate Installation
And Adjustment
(Figures 6 and 13)
If the wear plate (24) was removed for replacement, carefully center it on the back cover plate
(32) and secure it with the hardware (26 and 27).
TURN INDEX COLLARS
3 DETENTS COUNTERCLOCKWISE, THEN
TURN CLOCKWISE UNTIL SCREW HOLES
ALIGN
Figure 13. Installing and Adjusting Back Cover
Screw the four adjusting screws (30) into the
tapped holes in the back cover plate until they are
just flush with the machined surface on the back
side of the cover plate.
Align the back cover plate over the studs (23) and
slide it into the pump casing. Use two back cover
nuts (31) on diagonally opposing studs to press
the back cover into the pump casing until the wear
plate just touches the impeller when the shaft is
turned by hand. Tighten the nuts evenly to avoid
binding.
With the wear plate just touching the impeller, turn
the two free adjusting screws until they engage the
pump casing. Position the locking collars over the
MAINTENANCE & REPAIRPAGE E − 27
Page 50
PA SERIESOM−06341
adjusting screws so the holes in the collars for the
locking screws align approximately with the holes
in the cover plate.
Loosen the back cover nuts used to press the back
cover into the pump casing one full turn.
Pull the collars off the adjusting screws, index them
three detents counterclockwise, and reinstall the
collars on the adjusting screws. Use the collars to
turn the adjusting screws clockwise until the holes
in the locking collars realign with the tapped screw
holes in the back cover plate. Secure the locking
collars to the back cover plate with the hardware
(19 and 29). Install the two remaining back cover
nuts snugly against the adjusting screws.
Remove the first two back cover nuts from their
studs. Turn the adjusting screws clockwise until
they engage the pump casing. Install the locking
collars (28) and hardware (19 and 29). Reinstall the
back cover nuts.
Be sure the wear plate does not scrape against the
impeller.
Install the cover O-ring and secure the cover with
the previously removed hardware.
Apply a small amount of light grease to the gasket
to hold it in place and position it against the pump
casing flange. Position the discharge check valve
assembly and secure it with the prevousily removed hardware.
Priming Chamber Assembly And Installation
(Figure 9)
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".
Over time it may be necessary to repeat the adjustment process to compensate for normal wear between the impeller and wear plate. When all of the
adjustment has been used on the back cover side
of the pump, an additional 0.120 inch (3 mm) of adjustment may be obtained by removing the rotating assembly adjusting shims (17).
Allow an installed pump to completely cool before
draining liquid from the pump casing. Remove the
back cover. Remove the rotating assembly adjusting shims, then reinstall the hardware securing the
rotating assembly to the pump casing. Perform the
back cover adjustment procedure described
above to obtain the proper face clearance.
Discharge Check Valve Reassembly And
Installation
(Figure 4)
The flapper and cover O-ring are the only serviceable parts of the check valve. If the flapper requires
replacement, remove the hardware securing the
cover and gasket. Separate the cover and replace
the flapper.
Adjust the orifice button seating as necessary by
screwing the orifice button into or out of the linkage
bar. Proper adjustment is achieved when the orifice button fully seats against the orifice before the
linkage bar on the float bottoms against the
threads on the orifice button. When adjustment is
complete, install and tighten the lock washer and
hex nut securing the orifice button.
Install the strainer (6) and priming valve gasket (4).
Lower the float into the priming chamber (5) and
secure the priming valve with the previously removed hardware (2 and 3).
(Figure 8)
Install the baffle (9) and gasket (8) and use a sling
and suitable lifting device to position the priming
chamber assembly on the hopper spool (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 chamber assembly.
MAINTENANCE & REPAIRPAGE E − 28
Page 51
PA SERIES
OM−06341
LUBRICATION
(Figure 6)
Seal Assembly
Fill the seal cavity through the hole for the vented
plug (14) with SAE No. 30 non-detergent oil. Check
the oil level regularly and refill as required. When lubricating a dry seal cavity, add approximately
approximately 256 oz. or 8 U.S. quarts (7,6 liters) of
oil to level indicated.
Bearings
(Figure 7)
The bearing housing was fully lubricated when
shipped from the factory. Check the oil level regularly through the sight gauges (5)and maintain it at
the midpoint of the gauge. When lubrication is required, remove the air vent and bushing (9 and 10)
and add SAE No. 30 non-detergent oil through the
opening. When lubricating a dry (overhauled)
bearing housing, fill the bearing cavity with approximately 40 ounces (1,2 liters) of oil. Clean and reinstall the air vent. Do not over-lubricate. Over-lubrication can cause the bearings to over-heat, resulting in premature bearing failure.
NOTE
The white reflector in the sight gauge must be positioned horizontally to provide proper drainage.
Under normal conditions, drain the bearing housing once each year and refill with clean oil. Change
the oil more frequently if the pump is operated continuously or installed in an environment with rapid
temperature change.
Monitor the condition of the bearing lubricant regularly for evidence of rust or moisture condensation. This is especially important in areas where variable hot and
cold temperatures are common.
For cold weather operation, consult the factory or a
lubricant supplier for the recommended grade of
oil.
Engine
Consult the literature supplied with the engine, or
contact your local engine representative.
MAINTENANCE & REPAIRPAGE E − 29
Page 52
For U.S. and International Warranty Information,
Please Visit www.grpumps.com/warranty
or call:
U.S.: 419−755−1280
International: +1−419−755−1352
For Canadian Warranty Information,
Please Visit www.grcanada.com/warranty
or call:
519−631−2870
THE GORMAN-RUPP COMPANY MANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA
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