Gorman-Rupp Pumps PA6C60-4045T-ESP User Manual

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Page 1

ACDEU

OM−06341−02

February 18, 2010

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

PA SERIES PUMP

MODEL

PA6C60−4045T−ESP

THE GORMAN-RUPP COMPANY  MANSFIELD, OHIO

www.grpumps.com

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

2010 The Gorman-Rupp Company

Page 2

Gorman-Rupp pump online at

www.grpumps.com

Valid serial number and e-mail address required.

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

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

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

Pump Model:

Serial Number:

Page 3

TABLE OF CONTENTS

INTRODUCTION PAGE I − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY - SECTION A PAGE A − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION − SECTION B PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Dimensions PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREINSTALLATION INSPECTION PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Installation PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POSITIONING PUMP PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Materials PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Configuration PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections to Pump PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gauges PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION LINES PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fittings PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainers PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealing PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Page 4

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 5

INTRODUCTION

OM−06341PA 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 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 − 2 SAFETY

Page 8

PA SERIES OM−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−06341 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 indicated by the arrow on the pump body and on the accompanying decal. Otherwise, the impeller could become loosened from the shaft and seriously damage the pump.

d. Check levels and lubricate as necessary. Re-

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

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

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

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

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 − 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 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 SERIES OM−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−06341 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 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 − 4 INSTALLATION

Page 12

PA SERIES OM−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−06341 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 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)

(Emptying)

OFF

(Filling)

OPERATING

RANGE

(See Table Below)

OFF

(Emptying)

(Filling)

Figure 3. Float Switch Data

3.0

(0.9)

2.5

(.76)

2.0

(0.6)

1.5

(.46)

1.0

(0.3)

0.5

(.15)

1.0

(0.3)

APPROXIMATE FREE CORD LENGTH IN FT. (M)

2.0

(0.6)

3.0

(0.9)

4.0

(1.2)

PAGE B − 6 INSTALLATION

Page 14

PA SERIES

OM−06341

OPERATION − SECTION C

Review all SAFETY information in Section A.

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

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 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 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-

OPERATION PAGE C − 1

Page 15

OM−06341 PA SERIES

AL’. After the engine starts and the unit is fully primed, adjust the engine RPM until the desired flow rate is achieved.

Pump speed and operating condition points must be within the continuous 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

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 (71C). Do not apply it at a higher operating temperature.

Overheating can occur if operated with the valves in the suction or discharge lines closed. Operating against closed valves could bring the liquid to a boil, build pressure, and cause the pump to 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.

OPERATION PAGE 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−06341 PA 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 and corrected before putting the unit back into service. The engine will not restart until the key switch has been returned to the ‘OFF’ position for at least 10 seconds.

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

Checking bearing temperatures by hand is 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.

OPERATION PAGE 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

TROUBLE POSSIBLE CAUSE PROBABLE 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.

TROUBLESHOOTING PAGE D − 1

Page 20

OM−06341

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PA SERIES

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE (cont.)

PUMP REQUIRES TOO MUCH POWER

Strainer clogged.

Discharge check valve clogged.

Suction intake not submerged at proper level or sump too small.

Impeller or other wearing parts worn or damaged.

Discharge head too high.

Suction lift too high.

Pump speed too slow. Check engine output; consult en-

Belt or flexible coupling broken. Check and replace as necessary.

Pump speed too high. Check engine output.

Extreme ambient temperature. Reduce pump output.

Discharge head too low. Fuel filter clogged. Check & replace often in extreme

Check strainer and clean if 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.

Free impeller of debris.Impeller clogged.

Install bypass line.

Measure lift w/vacuum gauge. Reduce lift and/or friction losses in suction line.

gine operation manual.

Adjust discharge valve.

operating conditions.

PUMP CLOGS FREQUENTLY

EXCESSIVE NOISE

Dilute if possible.Liquid solution too thick.

Check and replace as required.Fuel contaminated.

Pump or jack shaft bearing(s) frozen. Disassemble, check and replace

bearing(s) as required..

Discharge flow too slow.

Suction check valve or foot valve clogged or binding.

Liquid solution too thick.

Cavitation in pump. Reduce suction lift and/or friction

Pumping entrained air.

Impeller clogged or damaged.

Open discharge valve fully to 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

TROUBLE POSSIBLE CAUSE PROBABLE 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.

TROUBLESHOOTING PAGE D − 3

Page 22

OM−06341

PA SERIES

Preventive Maintenance Schedule

Service Interval*

Item

General Condition (Temperature, Unusual

Noises or Vibrations, Cracks, Leaks,

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

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

Daily Weekly Monthly Semi-

Annually

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

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

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

TROUBLESHOOTINGPAGE D − 4

Page 23

PA SERIES

OM−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 70F (21C) 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.

MAINTENANCE & REPAIR PAGE E − 1

Page 24

OM−06341 PA SERIES

PARTS PAGE

Figure 1. Pump Model PA6C60−4045T−ESP

MAINTENANCE & REPAIRPAGE E − 2

Page 25

PA SERIES

ITEM

PART NAME PART

NO.

Pump Model PA6C60−4045T−ESP

PARTS LIST

(From S/N 1450296 Up)

NUMBER

MAT’L CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

OM−06341

MAT’L CODE

QTY

1 PA6C60−(SAE 4/10) 46133−667 −−− 1 2 J.D. 4045T ENGINE 29224−308 −−− 1 3  ENCLOSURE ASSY 42164−031 −−− 1 4 HOSE CLAMP 26518−678 −−− 2 5 BRACKET 34184−007 15120 1 6 FLAT WASHER K06 15991 12 7 HEX NUT D06 15991 14 8 4.5" ID x 48" LG. HOSE 18533−172 −−− 1

 CONSULT FACTORY FOR ADDITIONAL ENCLOSURE PARTS

29 BATT BOX LID ASSY 42113−012 24150 1 30 BATTERY SEE OPTIONS 1 31 POS BATTERY CABLE 47311−137 −−− 1 32 NEG BATTERY CABLE 47311−173 −−− 1 33 BATTERY BOX ASSY 42431−030 24150 1 34 FLANGED HEX NUT 21765−314 −−− 4 35 FLAT WASHER K08 15991 11 36 SKID BASE ASSY 41565−596 −−− 1 37 HEX HD CAPSCREW B0505 15991 10 38 HEX NUT D08 15991 3 39 STUD MOUNT 24631−011 −−− 2 40 BRACKET ASSY 41881−706 24150 1 41 CROSS RAIL 34412−035 15080 1 42 CABLE TIE MTG BLOCK 27111−352 −−− 2 43 PIPE NIPPLE T9624 −−− 1 44 CHECK VALVE SUPPORT 34561−012 15080 1 45 HEX HD CAPSCREW B0606 15991 2 46 HEX HD CAPSCREW B1213 15991 8 47 6" NPT FLANGE 1758 10010 2 48 GASKET 25113−036 −−− 2 49 LOCK WASHER J12 15991 18 50 HEX NUT D12 15991 8 51 PUMP SUPPORT 34265−051 15080 1 52 HEX HD CAPSCREW B0806 15991 2 53 HEX HD CAPSCREW B1206 15991 2 54 PIPE NIPPLE T9648 15070 1 55 HEX HD CAPSCREW B1209 15991 8

MAINTENANCE & REPAIR PAGE E − 3

Page 26

OM−06341 PA SERIES

Figure 2. Pump Model PA6C60−4045T−ESP

MAINTENANCE & REPAIRPAGE E − 4

Page 27

PA SERIES

ITEM

PART NAME PART

NO.

Pump Model PA6C60−4045T−ESP

PARTS LIST (Cont’d)

NUMBER

MAT’L CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

OM−06341

MAT’L CODE

QTY

2 J.D. 4045T ENGINE 29224−313 −−− 1

3  ENCLOSURE ASSY 42164−031 −−− 1

4 HOSE CLAMP 26518−678 −−− 2

5 BRACKET 34184−007 15120 1

6 FLAT WASHER K06 15991 12

7 HEX NUT D06 15991 14

8 4.5" ID x 48" LG. HOSE 18533−172 −−− 1

9 HOIST BAIL ASSY 44715−044 24150 1 10 GASKET 33311−060 19460 1 11 MOUNTING BRACKET 34741−021 13000 1 12 HEX HD CAPSCREW B0604 15991 10 13 FLAT WASHER K04 15991 16 14 CONTROL PANEL 29284−012 −−− 1 15 PLUG CONNECTOR 27261−301 −−− 1 16 16/4 x 80" LG. CABLE 18141−147 −−− 1 17 HEX HD CAPSCREW B0605 15991 4 18 LOCK WASHER J06 17090 14 19 HEX HD CAPSCREW B0805 15991 11 20 LOCK WASHER J08 15991 15 21 U-BOLT 29334−268 −−− 2 22 WEATHER CAP S1706 −−− 1 23 EXHAUST ELBOW 29334−381 −−− 1 24 MOUNTING ASSY 41881−788 −−− 2 25 HEX HD CAPSCREW B0504 15991 14 26 LOCK WASHER J05 15991 24 27 FLAT WASHER K05 15991 24 28 HEX HD CAPSCREW B0606−1/2 15991 2 29 BATT BOX LID ASSY 42113−012 24150 1 30 BATTERY SEE OPTIONS 1 31 POS BATTERY CABLE 47311−137 −−− 1 32 NEG BATTERY CABLE 47311−173 −−− 1 33 BATTERY BOX ASSY 42431−030 24150 1 34 FLANGED HEX NUT 21765−314 −−− 4 35 FLAT WASHER K08 15991 11 36 SKID BASE ASSY 41565−596 −−− 1 37 HEX HD CAPSCREW B0505 15991 10

 CONSULT FACTORY FOR ADDITIONAL ENCLOSURE PARTS

38 HEX NUT D08 15991 3 39 STUD MOUNT 24631−011 −−− 2 40 BRACKET ASSY 41881−706 24150 1 41 CROSS RAIL 34412−035 15080 1 42 CABLE TIE MTG BLOCK 27111−352 −−− 2 43 PIPE NIPPLE T9624 −−− 1 44 CHECK VALVE SUPPORT 34561−012 15080 1 45 HEX HD CAPSCREW B0606 15991 2 46 HEX HD CAPSCREW B1213 15991 8 47 6" NPT FLANGE 1758 10010 2 48 GASKET 25113−036 −−− 2 49 LOCK WASHER J12 15991 18 50 HEX NUT D12 15991 8 51 PUMP SUPPORT 34265−051 15080 1 52 HEX HD CAPSCREW B0806 15991 2 53 HEX HD CAPSCREW B1206 15991 2 54 PIPE NIPPLE T9648 15070 1 55 HEX HD CAPSCREW B1209 15991 8 56 T-BOLT CLAMP 26581−166 −−− 1 57 SHIM SET 48261−045 −−− 4 58 RED ELBOW 29284−041 −−− 1 59 AIR INTAKE PIPE 31417−070 15210 1 60 T-BOLT CLAMP 26518−164 −−− 5 61 SOCKET CONNECTOR 27263−001 −−− 1 62 FLANGED CAPSCREW 21634−505 −−− 1 63 HEX HD CAPSCREW B0404 15991 8 64 LOCK WASHER J04 15991 12 65 ELBOW 29284−039 −−− 1 66 AIR INTAKE PIPE 31417−068 15210 1 67 DISCHARGE COVER 34851−530 13000 1 68 GASKET 38687−588 19460 1 69 DISCH COVER PLATE 33282−038 13000 2 70 3" x 3" HUMP HOSE 29284−056 −−− 1 71 MUFFLER BRKT ASSY 41888−110 24150 1 72 MUFFLER 29334−110 −−− 1

MAINTENANCE & REPAIR PAGE E − 5

Page 28

OM−06341 PA SERIES

Figure 3. Pump Model PA6C60−4045T−ESP

MAINTENANCE & REPAIRPAGE E − 6

Page 29

PA SERIES

ITEM

PART NAME PART

NO.

Pump Model PA6C60−4045T−ESP

PARTS LIST (Cont’d)

NUMBER

MAT’L CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

OM−06341

MAT’L CODE

QTY

3  ENCLOSURE ASSY 42164−031 −−− 1

4 HOSE CLAMP 26518−678 −−− 2

5 BRACKET 34184−007 15120 1

6 FLAT WASHER K06 15991 12

7 HEX NUT D06 15991 14

8 4.5" ID x 48" LG. HOSE 18533−172 −−− 1

 CONSULT FACTORY FOR ADDITIONAL ENCLOSURE PARTS

40 BRACKET ASSY 41881−706 24150 1 41 CROSS RAIL 34412−035 15080 1 42 CABLE TIE MTG BLOCK 27111−352 −−− 2 43 PIPE NIPPLE T9624 −−− 1 44 CHECK VALVE SUPPORT 34561−012 15080 1 45 HEX HD CAPSCREW B0606 15991 2 46 HEX HD CAPSCREW B1213 15991 8 47 6" NPT FLANGE 1758 10010 2 48 GASKET 25113−036 −−− 2 49 LOCK WASHER J12 15991 18 50 HEX NUT D12 15991 8 51 PUMP SUPPORT 34265−051 15080 1 52 HEX HD CAPSCREW B0806 15991 2 53 HEX HD CAPSCREW B1206 15991 2 54 PIPE NIPPLE T9648 15070 1 55 HEX HD CAPSCREW B1209 15991 8 56 T-BOLT CLAMP 26581−166 −−− 1 57 SHIM SET 48261−045 −−− 4 58 RED ELBOW 29284−041 −−− 1 59 AIR INTAKE PIPE 31417−070 15210 1 60 T-BOLT CLAMP 26518−164 −−− 5 61 SOCKET CONNECTOR 27263−001 −−− 1 62 FLANGED CAPSCREW 21634−505 −−− 1 63 HEX HD CAPSCREW B0404 15991 8 64 LOCK WASHER J04 15991 12 65 ELBOW 29284−039 −−− 1 66 AIR INTAKE PIPE 31417−068 15210 1 67 DISCHARGE COVER 34851−530 13000 1 68 GASKET 38687−588 19460 1 69 DISCH COVER PLATE 33282−038 13000 2 70 3" x 3" HUMP HOSE 29284−056 −−− 1 71 MUFFLER BRKT ASSY 41888−110 24150 1 72 MUFFLER 29334−110 −−− 1 73 FOAM INSRT SIDE PANEL 33643−205 19460 2 74 GASKET 33461−054 19460 1 75 COVER PLATE 34851−318 13000 1 76 HEX HD CAPSCREW B0405 15991 4

MAINTENANCE & REPAIR PAGE E − 7

Page 30

OM−06341 PA SERIES

Figure 4. Pump Model PA6C60−4045T−ESP

MAINTENANCE & REPAIRPAGE E − 8

Page 31

PA SERIES

ITEM

PART NAME PART

NO.

Pump Model PA6C60−4045T−ESP

PARTS LIST (Cont’d)

NUMBER

MAT’L CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

OM−06341

MAT’L CODE

QTY

77 RED PIPE BUSHING AP2008 11999 1 78 HOSE CLAMP 26518−641 −−− 2 79 RED PIPE BUSHING AP1206 14990 2 80 FUEL PICKUP 29332−146 −−− 1 81 HOSE BARB FITTING 26523−386 −−− 2 82 1/8" ID x 30" LG. HOSE 18513−301 −−− 1 83 FUEL PICKUP 29332−144 −−− 1 84 HOSE BARB FITTING 26523−015 −−− 1 85 CONNECTOR S1447 −−− 1 86 STREET ELBOW RD08 11999 2 87 PIPE TEE U08 11999 1 88 PIPE UNION AH08 11999 1 89 RED PIPE BUSHING AP0806 15079 1 90 CHECK VALVE 26641−092 −−− 1 91 HOSE CLAMP 26518−666 −−− 1 92 1/2" ID x 13.5" LG. HOSE 18513−056 −−− 1 93 MALE HOSE END 26525−020 −−− 5 94 HOSE CLAMP 26518−642 −−− 8 95 HOSE FITTING 26523−335 −−− 2 96 1/2" ID x 60" LG. HOSE 18513−056 −−− 1 97 3/4" ID x 25" LG. HOSE 18513−115 −−− 1 98 3/8" ID x 89" LG. HOSE 18513−054 −−− 1 99 1/2" ID x 25" LG. HOSE 18513−056 −−− 1

100 HOSE BARB FITTING 26523−047 −−− 1 101 CONNECTOR S1598 −−− 1 102 1/2" ID x 45" LG. HOSE 18513−113 −−− 1 103 CONNECTOR 26351−065 −−− 2 104 HOSE ASSY 46341−426 −−− 1 105 3/8" ID x 23.5" LG. HOSE 18513−054 −−− 1 106 CABLE CLAMP 27111−105 −−− 1 107 TAP SCREW 21281−446 −−− 1 108 3/8" ID x 36" LG. HOSE 18513−302 −−− 1 109 HOSE BARB 26523−333 −−− 1 110 PRESS RELIEF VALVE 26662−028 −−− 1

111 BALL VALVE 26631−023 −−− 1 112 CLOSE PIPE NIPPLE T08 15079 1 113 VENTURI 26817−002 −−− 1 114 PIPE COUPLING AE08 15079 1 115 STREET ELBOW AGS08 11999 1 116 HOSE BARB FITTING 26523−446 −−− 1

NOT SHOWN:

PRIME AIRE DECAL 38812−078 −−− 1 SUCTION STICKER 6588AG −−− 1 SILENT PUMP DECAL KIT 48154−813 −−− 1 DISCHARGE STICKER 6588BJ −−− 1 WARNING DECAL 38816−203 −−− 4 CAUTION DECAL 2613FJ −−− 1 ENGINE STARTUP TAG 38816−269 −−− 1 INSTRUCTION TAG 38817−085 −−− 1 LEVEL CONTROL LABEL 38816−332 −−− 1 OIL DRAIN LABEL 38816−323 −−− 1 268" LG. FOAM TAPE 18668−003 −−− 1 WARNING DECAL 38816−345 −−− 2 INSTRUCTION DECAL 38818−144 −−− 1 RADIATOR DRAIN LABEL 38816−322 −−− 1 PUMP DRAIN LABEL 38816−320 −−− 1 FUEL TANK DRAIN LABEL 38816−321 −−− 1 FLOAT SWITCH KIT 48312−980 −−− 1 CABLE TIE 27111−205 −−− 2 WARNING DECAL 2613FE −−− 2

OPTIONAL:

12V DRY BATTERY 29331−506 −−− 1 12V WET BATTERY 29331−526 −−− 1 EPS CONT PANEL KIT 48122−522 −−− 1 GAUGE KIT 48213−112 −−− 1 DUAL FLOAT SW KIT 48312−981 −−− 1 HEATED FUEL FILTER KIT 48122−914 −−− 1

MAINTENANCE & REPAIR PAGE E − 9

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OM−06341 PA SERIES

Figure 5. PA6C60−(SAE 4/10) Pump Assembly

MAINTENANCE & REPAIRPAGE E − 10

Page 33

PA SERIES

OM−06341

PA6C60−(SAE 4/10) Pump Assembly

PARTS LIST

ITEM NO.

1 66F60−(SAE 4/10) PUMP SUBASSEMBLY SEE FIGURE 6 −−− 1 2 6" CHECK VALVE KIT 48274−015 −−− 1

3 PRIMING CHAMBER KIT 48275−005 −−− 1

NOT SHOWN:

OPTIONAL:

PART NAME

−CHECK VALVE 26642−126 −−− 1

−FLAPPER 26688−001 −−− 1

−COVER O-RING 25152−377 −−− 1

−FLANGE GASKET 25113−036 −−− 1

STRAINER 7823A 24000 1 SUCTION STICKER 6588AG −−− 1 DISCHARGE STICKER 6588BJ −−− 1 WARNING DECAL 2613FE −−− 1 G-R DECAL GR−06 −−− 1 LUBE DECAL 11421A −−− 1 OIL LEVEL DECAL 38816−123 −−− 1

HEATED PRIMING CHAMBER KIT 48275−007 −−− 1

PART NUMBER

MAT’L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E − 11

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OM−06341 PA SERIES

Figure 6. 66F60−(SAE 4/10) Pump Subassembly

MAINTENANCE & REPAIRPAGE E − 12

Page 35

PA SERIES

ITEM

PART NAME PART

NO.

PARTS LIST

66F60−(SAE 4/10) Pump Subassembly

NUMBER

MAT’L CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

OM−06341

MAT’L CODE

QTY

1 PUMP CASING 38218−303 11010 1

2 REPAIR ROTATING ASSY 44163−430 −−− 1

3 BLIND FLANGE ASSY 42111−349 −−− 1

4 HEX HD CAPSCREW B1213 15991 8

5 LOCK WASHER J12 15991 8

6 HEX NUT D12 15991 8

GASKET 25113−036 −−− 1

8 SEAL CVTY SIGHT GAUGES1471 −−− 1

9 NOT USED 10 PIPE PLUG P08 15079 6 11 NOT USED 12 NOT USED 13 NOT USED 14 VENTED PLUG 4823A 15079 1

15 SEAL PLATE O-RING 25152−381 −−− 1

16 BEARING HSG O-RING S1676 −−− 1

16A BACK COVER O-RING S1676 −−− 1

17 ROT ASSY SHIM 13131−3 17040 8

INDICATES PARTS RECOMMENDED FOR STOCK

18 HEX HD CAPSCREW B0806 15991 4 19 LOCK WASHER J08 15991 12 20 DRIVE ASSY 44162−159 −−− 1 21 PIPE PLUG P12 15079 1 22 STREET ELBOW 25412−004 −−− 1 23 STUD C1213 15991 4

24 WEAR PLATE 38691−864 11010 1

25 WEAR PLATE O-RING 25152−453 −−− 1 26 LOCK WASHER J06 17090 4 27 HEX HD CAPSCREW B0604−1/2 17000 4 28 LOCK COLLAR 38115−551 15001 4 29 HEX HD CAPSCREW B0804−1/2 15991 4 30 ADJUSTING SCREW 31871−070 1500G 4 31 BACK COVER NUT 31871−073 15000 4 32 BACK COVER PLATE 38243−468 11010 1

NOT SHOWN:

OIL LEVEL DECAL 38816−123 −−− 1 NAME PLATE 38818−127 13000 1 DRIVE SCREW BM#04−03 17000 2

MAINTENANCE & REPAIR PAGE E − 13

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OM−06341 PA SERIES

Figure 7. 44163−430 Repair Rotating Assembly

MAINTENANCE & REPAIRPAGE E − 14

Page 37

PA SERIES

ITEM

PART NAME PART

NO.

PARTS LIST

44163−430 Repair Rotating Assembly

NUMBER

MAT’L CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

OM−06341

MAT’L CODE

QTY

1 IMPELLER 38615−092 11010 1

2 SEAL ASSY 46512−149 −−− 1

3 INNER BALL BEARING 23422−019 −−− 1

4 BEARING HOUSING 38251−513 10000 1

5 VENTED PLUG 4823A 15079 1

6 AIR VENT S1530 −−− 1

7 REDUCER PIPE BUSHING AP0802 15079 1

8 OUTER BALL BEARING 23422−414 −−− 1

9 DRIVE FLANGE 38545−004 10000 1

10 SHAFT KEY N0812 15990 REF

11 IMPELLER SHAFT 38515−592 1706H 1

12 OIL SEAL S1907 −−− 1 13 BRG SNAP RING S720 −−− 1 14 THRUST WASHER 31134−115 15000 1 15 HEX HD CAPSCREW B0608 15991 6 16 LOCKWASHER J06 15991 6 17 BRG HOUSING GSKT 38683−474 18000 1

18 OIL SEAL 25227−771 −−− 1 19 HEX HD CAPSCREW B0805−1/2 15991 4 20 LOCKWASHER J08 15991 4

INDICATES PARTS RECOMMENDED FOR STOCK

21 SEAL PLATE 38272−256 10000 1 22 SOC HD CAPSCREW DM1004S 17090 1 23 IMPELLER WASHER 31514−015 17000 1 24 PIPE PLUG P08 15079 1 25 SIGHT GAUGE S1471 −−− 1 26 BRG HSG DRAIN PLUG P08 15079 1 27 SEAL CVTY DRAIN PLUG P08 15079 1 28 OIL LVL SIGHT GAUGE S1471 −−− 1 29 INTERM GUARD ASSY 42381−509 24152 2

30 SHAFT SLEEVE O-RING 25154−131 −−− REF

31 IMPELLER ADJ SHIM SET 48261−057 −−− REF 32 SHAFT SLEEVE 31163−019 1706H 1 33 SHIPPING PLUG 11495B 15079 1 34 SHIPPING PLUG 11495B 15079 1

35 ROT ASSY ADJ SHIM 13131−3 17040 12

36 BRG HSG O-RING S1676 −−− 1

37 SEAL PLATE O-RING 25152−381 −−− 1

NOT SHOWN:

INSTRUCTION TAG 6588U −−− 1

MAINTENANCE & REPAIR PAGE E − 15

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OM−06341 PA SERIES

Figure 8. 48275−005 Priming Chamber Kit

ITEM NO.

1 PRIMING CHAMBER ASSY 46112−709 −−− 1 2 PIPE BUSHING AP1608 11999 1 3 STREET ELBOW RS08 11999 1 4 BALL VALVE 26631−052 −−− 1 5 STUD C0809 15991 4 6 HEX NUT D08 15991 4 7 LOCK WASHER J08 15991 4 8 GASKET 38687−053 19060 1 9 BAFFLE 31113−011 17000 1

INDICATES PARTS RECOMMENDED FOR STOCK

PART NAME

PART NUMBER

MAT’L CODE

MAINTENANCE & REPAIRPAGE E − 16

QTY

Page 39

PA SERIES

OM−06341

Figure 9. 46112−709 Priming Chamber Assembly

PARTS LIST

ITEM NO.

1 PRIMING VALVE 26664−007 −−− 1

2 HEX HD CAPSCREW B0806 15991 8 3 LOCKWASHER J08 15991 8 4 PRIMING VALVE GASKET 38683−657 19060 1 5 PRIMING CHAMBER 38343−020 10000 1 6 STRAINER ASSY 46641−222 17000 1

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E − 17

PART NAME

−ORIFICE BUTTON 26688−021 −−− 1

PART NUMBER

MAT’L CODE

QTY

Page 40

OM−06341 PA SERIES

Figure 10. 44162−159 Drive Assembly

ITEM NO.

1 COUPLING KIT 44165−016 −−− 1 2 BUSHING 24131−498 −−− 1 3 −KEY 24113−603 −−− REF 4 DRIVE FLANGE 38545−004 10000 REF 5 IMPELLER SHAFT 38515−586 1706H REF 6 LOCKWASHER 21171−536 −−− 8 7  SOC HD CAPSCREW BD0606 1/2 15991 8 7  SOC HD CAPSCREW 22644−220 −−− 8 8  HEX HD CAPSCREW B0605 15991 8 8  HEX HD CAPSCREW 22645−164 −−− 8 9  LOCKWASHER J06 15991 8 9  LOCKWASHER 21171−511 −−− 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 & REPAIR PAGE 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 & REPAIR PAGE 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 250F (120C), and slide the bearings

onto the shaft, one at a time, until they are fully seated. This should be done quickly, in one 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 & REPAIR PAGE 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 1.44 inches (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 based lubricant 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).

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PA SERIESOM−06341

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 160F (71C). 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 just flush 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.

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PA SERIES

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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 & REPAIR PAGE E − 27

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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.

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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 & REPAIR PAGE 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