Gorman-Rupp Pumps PAH4A60C-B User Manual

Page 1
ACDEU
OM-06443-01
February 24, 2012
Rev. A 03‐27‐13
AND MAINTENANCE MANUAL
WITH PARTS LIST
PAH SERIES PUMP
MODEL
PAH4A60C-B
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A
www.grpumps.com.
2012 The Gorman‐Rupp Company
Page 2
Register your new
Gorman‐Rupp pump online at
www.grpumps.com
Valid serial number and e‐mail address required.
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....................................
PREINSTALLATION INSPECTION PAGE B - 1............................................
POSITIONING PUMP PAGE B - 1.......................................................
Lifting PAGE B - 2.................................................................
Mounting PAGE B - 2.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 2.........................................
Materials PAGE B - 2..............................................................
Line Configuration PAGE B - 2......................................................
Connections to Pump PAGE B - 2..................................................
Gauges PAGE B - 2...............................................................
SUCTION LINES PAGE B - 2...........................................................
Fittings PAGE B - 2...............................................................
Strainers PAGE B - 2..............................................................
Sealing PAGE B - 3...............................................................
Suction Lines In Sumps PAGE B - 3.................................................
Suction Line Positioning PAGE B - 3................................................
DISCHARGE LINES PAGE B - 4........................................................
Siphoning PAGE B - 4.............................................................
Valves PAGE B - 4................................................................
ALIGNMENT PAGE B - 4..............................................................
Coupled Drives PAGE B - 4........................................................
Drive Belts PAGE B - 5............................................................
DRIVE BELT TENSIONING PAGE B - 5..................................................
General Rules of Tensioning PAGE B - 5.............................................
OPERATION - SECTION C PAGE C - 1......................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 1................................................................
Rotation PAGE C - 1..............................................................
OPERATION PAGE C - 1..............................................................
Leakage PAGE C - 1..............................................................
Liquid Temperature And Overheating PAGE C - 1.....................................
Strainer Check PAGE C - 2.........................................................
Pump Vacuum Check PAGE C - 2..................................................
STOPPING PAGE C - 3................................................................
BEARING TEMPERATURE CHECK PAGE C - 3..........................................
Cold Weather Preservation PAGE C - 3..............................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...............................................
PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................
STANDARD PERFORMANCE CURVE PAGE E - 1........................................
i
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TABLE OF CONTENTS
(continued)
PARTS LISTS:
Pump Model PAGE E - 3..........................................................
Pump End Assembly PAGE E - 5...................................................
Priming Chamber Kit PAGE E - 6...................................................
Priming Chamber Assembly PAGE E - 7.............................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 8.........................
Priming Chamber Removal And Disassembly PAGE E - 8..............................
Discharge Check Valve Removal and Disassembly PAGE E - 9.........................
Suction Spool Removal PAGE E - 9.................................................
Pump Casing and Wear Ring Removal PAGE E - 9....................................
Impeller Removal PAGE E - 9......................................................
Seal Removal PAGE E - 10..........................................................
Pump Shaft and Bearing Removal and Disassembly PAGE E - 10........................
Bearing Cleaning And Inspection PAGE E - 11........................................
Pump Shaft and Bearing Reassembly and Installation PAGE E - 11......................
Seal Reassembly and Installation PAGE E - 13........................................
Impeller Installation PAGE E - 14.....................................................
Pump Casing and Wear Ring Installation PAGE E - 15..................................
Discharge Check Valve Assembly and Installation PAGE E - 16..........................
Priming Chamber Assembly And Installation PAGE E - 16...............................
LUBRICATION PAGE E - 16.............................................................
Seal Assembly PAGE E - 16.........................................................
Bearings PAGE E - 16..............................................................
Power Source PAGE E - 17.........................................................
ii
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PAH SERIES
OM-06443

INTRODUCTION

Thank You for purchasing a Gorman‐Rupp pump. Read this manual carefully to learn how to safely
install and operate your pump. Failure to do so could result in personal injury or damage to the pump.
This pump is a PAH Series, priming‐assisted cen trifugal model. The unit is designed for handling non‐volatile, non‐flammable liquids containing specified entrained solids. The basic material of construction is ductile iron, with alloy steel shaft and ductile iron wear ring.
This manual will alert personnel to known proce dures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel. However, because pump installations are seldom identical, this manual cannot possibly provide detailed in structions and precautions for every aspect of each specific application. Therefore, it is the re sponsibility of the owner/installer of the pump to ensure that applications not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity are com promised by the installation. Pumps and related equipment must be installed and operated ac cording to all national, local and industry stan dards.
The following are used to alert personnel to proce dures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel:
Immediate hazards which WILL result in severe personal injury or death. These instructions describe the procedure re quired and the injury which will result from failure to follow the procedure.
Hazards or unsafe practices which COULD result in severe personal injury or death. These instructions describe the procedure required and the injury which could result from failure to follow the procedure.
If there are any questions regarding the pump which are not covered in this manual or in other lit erature accompanying the unit, please contact your Gorman‐Rupp distributor or the Gorman‐ Rupp Company:
The Gorman‐Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: (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 de scribe the requirements and the possible damage which could result from failure to follow the procedure.
NOTE
Instructions to aid in installation, operation, and maintenance or which clarify a procedure.
PAGE I - 1INTRODUCTION
Page 6
Page 7
PAH SERIES

SAFETY ‐ SECTION A

This information applies to Prime Aire Series basic pumps. Gorman‐Rupp has no control over or particular knowledge of the power source which will be used. Refer to the manual accompanying the power source before attempting to be gin operation.
Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and pre cautions for each specific application. Therefore, it is the owner/installer's re sponsibility to ensure that applications not addressed in this manual are per formed only after establishing that nei ther operator safety nor pump integrity are compromised by the installation.
OM-06443
sive, or flammable liquids which may damage the pump or endanger person nel as a result of pump failure.
Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or dam age to equipment. Attach lifting equip ment to the lifting device fitted to the pump. If chains or cable are wrapped around the pump to lift it, make certain that they are positioned so as not to damage the pump, and so that the load will be balanced. The bail is intended for use in lifting the pump assembly only. Suction and discharge hoses and pip ing must be removed from the pump be fore lifting.
Before attempting to open or service the pump:
1. Familiarize yourself with this man ual.
2. Disconnect or lock out the power source to ensure that the pump will remain inoperative.
3. Allow the pump to completely cool if overheated.
4. Check the temperature and make sure the pump is cool before open ing any covers, plates, or plugs.
5. Close the suction and discharge valves.
6. Vent the pump slowly and cau tiously.
7. Drain the pump.
After the pump has been installed, make certain that the pump and all piping or hose connections are tight, properly supported and secure before operation.
Do not operate the pump against a closed discharge valve. If operated against a closed discharge valve, pump components will deteriorate, and the liquid could come to a boil, build pres sure, and cause the pump casing to rup ture or explode. Momentary closure of a discharge valve is acceptable only when required for startup or shutdown procedures.
This pump is designed to handle most non‐volatile, non‐flammable liquids containing specified entrained solids. Do not attempt to pump volatile, corro
Do not operate the pump without the
PAGE A - 1SAFETY
Page 8
guards in place over the rotating parts. Exposed rotating parts can catch cloth ing, fingers, or tools, causing severe in jury to personnel.
Do not remove plates, covers, gauges, pipe plugs, or fittings from an over heated pump. Vapor pressure within the pump can cause parts being disen gaged to be ejected with great force. Al low the pump to cool completely before servicing.
PAH SERIESOM-06443
This pump may be used to handle mate rials which could cause illness through direct exposure or emitted fumes. Wear adequate protective clothing when working on the pump or piping.
Pumps and related equipment must be in stalled and operated according to all na tional, local and industry standards.
PAGE A - 2 SAFETY
Page 9

INSTALLATION - SECTION B

Review all SAFETY information in Section A.
Since pump installations are seldom identical, this section offers only general recommendations and practices required to inspect, position, and ar range the pump and piping.
Most of the information pertains to a standard static lift application where the pump is posi tioned above the free level of liquid to be pumped.
If installed in a flooded suction application where the liquid is supplied to the pump under pressure, some of the information such as mounting, line configuration, and priming must be tailored to the specific application. Since the pressure supplied to the pump is critical to performance and safety, be sure to limit the incoming pressure to 50% of the maximum permissible operating pressure as shown on the pump performance curve.
For further assistance, contact your Gorman‐Rupp distributor or the Gorman‐Rupp Company.
OM-06443PAH SERIES
Only operate this pump in the direction in dicated by the arrow on the pump body and on the accompanying decal. Refer to ROTATION in OPERATION, Section C.
d. Check levels and lubricate as necessary. Re
fer to LUBRICATION in the MAINTENANCE AND REPAIR section of this manual and per form duties as instructed.
e. If the pump and power source have been
stored for more than 12 months, some of the components or lubricants may have ex ceeded their maximum shelf life. These must be inspected or replaced to ensure maxi mum pump service.
If the maximum shelf life has been exceeded, or if anything appears to be abnormal, contact your Gorman‐Rupp distributor or the factory to deter mine the repair or updating policy. Do not put the pump into service until appropriate action has been taken.
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be fore shipment from the factory. Before installation, inspect the pump for damage which may have oc curred during shipment. Check as follows:
a. Inspect the pump for cracks, dents, damaged
threads, and other obvious damage.
b. Check for and tighten loose attaching hard
ware. Since gaskets tend to shrink after dry ing, check for loose hardware at mating sur faces.
c. Carefully read all warnings and cautions con
tained in this manual or affixed to the pump, and perform all duties indicated. Note the di rection of rotation indicated on the pump. Check that the pump shaft rotates counter clockwise when facing the impeller.
POSITIONING PUMP
Lifting
Pump unit weights will vary depending on the mounting and drive provided. Check the shipping tag on the unit packaging for the actual weight, and use lifting equipment with appropriate capacity. Drain the pump and remove all customer‐installed equipment such as suction and discharge hoses or piping before attempting to lift existing, installed units.
The pump assembly can be seriously damaged if the cables or chains used to lift and move the unit are improperly wrapped around the pump.
PAGE B - 1INSTALLATION
Page 10
OM-06443 PAH SERIES
Mounting
Locate the pump in an accessible place as close as practical to the liquid being pumped. Level mount ing is essential for proper operation.
The pump may have to be supported or shimmed to provide for level operation or to eliminate vibra tion.
SUCTION AND DISCHARGE PIPING
Pump performance is adversely effected by in creased suction lift, discharge elevation, and fric tion losses. See the performance curve and oper ating range shown on Page E‐1 to be sure your overall application allows pump to operate within the safe operation range.
Materials
to secure them when filled with liquid and under pressure.
Gauges
Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges. If these gauges are desired for pumps that are not tapped, drill and tap the suction and discharge lines not less than 18 inches (457,2 mm) from the suction and discharge ports and install the lines. Installation closer to the pump may result in erratic readings.
SUCTION LINES
To avoid air pockets which could affect pump prim ing, the suction line must be as short and direct as possible. When operation involves a suction lift, the line must always slope upward to the pump from the source of the liquid being pumped; if the line slopes down to the pump at any point along the suction run, air pockets will be created.
Either pipe or hose maybe used for suction and discharge lines; however, the materials must be compatible with the liquid being pumped. If hose is used in suction lines, it must be the rigid‐wall, rein forced type to prevent collapse under suction. Us ing piping couplings in suction lines is not recom mended.
Line Configuration
Keep suction and discharge lines as straight as possible to minimize friction losses. Make mini mum use of elbows and fittings, which substan tially increase friction loss. If elbows are necessary, use the long‐radius type to minimize friction loss.
Connections to Pump
Before tightening a connecting flange, align it ex actly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or cou plings.
Lines near the pump must be independently sup ported to avoid strain on the pump which could cause excessive vibration, decreased bearing life, and increased shaft and seal wear. If hose‐type lines are used, they should have adequate support
Fittings
Suction lines should be the same size as the pump inlet. If reducers are used in suction lines, they should be the eccentric type, and should be in stalled with the flat part of the reducers uppermost to avoid creating air pockets. Valves are not nor mally used in suction lines, but if a valve is used, install it with the stem horizontal to avoid air pock ets.
Strainers
If a strainer is furnished with the pump, be certain to use it; any spherical solids which pass through a strainer furnished with the pump will also pass through the pump itself.
If a strainer is not furnished with the pump, but 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 - 2 INSTALLATION
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OM-06443PAH SERIES
Sealing
Since even a slight leak will affect priming, head, and capacity, especially when operating with a high suction lift, all connections in the suction line should be sealed with pipe dope to ensure an air tight seal. Follow the sealant manufacturer's rec ommendations when selecting and applying the pipe dope. The pipe dope should be compatible with the liquid being pumped.
Suction Lines In Sumps
If a single suction line is installed in a sump, it should be positioned away from the wall of the sump at a distance equal to 1 1/2 times the diame ter of the suction line.
If there is a liquid flow from an open pipe into the sump, the flow should be kept away from the suc tion inlet because the inflow will carry air down into the sump, and air entering the suction line will re duce pump efficiency.
If it is necessary to position inflow close to the suc tion inlet, install a baffle between the inflow and the
suction inlet at a distance 1 1/2 times the diameter of the suction pipe. The baffle will allow entrained air to escape from the liquid before it is drawn into the suction inlet.
If two suction lines are installed in a single sump, the flow paths may interact, reducing the efficiency of one or both pumps. To avoid this, position the suction inlets so that they are separated by a dis tance equal to at least 3 times the diameter of the suction pipe.
Suction Line Positioning
The depth of submergence of the suction line is critical to efficient pump operation. recommended minimum submergence vs. veloc
ity.
Figure 2 shows
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).
Figure 1. Recommended Minimum Suction Line Submergence vs. Velocity
PAGE B - 3INSTALLATION
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OM-06443 PAH SERIES
DISCHARGE LINES
Siphoning
Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a si phon breaker is used in the line. Otherwise, a si phoning action causing damage to the pump could result.
Valves
This pump is designed with a check valve in the discharge line.
If a throttling valve is desired in the discharge line, use a valve as large as the largest pipe to minimize friction losses. Never install a throttling valve in a suction line.
With high discharge heads, it is recommended that a throttling valve and a system check valve be in stalled in the discharge line to protect the pump from excessive shock pressure and reverse rota tion when it is stopped.
When mounted at the Gorman‐Rupp factory, driver and pump are aligned before shipment. Misalign ment will occur in transit and handling. Pumps must be checked and realigned before operation. Before checking alignment, tighten the foundation bolts. The pump casing feet and/or pedestal feet, and the driver mounting bolts should also be tightly secured.
When checking alignment, disconnect the power source to ensure that the pump will remain inoperative.
Adjusting the alignment in one direction may alter the alignment in another direc tion. check each procedure after altering alignment.
Coupled Drives
If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.
ALIGNMENT
The alignment of the pump and its power source is critical for trouble‐free mechanical operation. In either a flexible coupling or V‐belt driven system, the driver and pump must be mounted so that their shafts are aligned with and parallel to each other. It is imperative that alignment be checked after the pump and piping are installed, and before opera tion.
NOTE
Check Rotation, Section C, before final alignment of the pump.
When using couplings, the axis of the power source must be aligned to the axis of the pump shaft in both the horizontal and vertical planes. Most couplings require a specific gap or clearance between the driving and the driven shafts. Refer to the coupling manufacturer's service literature.
Align spider insert type couplings by using calipers to measure the dimensions on the circumference of the outer ends of the coupling hub every 90. The coupling is in alignment when the hub ends are the same distance apart at all points (see Fig ure 2).
Figure 2. Aligning Spider‐Type Couplings
PAGE B - 4 INSTALLATION
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OM-06443PAH SERIES
Figure 3. Aligning Non‐Spider Type Couplings
Align non‐spider type couplings by using a feeler gauge or taper gauge between the coupling halves every 90. The coupling is in alignment when the hubs are the same distance apart at all points (see Figure 3).
Check parallel adjustment by laying a straightedge across both coupling rims at the top, bottom, and
side. When the straightedge rests evenly on both
halves of the coupling, the coupling is in horizontal
parallel alignment. If the coupling is misaligned, use a feeler gauge between the coupling and the
straightedge to measure the amount of misalign
ment.
MISALIGNED:
SHAFTS
NOT PARALLEL
MISALIGNED:
SHAFTS
NOT IN LINE
ALIGNED: SHAFTS
PARALLEL AND
SHEAVES IN LINE
Figure 4. Alignment of V‐Belt Driven Pumps
Tighten the belts in accordance with the belt manu facturer's instructions. If the belts are too loose, they will slip; if the belts are too tight, there will be excessive power loss and possible bearing failure. Select pulleys that will match the proper speed ra tio; overspeeding the pump may damage both pump and power source.
Do not operate the pump without the guard in place over the rotating parts. exposed rotating parts can catch cloth ing, fingers, or tools, causing severe in jury to personnel.
DRIVE BELT TENSIONING
General Rules of Tensioning
Drive Belts
When using drive belts, the power source and the
pump must be parallel. Use a straightedge along
the sides of the pulleys to ensure that the pulleys
are properly aligned (see Figure 4). In drive sys tems using two or more belts, make certain that the
belts are a matched set; unmatched sets will cause
accelerated belt wear.
For new drive belts, check the tension after 5, 20 and 50 hours of operation and re‐tension as re quired (see the following procedure for measuring belt tension). Thereafter, check and re‐tension if re quired monthly or at 500 hour intervals, whichever comes first.
Ideal drive belt tension is the lowest tension at which the belt will not slip under peak load condi tions. Do not over‐tension drive belts. Over‐ten sioning will shorten both drive belt and bearing life. Under‐tensioning will cause belt slippage. Always keep belts free from dirt, grease, oil and other for eign material which may cause slippage.
PAGE B - 5INSTALLATION
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PAH SERIES
OM-06443

OPERATION - SECTION C

Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and decals attached to the pump.
This pump is designed to handle liquids containing large entrained solids and slurries. Do not attempt to pump vola tile, corrosive, or flammable liquids which may damage the pump or endan ger personnel as a result of pump fail ure.
Pump speed and operating condition points must be within the continuous per formance range shown on the perfor mance curve in Section E on page E-1.
Rotation
The correct direction of pump rotation is counter clockwise when facing the impeller. The pump could be damaged and performance adversely af fected by incorrect rotation. If pump performance is not within the specified limits (see the curve on page E‐1), check the direction of power source ro tation before further troubleshooting.
If an electric motor is used to drive the pump, re move V‐belts, couplings, or otherwise disconnect the pump from the motor before checking motor rotation. Operate the motor independently while observing the direction of the motor shaft, or cool ing fan.
If rotation is incorrect on a three‐phase motor, have a qualified electrician interchange any two of the three phase wires to change direction. If rotation is incorrect on a single‐phase motor, consult the liter ature supplied with the motor for specific instruc tions.
Priming
PRIMING
Install the pump and piping as described in IN STALLATION. Make sure that the piping connec
tions are tight, and that the pump is securely mounted. Check that the pump is properly lubri cated (see LUBRICATION in MAINTENANCE AND REPAIR).
The pump will begin to prime upon startup. The air in the suction line will be discharged from the educ tor discharge line. Complete priming is indicated by a positive discharge pressure reading.
If full priming is not achieved, the discharge check valve may be malfunctioning. If this occurs, shut down the pump and consult Maintenance and
Repair, Section E for further details.
STARTING
Consult the operations manual furnished with the power source.
The pump will begin to prime upon startup. The air in the suction line will be discharged from the educ tor discharge line. Complete priming is indicated by a positive discharge pressure reading.
If full priming is not achieved, the discharge check valve may be malfunctioning. If this occurs, shut down the pump and consult the separate Mainte
nance and Repair manual for further details.
OPERATION
Leakage
Once the pump is fully primed, no leakage should be visible at pump mating surfaces, or at pump connections or fittings. Keep all line connections and fittings tight to maintain maximum pump effi ciency.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is 160 F (71C). Do not apply it at a higher operating temperature.
OPERATION PAGE C - 1
Page 15
OM-06443 PAH SERIES
Overheating can occur if operated with the valves in the suction or discharge lines closed. Operating against closed valves could bring the liquid to a boil, build pressure, and cause the pump to rup ture or explode. If overheating occurs, stop the pump immediately and allow it to completely cool before servicing it. Approach any over‐heated
pump cautiously.
Allow an over‐heated pump to com pletely cool before servicing. Do not re move plates, covers, gauges, or fittings from an overheated pump. Liquid within the pump can reach boiling tempera tures, and vapor pressure within the pump can cause parts being disen gaged to be ejected with great force. Af ter the pump cools, drain the liquid from the pump by removing the casing drain plug. Use caution when removing the plug to prevent injury to personnel from hot liquid.
Never introduce air or steam pressure into the
pump casing or piping to remove a blockage. This could result in personal injury or damage to the equipment. If backflushing is absolutely neces sary, liquid pressure must be limited to 50% of the maximum permissible operating pressure shown on the pump performance curve.
Pump Vacuum Check
With the pump inoperative, install a vacuum gauge in the system, using pipe dope on the threads. Block the suction line and start the pump. At oper ating speed the pump should pull a vacuum of 20 inches (508,0 mm) or more of mercury. If it does not, check for air leaks in the seal, gasket, or dis charge valve.
Open the suction line, and 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.
As a safeguard against rupture or explosion due to heat, this pump is equipped with a pressure relief valve which will open if vapor pressure within the pump casing reaches a critical point. If over‐heat ing does occur, stop the pump immediately and al low it to cool before servicing it. Approach any over‐heated pump cautiously. It is recom mended that the pressure relief valve assembly be replaced at each overhaul, or any time the pump casing over‐heats and activates the valve. Never replace this valve with a substitute which has not been specified or provided by the Gorman‐Rupp Company.
Strainer Check
If a suction strainer has been shipped with the pump or installed by the user, 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 block age.
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.
On engine driven pumps, reduce the throttle speed slowly and allow the engine to idle briefly be fore stopping.
If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.
Do not operate the pump against a closed discharge throttling valve for long periods of time. If operated against
OPERATIONPAGE C - 2
Page 16
PAH SERIES
OM-06443
a closed discharge throttling valve, pump components will deteriorate, and the liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode.
After stopping the pump, switch off the engine igni tion and remove the key to ensure that the pump will remain inoperative.
PERIODIC CHECKS
Seal Cavity And Bearing Lubrication
Both the seal and bearing cavities were fully lubri cated at the factory. Check the lubrication levels before startup, and regularly thereafter as indi cated in Section E, Maintenance and Repair. When lubrication is required, use only SAE No. 30 non‐detergent oil.
Bearing Temperature Check
to operate properly. Make certain that the bearing lubricant is of the proper viscosity and at the cor rect level (see LUBRICATION in Section E, Main tenance and Repair). Bearing overheating can also be caused by shaft misalignment and/or ex cessive vibration.
When pumps are first started, the bearings may seem to run at temperatures above normal. Con tinued operation should bring the temperatures down to normal levels.
Air Compressor
The air compressor was lubricated for test at the factory. However, always check the lubrication lev el before startup.
Consult the manual accompanying the air com pressor and preform all duties and checks as indi cated.
COLD WEATHER PRESERVATION
Bearings normally run at higher than ambient tem peratures because of heat generated by friction. Temperatures up to 160F (71C) are considered normal for bearings, and they can operate safely to at least 180F (82C).
Checking bearing temperatures by hand is inaccu rate. Bearing temperatures can be measured ac curately by placing a contact‐type thermometer against the housing. Record this temperature for future reference.
A sudden increase in bearing temperatures is a warning that the bearings are at the point of failing
In below freezing conditions, drain the pump to prevent damage from freezing. Also, clean out any solids by flushing with a hose. Operate the pump for approximately one minute; this will remove any remaining liquid that could freeze the pump rotat ing parts. If the pump will be idle for more than a few hours, or if it has been pumping liquids con taining a large amount of solids, drain the pump, and flush it thoroughly with clean water. To prevent large solids from clogging the drain port and pre venting the pump from completely draining, insert a rod or stiff wire in the drain port, and agitate the liquid during the draining process. Clean out any remaining solids by flushing with a hose.
OPERATION PAGE C - 3
Page 17
Page 18
PAH 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. Lock out or disconnect the power source 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-06443
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO PRIME
PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE
Discharge check valve contami nated, damaged, or unable to seat.
Air leak in suction line. Correct leak.
Lining of suction hose collapsed. Replace suction hose.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
Suction lift or discharge head too high. Check piping installation and install
Air compressor damaged or belts bro ken.
Strainer clogged. Check strainer and clean if neces
Eductor clogged. Check and clean eductor.
Air leak in suction line. Correct leak.
Lining of suction hose collapsed. Replace suction hose.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
Clean or replace check valve.
leaking or worn seal or gasket.
bypass line if needed. See INSTAL LATION.
Check and repair/replace.
sary.
leaking or worn seal or gasket.
TROUBLESHOOTING PAGE D - 1
Page 19
OM-06443
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PAH 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.
Suction lift too high.
Pump speed too slow. Check driver output; consult driver
Belt or flexible coupling broken. Check and replace as necessary.
Pump speed too high. Check driver output.
Extreme ambient temperature. Reduce pump output.
Discharge head too low. Fuel filter clogged. Check & replace often in extreme
Check strainer and clean if neces sary.
Check and clean check valve.
Check installation and correct submergence as needed.
Replace worn or damaged parts. Check that impeller is properly centered and rotates freely.
Free impeller of debris.Impeller clogged.
Measure lift w/vacuum gauge. Re duce lift and/or friction losses in suction line.
operation manual.
Adjust discharge valve.
operating conditions.
PUMP CLOGS FREQUENTLY
EXCESSIVE NOISE
Dilute if possible.Liquid solution too thick.
Check and replace as required.Fuel contaminated.
Pump or jack shaft bearing(s) frozen. Disassemble, check and replace
bearing(s) as required..
Discharge flow too slow.
Suction check valve or foot valve clogged or binding.
Liquid solution too thick.
Cavitation in pump. Reduce suction lift and/or friction
Pumping entrained air.
Impeller clogged or damaged.
Open discharge valve fully to in crease flow rate, and run engine at maximum governed speed.
Clean valve.
Dilute if possible.
losses in suction line. Record vac uum and pressure gauge readings and consult local representative or factory.
Locate and eliminate source of air bubble.
Secure mounting hardware.Pump or drive not securely mounted.
Clean out debris; replace damaged parts.
TROUBLESHOOTINGPAGE D - 2
Page 20
PAH SERIES
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
OM-06443
BEARINGS RUN TOO HOT
Bearing temperature is high, but within limits.
Low or incorrect lubricant.
Suction and discharge lines not prop erly supported.
Excessive tension on drive belt.
PREVENTIVE MAINTENANCE
Since pump applications are seldom identical, and pump wear is directly affected by such things as the abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however, following a routine pre ventive maintenance schedule will help assure trouble‐free performance and long life from your Gorman‐Rupp pump. For specific questions con cerning your application, contact your Gorman‐ Rupp distributor or the Gorman‐Rupp Company.
Record keeping is an essential component of a good preventive maintenance program. Changes in suction and discharge gauge readings (if so
Check bearing temperature regu larly to monitor any increase.
Check for proper type and level of lubricant.
Check piping installation for proper support.
Align drive properly.Drive misaligned.
Check belt tension. Adjust as required.
equipped) between regularly scheduled inspec tions can indicate problems that can be corrected before system damage or catastrophic failure oc curs. The appearance of wearing parts should also be documented at each inspection for comparison as well. Also, if records indicate that a certain part (such as the seal) fails at approximately the same duty cycle, the part can be checked and replaced before failure occurs, reducing unscheduled down time.
For new applications, a first inspection of wearing parts at 250 hours will give insight into the wear rate for your particular application. Subsequent inspec tions should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently.
TROUBLESHOOTING PAGE D - 3
Page 21
OM-06443
PAH 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 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 (Back 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
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 22
PAH SERIES
OM-06443
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 PAH4A60C-B
Based on 70F (21C) clear water at sea level with minimum suction lift. Since pump installations are seldom identical, your performance may be dif ferent due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.
Contact the Gorman‐Rupp Company to verify per formance or part numbers.
Pump speed and operating condition
If your pump serial number is followed by an “N”, your pump is NOT a standard production model.
MAINTENANCE & REPAIR PAGE E - 1
points must be within the continuous per formance range shown on the curve.
Page 23
OM-06443 PAH SERIES

PARTS PAGE

ILLUSTRATION
AIR COMPRESSOR PIPING
PRIMING CHAMBER PIPING
Figure 1. Pump Model PAH4A60C-B
MAINTENANCE & REPAIRPAGE E - 2
Page 24
PAH SERIES
PARTS LIST
Pump Model PAH4A60C-B
(From S/N 1512753 Up)
ITEM
PART NAME PART
NO.
1 64P60C-(SAE 3/11.5) 46133-307 --- 1 2 SPACER 31141-034 15000 4 3 LOCK WASHER J04 15991 4 4 HEX HEAD CAP SCREW B0405 15991 4 5 FLAT WASHER K06 15991 8 6 SPROCKET 24271-008 --- 1 7 BUSHING 24131-564 --- 1
8 SYNCHRONOUS BELT 24186-008 --- 1
9 LOCK WASHER J06 15991 4 10 HEX HEAD CAP SCREW B0610 15991 4 11 BELT GUARD ASSY 42351-489 24150 1 12 AIR COMPRESSOR ASSY 46181-909 --- 1 13 STUD C1213 15991 8 14 GASKET 25113-036 --- 1 15 PRIMING CHAMBER KIT 48275-005 --- 1 16 LOCK WASHER J12 15991 8 17 HEX NUT D12 15991 8 18 SUCTION SPOOL 38644-814 10000 1 19 GASKET 25113-034 --- 1 20 BLIND FLANGE ASSY 42111-358 --- 1 21 LOCK WASHER J10 15991 8 22 HEX HEAD CAP SCREW B1007 15991 8 23 CHECK VALVE KIT 48274-003 --- 1
-CHECK VALVE 26642-124 --- 1
-FLAPPER 26688-005 --- 1
NUMBER
MAT'L CODE
QTY ITEM
NO.
24 1/2” I.D. X 41” LG HOSE 18513-113 --- 1 25 HOSE BARB FTG 26523-047 --- 1 26 CONNECTOR S1598 --- 1 27 1/2” I.D. X 24” LG HOSE 18513-113 --- 1 28 HOSE CLAMP 26518-666 --- 1 29 HOSE BARB FITTING 26523-446 --- 2 30 1/2” CHECK VALVE 26641-092 --- 1 31 HOSE BARB FITTING 26523-387 --- 1 32 HOSE CLAMP 26518-642 --- 1 33 3/8” I.D. X 24” LG HOSE 18513-302 --- 1
34
NOT SHOWN:
OM-06443
PART NAME PART
NUMBER
-COVER O‐RING 25152-366 --- 1
-FLANGE GASKET 25113-034 --- 1
SHAFT KEY N1012 15990 1
WARNING DECAL 2613FE --- 1 G‐R DECAL GR-06 --- 1 PRIME AIRE PLUS DECAL 38812-099 --- 1 WARNING PLATE 2613EV 13990 1 DISCHARGE STICKER 6588BJ --- 1 OIL LEVEL DECAL 38816-123 --- 1 LUBE DECAL 11421A --- 1 NAME PLATE 38818-156 13000 1 DRIVE SCREW BM#04-03 17000 4 SUCTION STICKER 6588AG --- 1 STRAINER 7823A 24000 1
MAT'L CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 3
Page 25
OM-06443 PAH SERIES
ILLUSTRATION
Figure 2. 46133-307 Pump Assembly
MAINTENANCE & REPAIRPAGE E - 4
Page 26
PAH SERIES
OM-06443
PARTS LIST
46133-307 Pump End Assembly
ITEM NO.
1 PUMP CASING SEE NOTE BELOW 1 2 WEAR RING 38691-363 11010 1 3 SUCTION HEAD O‐RING 25152-383 --- 2
3A PUMP CASING O‐RING 25152-383 --- 2
4 PIPE PLUG P04 15079 1 5 PIPE PLUG P08 15079 3 6 STUD C1211 15991 8 7 LOCK WASHER J12 15991 8 8 HEX NUT D12 15991 8
9 REPAIR ROTATING ASSEMBLY 44163-514 --- 1 10 STUD C1213 15991 4 11 ADJUSTING SCREW 31871-070 1500G 4 12 LOCK COLLAR 38115-551 15001 4 13 BACK COVER NUT 31871-073 15000 4 14 HEX HEAD CAP SCREW B0804 15991 4 15 LOCK WASHER J08 15991 4 16 SUCTION HEAD 38246-613 10000 1
INCLUDED W/REPAIR PUMP CASING ASSY 46474-908 --- 1
PART NAME
PART NUMBER
MAT'L CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 5
Page 27
OM-06443 PAH SERIES
ILLUSTRATION
Figure 3. 44163-514 Repair Rotating Assembly
MAINTENANCE & REPAIRPAGE E - 6
Page 28
PAH SERIES
OM-06443
ARTS LIST
44163-514 Repair Rotating Assembly
ITEM NO.
1 IMPELLER 38621-733 11010 1
2 SOCKET HEAD CAP SCREW BD1006 15991 1
3 IMPELLER WASHER 31167-038 17000 1
4 ROLL PIN S2197 --- 1
5 SHIM SET 48261-033 --- 1
6 MECH SEAL 25285-822 --- 1
7 SHAFT SLEEVE 31163-022 17000 1
8 O‐RING 25152-150 --- 1
9 SEAL PLATE 38272-533 10000 1 10 BEARING CAVITY SIGHT GAUGE S1471 --- 2
10A SEAL CAVITY SIGHT GAUGE S1471 --- 2
11 REDUCER PIPE BUSHING AP1202 15079 1 12 LIP SEAL 25227-856 --- 2 13 SEAL CAVITY AIR VENT S1530 --- 2
13A BEARING CAVITY AIR VENT S1530 --- 1
14 GASKET 38683-665 18000 1 15 LOCK WASHER J10 15991 14 16 HEX HEAD CAP SCREW B1007 15991 14 17 DRIVE FLANGE GASKET 38683-664 18000 1 18 PEDESTAL 38257-210 10000 1 19 PIPE PLUG P12 15079 3
19A BEARING CAVITY DRAIN PLUG P12 15079 1 19B SEAL CAVITY DRAIN PLUG P12 15079 1
20 OIL SEAL 25258-845 --- 1 21 DRIVE FLANGE 38545-015 10000 1 22 BEARING LOCKNUT 23962-015 --- 1 23 BEARING LOCK WASHER 23962-515 --- 1 24 BALL BEARING 23422-417 --- 1 25 IMPELLER SHAFT 38512-526 16000 1 26 KEY N0806 15990 1 27 ROLLER BEARING 23535-001 --- 1 28 KEY N1012 15990 1
NOT SHOWN:
PART NAME
PUMP CASING O‐RING 25152-383 --- 1 SHIPPING PLUG 11495B 15079 2 INSTRUCTION TAG 6588U --- 1
PART NUMBER
MAT'L CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 7
Page 29
OM-06443 PAH SERIES
ILLUSTRATION
Figure 4. 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 - 8
QTY
Page 30
PAH SERIES
OM-06443
ILLUSTRATION
Figure 5. 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 - 9
PART NAME
-ORIFICE BUTTON 26688-021 --- 1
PART NUMBER
MAT'L CODE
QTY
Page 31
OM-06443 PAH SERIES
ILLUSTRATION
Figure 6. 46181-909 Air Compressor Assembly
ITEM NO.
1 MACH SCREW X#10-02 15991 4
2 HEX NUT D#10 15991 4
3 LOCK WASHER J#10 15991 4
4 FLAT WASHER K#10 15991 4
5 AIR COMPRESSOR COVER 38354-043 15120 1
6 AIR COMPRESSOR 26813-111 --- 1
7 PIPE CAP V06 15079 1
8 PIPE NIPPLE T0616 15079 1
9 90° ADAPTER 25412-003 --- 1 10 PULLEY ASSEMBLY 44112-004 --- 1 11 AIR COMPRESSOR KNOB 38429-501 19220 1 12 SERVICE TEE US08 11999 1 13 REDUCER PIPE BUSHING AP0806 15079 1 14 VENTURI 26817-002 --- 1 15 PIPE COUPLING AE08 15079 1 16 PIPE ELBOW R08 11999 1 17 PRESSURE RELIEF VALVE 26662-028 --- 1
PART NAME
PART NUMBER
MAT'L CODE
MAINTENANCE & REPAIRPAGE E - 10
QTY
Page 32
PAH SERIES
OM-06443

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Review all SAFETY information in Section A.
Follow the instructions on all tags, label and de cals attached to the pump.
This pump requires little service due to its rugged, minimum‐maintenance design. However, if it be comes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the illustrations (see Figures 1 through 6) and the corresponding parts lists. Instructions for the air compressor are covered separately in specific liter ature available from the manufacturer.
Some pump service functions may be performed without separating the pump end assembly from the engine. However, the priming chamber (15, Figure 1) and discharge check valve assembly (23, Figure 1) must be removed to service most pump components. The following instructions assume complete disassembly of the pump is required.
Before attempting to service the pump, lock out or disconnect the power source and take precautions to ensure that it will remain inoperative. Close all valves in the suction and discharge lines and drain the pump casing by removing the lowermost pipe plug (5, Figure 2). Clean and reinstall the pipe plug.
pump integrity are compromised by such practices.
Before attempting to open or service the pump:
1. Familiarize yourself with this man ual.
2. Lock out or disconnect the power source to ensure that the pump will remain inoperative.
3. Allow the pump to completely cool if overheated.
4. Check the temperature and make sure it is cool before opening any covers, plates, gauges, or plugs.
5. Close the suction and discharge valves.
6. Vent the pump slowly and cau tiously.
7. Drain the pump.
Use only replacement parts provided or approved by Gorman‐Rupp. Use of non‐ authorized parts may result in damage to the equipment and/or injury to personnel and will invalidate the warranty.
This manual will alert personnel to known procedures which require spe cial attention, to those which could damage equipment, and to those which could be dangerous to personnel. How ever, this manual cannot possibly antici pate and provide detailed instructions and precautions for every situation that might occur during maintenance of the
Priming Chamber Removal And Disassembly
(Figure 4)
Disconnect both the suction piping and the air dis charge 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, gasket (8) and baffle (9) from the pump assembly.
unit. Therefore, it is the responsibility of the owner/maintenance personnel to ensure that only safe, established main tenance procedures are used, and that any procedures not addressed in this manual are performed only after estab lishing that neither personal safety nor
MAINTENANCE & REPAIR PAGE E - 11
(Figure 5)
Remove the hardware (2 and 3) securing the prim ing valve (1) to the priming chamber (5). Carefully lift the valve components from the priming cham ber. Remove the gasket (4) and clean the mating surfaces.
Page 33
PAH SERIESOM-06443
If the priming valve float is stuck or the strainer (6) is clogged, it can usually be cleaned without further disassembly.
The only serviceable part of the priming valve is the orifice button (not shown). If liquid continues to by pass through the priming chamber after adjusting the orifice button (see Priming Chamber Reas sembly and Installation for adjustment), the but ton may require replacement. To replace the orifice button, remove one of the “e‐clips” from the pivot pin closest to the orifice button and remove the piv ot pin. This will allow the linkage to be raised high enough to access the orifice button.
Remove the hex nut and lock washer securing the orifice button to the linkage bar and unscrew the orifice button from the linkage bar.
Discharge Check Valve Removal and Disassembly
(Figure 1)
Support the discharge check valve assembly (23) using a sling and a suitable lifting device. Remove the hardware (not shown) and separate the dis charge check valve assembly and gasket (not shown) from the pump assembly (1).
The flapper and cover O‐ring are the only service able parts of the check valve. If the flapper requires replacement, remove the hardware securing the cover. Separate the cover and O‐ring and remove the flapper.
screws (11) to press the suction head out of the pump casing.
Remove and discard the O‐ring (3).
Inspect the wear ring and, if replacement is re quired, install two 5/8-11 UNC‐2B capscrews (not supplied) in the tapped holes in the suction head and use the screws to press the wear ring out of the suction head.
Pump Casing Removal
(Figure 2)
If the impeller (1, Figure 3) is to be removed, the im peller screw (2, Figure 3) must be removed before removing the pump casing (1). With the discharge check valve removed, insert a soft metal bar or rod through the discharge port to block impeller rota tion.
Use an impact wrench with a hex key to loosen the impeller capscrew, then remove the capscrew, washer (3, Figure 3) and roll pin (4, Figure 3). Re move the metal bar or rod blocking impeller rota tion.
Support the pump casing (1) using a suitable hoist and sling. Disengage the hardware (7 and 8) se curing the pump casing to the rotating assembly (9). Use the hoist and sling to pull the pump casing straight away from the rotating assembly. Use cau tion to ensure that the pump casing does not fall onto and damage the impeller.
Remove and discard the pump casing O‐ring (3A).
Suction Head and Wear Ring Removal
(Figure 2)
The wear ring (2) is easily accessible and may be serviced by removing the suction head (16). Before attempting to service the pump, remove the lower most pipe plug (5) from the pump casing drain the pump. Clean and reinstall the drain plug.
It is not necessary to remove the suction spool (18, Figure 1) from the suction head unless replace ment of the spool, gasket (14, Figure 1) or suction head is required. To remove the suction head, re move the back cover nuts (13) and two diagonally opposing locking collars (12). Use the adjusting
Removing Air Compressor
(Figure 1)
Further disassembly of the pump requires remov ing the air compressor assembly (12) from the ro tating assembly (9, Figure 2).
Disengage the hardware (3, 4 and 5) and remove the belt guard assembly (11).
Remove the hardware (5, 9 and 10) securing the air compressor assembly (12) to the mounting flange (20, Figure 3). Use a pry bar to raise the air com pressor high enough to remove the spacers (2). Remove the belt (8) from the air compressor drive pulley (not shown).
MAINTENANCE & REPAIRPAGE E - 12
Page 34
PAH SERIES
OM-06443
Disconnect all hoses and fittings from the air com pressor and use a suitable hoist and sling to re move the air compressor assembly.
Draining Oil From Seal Cavity
(Figure 3)
If any further disassembly is to be performed on the pump, the seal oil cavity must be drained to pre vent the oil in the seal cavity from escaping as the impeller is removed.
Position a clean container under the seal cavity drain plug (19B). Remove the plug and drain the oil from the seal cavity into the container. For shorter drain time, remove the vented plug (13). Clean and reinstall the drain plug and vent plug. Inspect the oil for water, dirt or a cloudy condition which could indicate seal failure.
Impeller Removal
Seal Removal
(Figures 3 and 7)
Remove the spring centering washer and seal spring. Slide the shaft sleeve (7) and rotating por tion of the seal off the shaft as a unit.
Apply oil to the shaft sleeve and work it up under the rubber bellows. Slide the rotating portion of the seal off the shaft sleeve. Remove the shaft sleeve O‐ring (8).
Use a pair of stiff wires with hooked ends to remove the stationary element and O‐ring from the seal plate bore.
An alternate method of removing the stationary seal components is to remove the hardware (15 and 16) and separate the seal plate and gasket (14) from the pedestal (18). Position the seal plate on a flat surface with the impeller side down. Use a wooden dowel or other suitable tool to press on the back side of the stationary element until the ele ment and its O‐ring can be removed.
(Figure 3)
With the pump casing removed, use a suitable three‐jawed puller to remove the impeller (1) and key (26) from the shaft (25). Use caution when re moving the impeller; tension on the shaft seal spring will be released as the impeller is removed.
NOTE
An alternate method of removing the impeller is to insert a pair of wedges 180_ apart between the im peller and seal plate (9). Tap the wedges evenly in an alternating pattern to “walk” the impeller off the shaft.
Remove the impeller adjusting shims (5); tie and tag the shims, or measure and record their thick ness for ease of reassembly.
Inspect the impeller and replace if cracked or badly worn.
Separating Rotating Assembly From Power Source
(Figure 1)
Further disassembly requires separating the rotat ing assembly from the power source. Remove the coupling securing the rotating assembly to the power source. Remove the belt (8).
Remove any hardware securing the pedestal (18, Figure 3) to the base. Use a suitable hoist and sling to move the rotating assembly to a clean, well‐ equipped workshop for further disassembly.
Remove the capscrews from the center of the bushing (7). Reinstall the capscrews in the tapped holes in the bushing and tighten them in an alter nating pattern until the bushing is “jacked” out of the sheave (6). Slide the bushing and sheave off the shaft. Remove the key (28, Figure 3).
Shaft and Bearing Removal and Disassembly
(Figure 3)
If no further disassembly is required, refer to Seal Installation.
MAINTENANCE & REPAIR PAGE E - 13
When the pump is properly operated and main tained, the bearing housing should not require dis
Page 35
PAH SERIESOM-06443
assembly. Disassemble the shaft and bearings only when there is evidence of wear or damage.
Shaft and bearing disassembly in the field is not recommended. These operations should be performed only in a properly equipped shop by qualified personnel.
Remove the bearing housing drain plug (19A) and drain the lubricant. Clean and reinstall the drain plug.
Disengage the hardware (15 and 16) and remove the mounting flange (21), gasket (17) and oil seal (20). Use a suitably sized dowel to press the oil seal from the mounting flange.
Place a block of wood against the impeller end of the shaft (25) and tap the shaft and assembled bearings (24 and 27) from the bearing housing. Press the oil seal (20) from the bearing housing.
precautions printed on solvent contain ers.
Clean the bearings thoroughly in fresh cleaning solvent. Dry the bearings with filtered compressed air and coat with light oil.
Bearings must be kept free of all dirt and foreign material. Failure to do so will great ly shorten bearing life. Do not spin dry bearings. This may scratch the balls or races and cause premature bearing fail ure.
Rotate the bearings by hand to check for rough ness or binding and inspect the bearing balls. If ro tation is rough or the bearing balls are discolored, replace the bearings.
The bearing tolerances provide a tight press fit onto the shaft and a snug slip fit into the bearing housing. Replace the bearings, shaft, or bearing housing if the proper bearing fit is not achieved.
After removing the shaft and bearings, clean and inspect the bearings in place as follows.
To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place. It is strongly recommended that the bearings be replaced any time the shaft and bear ings are removed.
Clean the bearing housing, shaft and all compo nent parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage and replace as necessary.
If bearing replacement is required, straighten the tab on the bearing lock washer (23). Use a spanner wrench to remove the bearing lock nut (22). Re move the bearing lock washer.
Use a bearing puller to remove the inboard and outboard bearings from the shaft.
Shaft and Bearing Reassembly and Installation
(Figure 3)
Inspect the shaft (25) for distortion, nicks or scratches, or for thread damage on the impeller end. Dress small nicks and burrs with a fine file or emery cloth. Replace the shaft if defective.
Clean and inspect the bearings as indicated in
Shaft And Bearing Removal And Disassembly.
Most cleaning solvents are toxic and flammable. Use them only in a well ven tilated area free from excessive heat, sparks, and flame. Read and follow all
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 - 14
Page 36
PAH SERIES
be replaced any time the shaft and bear ings are removed.
OM-06443
The bearings may be heated to ease installation. An induction heater, hot oil bath, electric oven, or hot plate may be used to heat the bearings. Bear ings should never be heated with a direct flame or directly on a hot plate.
NOTE
If a hot oil bath is used to heat the bearings, both the oil and the container must be absolutely clean. If the oil has been previously used, it must be thor oughly filtered.
NOTE
Position the outboard bearing (24) on the shaft with the retaining ring on the bearing O.D. toward the drive end of the shaft. The inboard bearing (27) is equipped with a flange ring that is shipped loose with the bearing. Install the flange ring on the shaft prior to heating and installing the bearings.
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 against the shaft shoulders. 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 during cooling. If movement has occurred, use a suitably sized sleeve and a press to reposition the bearings against the shaft shoulders.
It is recommended that a new bearing lock washer (23) be installed any time the shaft and bearings are disassembled. Re‐use of an old lock washer may create a pre‐load condition on the bearing, resulting in pre mature bearing failure.
Install the bearing lockwasher (23) and screw the bearing locknut (22) onto the shaft until tight. Torque the bearing lock nut to (150 ft. lbs. (20,8 m. kg.). After torquing, locate the tab on the lock washer that aligns with a slot in the lock nut and bend the tab over into the slot.
Apply a light coating of oil to the lip of the inboard oil seal (12) and press it into the pedestal bore with the lip positioned as shown in Figure 3. Press the oil seal into the pedestal until the face is just flush with the machined surface on the pedestal.
It is recommended that a sleeve be positioned against the inboard oil seal to prevent the lip of the oil seal from rolling as the shaft and bearings are installed in the pedestal. The O.D. of the sleeve should be just smaller than the bearing housing bore, while the I.D. of the sleeve should be just larg er than the O.D. of the lip seal area of the shaft.
With the lip seal sleeve in place, lubricate the lip seal area of the shaft and slide the shaft and as sembled bearings into the bearing housing until the retaining ring on the outboard bearing seats against the pedestal. Remove the lip seal sleeve.
When installing the shaft and bearings into
If heating the bearings is not practical, use a suit ably sized sleeve and an arbor (or hydraulic) press to install the bearings on the shaft.
When installing the bearings onto the shaft, never press or hit against the outer race, balls, rollers or cage. Press only on the inner race.
MAINTENANCE & REPAIR PAGE E - 15
the bearing bore, push against the outer race. Never hit the balls, rollers or cages.
Apply a light coating of oil to the lip of the outboard oil seal (12) and press it into the pedestal with the lip positioned as shown in Figure 3. The face of the oil seal should be just flush with the outer face of the bearing cap.
Apply a light coating of oil to the lip of the oil seal (20) and press it into the drive flange (21) with the lip positioned as shown in Figure 3. The oil seal should be centered in the flange bore.
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PAH SERIESOM-06443
Install the gasket (17) and slide the assembled drive flange and oil seal over the impeller shaft. Use caution not to cut or roll the lip of the oil seal (20) on the shaft keyway. Secure the drive flange to the pedestal with the hardware (15 and 16). Torque the capscrews (16) to 41 ft. lbs. (5,7 m. kg.).
Lubricate the bearings as indicated in LUBRICA
TION at the end of this section.
Securing Rotating Assembly to Power Source
(Figure 1)
Install the key (34) in the shaft keyway, making sure to leave room in the keyway for the drive key (28, Figure 3). Install the bushing (7) and sprocket (6) on the shaft to the dimension shown in Figure 7.
compressor and the mounting flange. Secure the compressor to the mounting flange with the hard ware (5, 9 and 10). Reinstall the guard (11) and se cure it with the hardware (3, 4 and 5).
Reinstall the drive coupling on the impeller shaft. Using a suitable lifting device, position the pedes tal assembly on the base and secure it with the pre viously removed hardware. Align the coupling as described in Installation, Section B.
Seal Reassembly and Installation
(Figures 3 and 8)
Most cleaning solvents are toxic and flammable. Use them only in a well ven tilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent contain ers.
Figure 7. Drive Sprocket Positioning
Secure the bushing and sheave to the shaft by torqueing the bushing screws to 15 ft. lbs. (180 in. lbs. or 2,1 m. kg.). Install the belt (8) over the sprocket and up through the slot in the mounting flange (20, Figure 3).
Use a suitable hoist and sling to position the air compressor assembly (12) on the mounting flange. Slide the belt (8) over the air compressor sprocket. Use a pry bar to raise the compressor high enough to install the spacers (2) between the
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.
A new seal assembly should be installed any time the old seal is removed from the pump. Wear patterns on the finished faces cannot be realigned during reassembly. Reusing an old seal could result in prema ture failure.
To ease installation of the seal, lubricate the shaft sleeve O‐ring and the stationary element O‐ring with a very small amount of light lubricating oil. See Figure 8 for seal part identification.
MAINTENANCE & REPAIRPAGE E - 16
Page 38
PAH SERIES
OM-06443
SPRING
IMPELLER
SHAFT
KEY
IMPELLER
SHAFT
SPRING
CENTERING
WASHER
RETAINER
IMPELLER
SHIMS
BELLOWS
ROTATING
ELEMENT
SEAL PLATE
O‐RING
SLEEVE O‐RING
SHAFT
SLEEVE
STATIONARY
ELEMENT
Figure 8. Seal Assembly
This seal is not designed for operation at temperatures above 160F (71C). Do not use at higher operating temperatures.
If the seal plate was removed, install the seal plate gasket (14). Position the seal plate over the shaft and secure it to the bearing housing with the hard ware (15 and 16).
Press the stationary element and its O‐ring into the seal plate until fully seated in the seal plate bore. A push tube cut from a length of plastic pipe would aid this process. The I.D. of the tube should be slightly larger than the O.D. of the shaft sleeve (7).
Install the shaft sleeve O‐ring (8) in the groove in the I.D. of the sleeve. Lubricate the O‐ring and the O.D. of the shaft sleeve with “P-80 Emulsion” or water. Do not use oil or any substitute lubricant other than water.
Slide the rotating subassembly (consisting of the rotating element, retainer and bellows) onto the
sleeve until the rotating element is just flush with the chamfered end of the sleeve. Slide the shaft sleeve and rotating subassembly onto the shaft until the seal faces contact and the shaft sleeve seats against the shoulder on the impeller shaft. Install the seal spring and spring centering washer.
Lubricate the seal assembly as indicated in LUBRICATION, after the impeller has been in stalled.
Impeller Installation And Adjustment
(Figure 3)
Inspect the impeller (1) and replace it if cracked or badly worn.
Install the same thickness of adjusting shims (5) as previously installed. Install the impeller key (26) in the shaft keyway. Align the keyway in the impeller with the shaft key and press the impeller onto the shaft until fully seated.
A clearance of .025 to .040 inch (0,64 to 1,02 mm) between the impeller and the seal plate is neces sary for maximum pump efficiency. Measure this clearance and add or remove impeller adjusting shims as required.
MAINTENANCE & REPAIR PAGE E - 17
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PAH SERIESOM-06443
Apply `Loctite Retaining Compound No. 242' or equivalent to the threads of the impeller capscrew (2). Install the roll pin (4) in the hole in the impeller. Position the impeller washer over the end of the im peller shaft so the hole in the washer aligns with the roll pin. Block impeller rotation as described in Im peller Removal and torque the impeller capscrew to 180 ft. lbs. (24,9 m. kg.).
Pump Casing Installation
(Figure 2)
Lubricate the O‐ring (3) with light grease and install it in the groove in the O.D. of the seal plate. Install a lifting eye in the uppermost hole in the pump cas ing (1) for the pipe plug (5). Be sure to screw the lifting eye tightly into the hole as far as it will go. At tach a suitable lifting device to the lifting eye and use the lifting device to position the pump casing over the rotating assembly. Install the hardware (7 and 8) on the studs (6) and use the hardware to ful ly seat the pump casing against the seal plate (9, Figure 3).
casing until the wear ring just touches the impeller when the shaft is turned. Tighten the back cover
nuts evenly to avoid binding.
With the wear ring just touching the impeller, turn the two free adjusting screws until they engage the pump casing. Position the locking collars over the adjusting screws so the holes in the collars for the locking screws align approximately with the holes in the suction head.
Loosen the back cover nuts used to press the suction head 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 (14 and 15). Install the two remaining hand knobs snugly against the adjusting screws.
Suction Head and Wear Ring Installation and Adjustment
(Figure 2)
If the wear ring (2) was removed, position the re placement wear ring in the suction head (16) and use an arbor (or hydraulic) press to press it into the suction head until fully seated.
Install the O‐ring (3) in the groove in the O.D. of the suction head and lubricate it with light grease. Position the suction head over the studs (10).
The clearance between the wear ring and the im peller is adjusted using the four back cover nuts (13) and locking collars (12). There are 18 detents on the I.D. of each locking collar. Indexing the col lars one detent on the adjusting screws represents approximately .005 inch (0,13 mm) of wear plate clearance. The recommended clearance between the wear ring and the impeller is .008 to .015 inch (0,2 to 0,4 mm).
Screw the four adjusting screws (11) 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.
Use two back cover nuts on diagonally opposing studs (10) to press the suction head into the pump
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 and hardware (14 and 15). Reinstall the back cover nuts.
Be sure the wear ring does not scrape against the impeller when the shaft is turned.
After the face clearance has been set, tighten the hardware securing the rotating assembly to the pump casing.
Discharge Check Valve Reassembly And Installation
(Figure 1)
If the discharge check valve (23) was disas sembled to replace the flapper or cover O‐ring, position the flapper in the valve body and check to ensure free movement.
Install the valve cover O‐ring and secure the cover to the body with the previously removed hardware.
Apply a small amount of light grease to the dis charge flange gasket to hold it in place and posi tion it against the pump casing flange. Support the discharge check valve assembly using a sling and a suitable lifting device. Using the previously re
MAINTENANCE & REPAIRPAGE E - 18
Page 40
PAH SERIES
OM-06443
moved hardware, secure the discharge check valve assembly and flange gasket to the pump as sembly (1).
Priming Chamber Assembly And Installation
(Figure 5)
Clean and inspect the components of the priming valve (1). Inspect the linkage and ensure the orifice button (not shown) squarely engages the valve seat. Replace the orifice button if required (see
Priming Chamber Removal and Disassembly
for orifice button removal).
If the orifice button was removed, screw the new orifice button into the linkage bar until fully seated. Align the hole in the linkage bar with the holes in the bracket and reinstall the pivot pin. Secure the pivot pin with the previously removed “e‐clip”.
Adjust the orifice button seating as necessary by screwing the orifice button into or out of the linkage bar. Proper adjustment is achieved when the ori fice button fully seats against the orifice before the linkage bar on the float bottoms against the threads on the orifice button. When adjustment is complete, install and tighten the lock washer and hex nut securing the orifice button.
Install the strainer (6) and priming valve gasket (4).
Lower the float into the priming chamber (5) and secure the priming valve with the previously re moved hardware (2 and 3).
ounces (5 liters) of SAE No. 30 non‐detergent oil to the center of the sight gauge (10A). Clean and rein stall the vented plug. Check the oil level regularly and maintain it at the middle of the sight gauge.
Bearings
(Figure 3)
The bearing housing was fully lubricated when shipped from the factory. Check the oil level regu larly through the sight gauge (10) and maintain it at the midpoint of the gauge. When lubrication is re quired, remove the air vent (13A) and add SAE No. 30 non‐detergent oil through the opening. When lubricating a dry (overhauled) intermediate, fill the bearing cavity with approximately 50 ounces (1,5 liters). 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 posi tioned horizontally to provide proper drainage.
Under normal conditions, drain the bearing hous ing once each year and refill with clean oil. Change the oil more frequently if the pump is operated con tinuously or installed in an environment with rapid temperature change.
(Figure 4)
Install the baffle (9) and gasket (8) on the suction spool (18, Figure 1) and use a sling and suitable lift ing device to position the priming chamber assem bly on the suction spool. Secure the priming cham ber assembly with the hardware (6 and 7).
Reconnect the suction piping to the hopper spool and the air discharge tubing to the priming cham ber assembly.
Monitor the condition of the bearing lubri cant regularly for evidence of rust or mois ture condensation. This is especially im portant in areas where variable hot and cold temperatures are common.
For cold weather operation, consult the factory or a lubricant supplier for the recommended grade of oil.
LUBRICATION
Seal Assembly
(Figure 3)
Before starting the pump, remove the air vent (13) and fill the seal cavity with approximately 170
MAINTENANCE & REPAIR PAGE E - 19
Power Source
Consult the literature supplied with the power source, or contact your local power source repre sentative.
Page 41
For U.S. and International Warranty Information,
Please Visit www.grpumps.com/warranty
or call:
U.S.: 419-755-1280
International: +1-419-755-1352
For Canadian Warranty Information,
Please Visit www.grcanada.com/warranty
or call:
519-631-2870
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA
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