Gorman-Rupp Pumps PAH6B60-6068H User Manual

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Page 1

ACDEU

OM-06602-01

December 20, 2012

Rev. A 01‐03‐14

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

PAH SERIES PUMP

MODEL

PAH6B60-6068H IT4

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

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 Lines In Sumps 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................................................................

Manual Starting PAGE C - 1........................................................

Automatic Starting PAGE C - 2.....................................................

Priming PAGE C - 2...............................................................

ROUTINE OPERATION PAGE C - 3.....................................................

OPERATION IN EXTREME HEAT PAGE C - 3............................................

OPERATIONAL CHECKS PAGE C - 3...................................................

Leakage PAGE C - 3..............................................................

Pump Vacuum Check PAGE C - 3..................................................

Liquid Temperature And Overheating PAGE C - 3.....................................

Strainer Check PAGE C - 4.........................................................

STOPPING PAGE C - 4................................................................

Manual Stopping PAGE C - 4.......................................................

Automatic Stopping PAGE C - 4....................................................

Safety Shutdown System PAGE C - 4...............................................

Page 4

TABLE OF CONTENTS

(continued)

PERIODIC CHECKS PAGE C - 5.......................................................

Seal Cavity and Bearing Lubrication PAGE C - 5......................................

Bearing Temperature Check PAGE C - 5.............................................

Engine Fuel Filter PAGE C - 5......................................................

Engine Oil PAGE C - 5.............................................................

Air Compressor PAGE C - 5........................................................

Air Compressor Drive Belt PAGE C - 5...............................................

COLD WEATHER PRESERVATION PAGE C - 5...........................................

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

PARTS LISTS:

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

Power Unit Kit PAGE E - 5.........................................................

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

Pump End Assembly PAGE E - 9...................................................

Repair Rotating Assembly PAGE E - 11...............................................

Priming Chamber Kit PAGE E - 12...................................................

Priming Chamber Assembly PAGE E - 13.............................................

Drive Assembly PAGE E - 14........................................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 15.........................

Priming Chamber Removal And Disassembly PAGE C - 15..............................

Discharge Check Valve Removal and Disassembly PAGE C - 16.........................

Separating Pump And Drive Assembly From Engine PAGE C - 16........................

Draining Oil From Seal Cavity PAGE C - 17............................................

Loosening Impeller PAGE C - 17.....................................................

Pump Casing And Wear Plate Removal PAGE C - 17...................................

Impeller Removal PAGE C - 18......................................................

Seal Removal PAGE C - 18..........................................................

Shaft and Bearing Removal and Disassembly PAGE C - 18.............................

Shaft and Bearing Reassembly and Installation PAGE C - 19............................

Securing Bearing Housing And Drive Assembly To Engine PAGE C - 20..................

Seal Reassembly and Installation PAGE C - 21........................................

Impeller Installation And Adjustment PAGE C - 24......................................

Pump Casing And Wear Plate Installation PAGE C - 24.................................

Discharge Check Valve Reassembly And Installation PAGE C - 24.......................

Priming Chamber Assembly And Installation PAGE C - 24...............................

LUBRICATION PAGE C - 25.............................................................

Seal Assembly PAGE C - 25.........................................................

Bearings PAGE C - 25..............................................................

Engine PAGE C - 25................................................................

Page 5

INTRODUCTION

OM-06602PAH 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 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.

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.

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

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.

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.

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

PAGE I - 1INTRODUCTION

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PAH SERIES

SAFETY ‐ SECTION A

This information applies to Prime Aire Series engine driven pumps. Refer to the manual accompanying the engine before attempting to begin 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.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Shut down the engine and discon nect the positive battery cable 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.

This pump is equipped with an automat ic starting system, and is subject to au tomatic restart. Keep hands and cloth ing away from the unit to prevent injury during automatic operation. Disconnect the positive battery cable before per

forming any maintenance. Failure to do so may result in serious personal injury.

Do not attempt to disengage any part of an overheated pump unit. Vapor pres sure within the pump casing can eject these parts with great force when they are disengaged. Allow the pump to completely cool before servicing it.

This pump is designed to handle most non‐volatile, non‐flammable liquids containing specified entrained solids. Do not attempt to pump volatile, corro sive, or flammable liquids which may damage the pump or endanger person nel as a result of pump failure.

Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.

After the pump has been installed, make certain that the pump and all piping or

OM-06602

PAGE A - 1SAFETY

Page 7

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.

PAH SERIESOM-06602

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

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

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.

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.

Fuel used by internal combustion en gines presents an extreme explosion and fire hazard. Make certain that all fuel lines are securely connected and free of leaks. Never refuel a hot or run ning engine. Avoid overfilling the fuel tank. Always use the correct type of fuel.

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 on page E-1 for the maximum continuous operating speed for this pump.

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

PAGE A - 2 SAFETY

The engine used on this unit is equipped with an exhaust filter which reduces the amount of nitrogen oxide produced while burning away particulate matter that would

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PAH SERIES

OM-06602

otherwise be expelled into the atmo sphere. The resultant soot and ash are trapped in the filter. The Engine Control Unit (ECU) will cause the filter to perform a self‐cleaning function (regeneration) peri odically to keep the soot collected by the filter at manageable levels.

Because the operator can choose to post pone the regeneration process, the ECU

could eventually force a regeneration, re sulting in loss of performance or even a to tal shut down of the engine. Refer to the manual accompanying the engine for a de tailed explanation of the regeneration pro cess and the indicator symbols that will display on the Engine Control Unit. Follow all of the instructions in the engine manual to ensure uninterrupted operation of the engine.

PAGE A - 3SAFETY

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PAH SERIES OM-06602

INSTALLATION - SECTION B

Review all SAFETY information in Section A.

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

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

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

OUTLINE DRAWING

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

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

Pump Dimensions

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

Figure 1. Pump Model PAH6B60-6068H IT4

PREINSTALLATION INSPECTION

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

a. Inspect the pump for cracks, dents, damaged

threads, and other obvious damage.

b. Check for and tighten loose attaching hard

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

PAGE B - 1INSTALLATION

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OM-06602 PAH SERIES

c. Carefully read all tags, decals, and markings

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

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

d. Check levels and lubricate as necessary. Re

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

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

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

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

POSITIONING PUMP

Lifting

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

Battery Installation

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

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

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

PAGE B - 2 INSTALLATION

Mounting

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

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

If the pump has been mounted on a moveable base, make certain the base is stationary by setting the brake and blocking the wheels before attempt ing to operate the pump.

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PAH SERIES OM-06602

to secure them when filled with liquid and under pressure.

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

SUCTION AND DISCHARGE PIPING

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

Materials

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

Line Configuration

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

Connections to Pump

Gauges

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

SUCTION LINES

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

Fittings

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

Strainers

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

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

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 11/16 inch (17,5 mm) diameter spherical solids.

PAGE B - 3INSTALLATION

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OM-06602 PAH SERIES

Sealing

Since even a slight leak will affect priming, head, and capacity, especially when operating with a high suction lift, all connections in the suction line should be sealed with pipe dope to ensure an air tight seal. Follow the sealant manufacturer's rec ommendations when selecting and applying the pipe dope. The pipe dope should be compatible with the liquid being pumped.

Suction Lines In Sumps

If a single suction line is installed in a sump, it should be positioned away from the wall of the sump at a distance equal to 1 1/2 times the diame ter of the suction line.

If there is a liquid flow from an open pipe into the sump, the flow should be kept away from the suc tion inlet because the inflow will carry air down into the sump, and air entering the suction line will re duce pump efficiency.

If it is necessary to position inflow close to the suc tion inlet, install a baffle between the inflow and the suction inlet at a distance 1‐1/2 times the diameter of the suction pipe. The baffle will allow entrained

air to escape from the liquid before it is drawn into the suction inlet.

If two suction lines are installed in a single sump, the flow paths may interact, reducing the efficiency of one or both pumps. To avoid this, position the suction inlets so that they are separated by a dis tance equal to at least 3 times the diameter of the suction pipe.

Suction Line Positioning

The depth of submergence of the suction line is critical to efficient pump operation. Figure 2 shows recommended minimum submergence vs. velocity.

Although not recommended, the vacuum assisted priming feature allows the pump to be operated temporarily in a “slurping” application with varying water levels.

NOTE

The pipe submergence required may be reduced by installing a standard pipe increaser fitting at the end of the suction line. The larger opening size will reduce the inlet velocity. Calculate the required submergence using the following formula based on the increased opening size (area or diameter).

PAGE B - 4 INSTALLATION

Page 13

PAH SERIES OM-06602

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

DISCHARGE LINES

Siphoning

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

Valves

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

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

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

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

ALIGNMENT

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

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

AUTO‐START

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

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

PAGE B - 5INSTALLATION

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OM-06602 PAH SERIES

Float Switch Installation

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

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

When installing the floats, note the following:

a. Be sure to provide sufficient room in the wet

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

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

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

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

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

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

d. Refer to Figure 3 for additional float switch

data.

ENGINE

CONTROL

BOX

CABLE

TETHER

POINT

1.25” Pipe (Not Furnished)

(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 15

PAH SERIES

OM-06602

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 educ tor discharge line. Complete priming is indicated by a positive discharge pressure reading.

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

Repair, Section E for further details.

STARTING

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

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

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

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

PRIMING

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

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

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

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

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

Manual Starting

On initial start‐up, set the engine speed at the half‐ throttle position. Turn the key switch on the control

OPERATION PAGE C - 1

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OM-06602 PAH SERIES

box to the “MANUAL” position, then press and hold the “ENTER” button until the engine starts.

Pump speed and operating condition points must be within the continuous per formance range shown on the curve on Page E‐1.

Automatic Starting

With the float system installed, follow the proce dures outlined for manual starting and adjust the throttle to the desired flow rate. Turn the key switch to “OFF”, then move it to the “AUTO” position.

The pump will start automatically when the liquid level in the sump or wet well increases and the float(s) rise to the “on” position. An alarm will sound and the control box will begin a countdown display before the unit starts. When the liquid is sufficiently pumped down, the unit will automatically shut down.

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

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 appli cable).

The unit can be stopped while in the “AUTO” mode by moving the key switch to the “OFF” position.

NOTE

If the key switch is moved to the “OFF” position while in the “AUTO” mode, the engine will stop. However, the auto‐start process will continue as soon as the key switch is moved back to the “AUTO” position.

The control panel is equipped with high oil temper ature, low oil pressure, engine overspeed and en gine overcrank safety shutdowns. If any of these problems occur, the engine will not start. When the problem is corrected, turn the key switch to the “OFF” position to reset the control.

Priming

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.

The engine used on this unit is equipped with an exhaust filter which reduces the amount of nitrogen oxide produced while burning away particulate matter that would otherwise be expelled into the atmo sphere. The resultant soot and ash are trapped in the filter. The Engine Control Unit (ECU) will cause the filter to perform a self‐cleaning function (regeneration) peri odically to keep the soot collected by the filter at manageable levels.

OPERATIONPAGE C - 2

Page 17

PAH SERIES

OM-06602

Because the operator can choose to post pone the regeneration process, the ECU could eventually force a regeneration, re sulting in loss of performance or even a to tal shut down of the engine. Refer to the manual accompanying the engine for a de tailed explanation of the regeneration pro cess and the indicator symbols that will display on the Engine Control Unit. Follow all of the instructions in the engine manual to ensure uninterrupted operation of the engine.

Operation In Extreme Heat

The safety shutdown system will automatically stop the unit if engine operating temperature ex ceeds design limits. If engine over‐temperature shutdown occurs, allow the unit to cool before re starting.

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.

and fittings tight to maintain maximum pump effi ciency.

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 pro portionate to static suction lift, and should then sta bilize. 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 installa tion 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 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

This pump is equipped with automatic liquid level controls, and is subject to automatic restart. Keep hands and clothing away from the unit to prevent injury during automatic operation. Dis connect the battery before performing any maintenance. Failure to do so may result in serious personal injury.

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

OPERATIONAL CHECKS

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

OPERATION PAGE C - 3

hot liquid.

Strainer Check

Check the strainer regularly, and clean it as neces sary. The strainer should also be checked if pump flow rate begins to drop. Monitor and record the

Page 18

OM-06602 PAH SERIES

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 neces sary, 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.

In the manual mode, reduce the throttle speed slowly, and allow the engine to idle briefly before switching the engine key switch to `OFF'.

2. If the engine oil pressure drops below design limits.

3. If the engine fails to start within a pre‐set peri od of time.

4. If the engine speed exceeds the safe operat ing 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.

All safety shutdown features are pre‐set at the fac tory for optimum performance and safety; do not attempt to adjust these settings.

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

After stopping the pump, switch off the engine igni tion and remove the key to ensure that the pump will remain inoperative.

Automatic Stopping

In the automatic mode, the pump will stop when the liquid in the wet well or sump lowers and acti vates the “Off” float switch(s). The pump will restart automatically when the liquid rises and activates the “On” float switch(s).

Safety Shutdown System

The unit is equipped with a safety system to auto matically shut down the engine under certain con ditions. The engine will automatically shut down:

Never disconnect any of the safety shut down features; this will void the warran ty and could result in serious damage to the unit and/or injury to personnel. Safe ty 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 ad ditional information.

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

1. If the engine exceeds its safe operating tem perature.

Bearings normally run at higher than ambient tem peratures because of heat generated by friction.

OPERATIONPAGE C - 4

Page 19

PAH SERIES

OM-06602

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

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 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.

Engine Fuel Filter

Consult the manual accompanying the engine, and change the fuel filter periodically as indicated. If operated under extremely dusty and/or humid conditions, change the filter more frequently. Irreg ular performance and loss of power usually indi cate a dirty fuel filter.



F (82C).

Engine Oil

The engine was lubricated for test at the factory. However, always check the lubrication level before startup.

Consult the manual accompanying the engine, and change the oil filter periodically as indicated. If operated under extremely dusty conditions, change the filter more frequently.

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

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 - 5

Page 20

PAH SERIES

OM-06602

TROUBLESHOOTING - SECTION D

Review all SAFETY information in Section A.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Shut down the engine and discon nect the positive battery cable to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4. Check the temperature before opening any covers, plates, or plugs.

5. Close the suction and discharge valves.

6. Vent the pump slowly and cau tiously.

7. Drain the pump.

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 21

OM-06602

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.

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 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.

Install bypass line.

Measure lift w/vacuum gauge. Re duce 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 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 22

PAH SERIES

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

OM-06602

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 23

OM-06602

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 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 24

PAH SERIES

OM-06602

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 PAH6B60-6068H IT4

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 25

OM-06602 PAH SERIES

PARTS PAGE

ILLUSTRATION

Figure 1. Pump Model PAH6B60-6068H IT4

MAINTENANCE & REPAIRPAGE E - 2

Page 26

PAH SERIES

OM-06602

Pump Model PAH6B60-6068H IT4

PARTS LIST

(From S/N 1529202 Up)

ITEM NO.

1 JOHN DEERE POWER UNIT 46143-130 --- 1 2 PUMP END ASSEMBLY 46133-293 --- 1 3 PUMP MOUNTING KIT 48157-019 --- 1 4 BATTERY SEE OPTIONS --- 1

NOT SHOWN:

OPTIONAL:

PART NAME

G‐R DECAL GR-06 --- 2 PRIME AIRE PLUS DECAL 38812-098 --- 2 LOW SULFUR FUEL DECAL 38816-196 1

BATTERY 29331-506 --- 1

PART NUMBER

MAT'L CODE

QTY

MAINTENANCE & REPAIR PAGE E - 3

Page 27

OM-06602 PAH SERIES

ILLUSTRATION

Figure 2. 46143-130 Power Unit Kit

MAINTENANCE & REPAIRPAGE E - 4

Page 28

PAH SERIES

PARTS LIST

46143-130 Power Unit Kit

ITEM

PART NAME PART

NO.

1 J.D. 6068H IT4 ENGINE 29224-431 --- 1 2 LIFTING BAIL KIT 48274-805 --- 1 3 CONT PANEL INST KIT 48122-554 --- 1 4 POS BATT CABLE ASSY 47311-214 --- 1 5 NEG BATT CABLE ASSY 47311-215 --- 1 6 BATTERY BOX ASSY GRP40-08D--- 1 7 BASE/FUEL TANK ASSY 41553-022 24150 1 8 FUEL PICKUP 29332-145 --- 2

9 CONNECTOR S1447 --- 1 10 HOSE ASSEMBLY 46341-789 --- 1 11 FUEL GAUGE 29332-135 --- 1 12 HEX ADAPTER 26523-188 --- 1 13 MALE ELBOW 26341-310 --- 1 14 HOSE BARB FTG 26523-047 --- 1 15 CONNECTOR S1598 --- 1 16 1/2” ID X 50” LG HOSE 18513-113 --- 1 17 HOSE BARB FITTING 26523-446 --- 1 18 VENTURI MTG BRACKET 41888-199 24150 1 19 HOSE ASSEMBLY 46341-422 --- 1 20 CONNECTOR 26351-065 --- 1 21 PRESSURE RELIEF VALVE 26662-028 --- 1 22 PIPE TEE U08 11999 1 23 REDUCER PIPE BUSHING AP1208 15079 1 24 PIPE UNION AH12 11999 1 25 VENTURI 26817-001 --- 1 26 RED COUPLING AE1608 15079 1 27 PIPE ELBOW R16 15079 1 28 CHECK VALVE 26641-092 --- 1 29 FLAT WASHER K10 15991 4

NUMBER

MAT'L CODE

QTY ITEM

NO.

30 HEX NUT D10 15991 4 31 LOCK WASHER J10 15991 4 32 HEX HEAD CAP SCREW B1009 15991 4 33 OIL DRAIN ASSY 46342-013 --- 1 34 HOSE BARB FITTING 26523-386 --- 2 35 HOSE CLAMP 26518-641 --- 2 36 FUEL LINE 11308G --- 1 37 3/8” ID X 36” LG HOSE 18513-302 --- 1 38 MALE ELBOW 26351-131 --- 1 39 1/2” ID X 66” LG HOSE 18513-056 --- 1 40 RD HD MACH SCREW CJ#10-04S15991 5 41 WIRE HARNESS 47381-045 --- 1 42 TOWER TERMINAL BODY 29331-415 --- 2 43 FEMALE TERMINAL 29331-413 --- 2 44 CABLE SEAL 29331-411 --- 2 45 JUNCTION BOX 38382-501 --- 1 46 GASKET 38683-481 20000 2 47 AUTO SENDING UNIT 29331-307 --- 1 48 CONDUIT LOCKNUT 27185-002 --- 1 49 CORD GRIP 27112-017 --- 1

NOT SHOWN:

OM-06602

PART NAME PART

NUMBER

LOW SULFUR FUEL DECAL 38816-196 --- 1 FLOAT SWITCH KIT 48312-980 --- 1 ENGINE STARTUP TAG 38816-269 --- 1 INSTRUCTION DECAL 38818-144 --- 1 WARNING DECAL 38816-203 --- 1 WARNING DECAL 38816-132 --- 1 WARNING DECAL 2613FE --- 1

MAT'L CODE

QTY

MAINTENANCE & REPAIR PAGE E - 5

Page 29

OM-06602 PAH SERIES

ILLUSTRATION

Figure 3. 46143-130 Power Unit Kit (Cont'd)

MAINTENANCE & REPAIRPAGE E - 6

Page 30

PAH SERIES

PARTS LIST

46143-130 Power Unit Kit (Cont'd)

ITEM

PART NAME PART

NO.

1 J.D. 6068H IT4 ENGINE 29224-431 --- 1

2 LIFTING BAIL KIT 48274-805 --- 1

3 CONT PANEL INST KIT 48122-554 --- 1

4 POS BATT CABLE ASSY 47311-214 --- 1

5 NEG BATT CABLE ASSY 47311-215 --- 1

6 BATTERY BOX ASSY GRP40-08D--- 1

7 BASE/FUEL TANK ASSY 41553-022 24150 1

8 FUEL PICKUP 29332-145 --- 2

NUMBER

MAT'L CODE

QTY ITEM

NO.

NOT SHOWN:

OM-06602

PART NAME PART

NUMBER

MAT'L CODE

QTY

MAINTENANCE & REPAIR PAGE E - 7

Page 31

OM-06602 PAH SERIES

ILLUSTRATION

Figure 4. 46133-293 Pump End Assembly

MAINTENANCE & REPAIRPAGE E - 8

Page 32

PAH SERIES

OM-06602

46133-293 Pump End Assembly

PARTS LIST

ITEM NO.

1 66J60-(SAE 3/11.5) 46133-292 --- 1 2 PRIMING CHAMBER KIT 48275-005 --- 1 3 STUD C1414 15991 12 4 GASKET 25113-040 1 5 LOCK WASHER J14 15991 12 6 HEX NUT D14 15991 12 7 SUCTION SPOOL 38644-807 10000 1 8 GASKET 25113-034 --- 1

9 BLIND FLANGE ASSEMBLY 42111-358 --- 1 10 LOCK WASHER J10 15991 8 11 HEX HEAD CAP SCREW B1007 15991 8 12 CHECK VALVE KIT 48274-005 --- 1

13 G‐R DECAL GR06 --- 1 14 PRIME AIRE PLUS DECAL 38812-099 --- 1

NOT SHOWN:

PART NAME

CHECK VALVE ASSY 26642-126 --- 1

-FLAPPER 26688-001 --- 1

-COVER O‐RING 25152-377 --- 1 FLANGE GASKET 25113-036 --- 1 HEX HD CAPSCREW B1213 15991 6 STUD C1211 15991 2 HEX NUT D12 15991 8 FLAT WASHER 21161-446 --- 8 LOCK WASHER J12 15991 8

OIL LEVEL DECAL 38816-123 --- 2 SUCTION STICKER 6588AG --- 1 DISCHARGE STICKER 6588BJ --- 1 WARNING DECAL 2613FE --- 1 LUBRICATION DECAL 11421A --- 1 INSTRUCTION TAG 38817-085 --- 1 DRIVE SCREW BM#04-03 17000 4 NAME PLATE 38818-156 13000 1 DRIVE ASSEMBLY 44162-176 --- 1 STRAINER 46641-011 24150 1

PART NUMBER

MAT'L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 9

Page 33

OM-06602 PAH SERIES

ILLUSTRATION

Figure 5. 46133-292 Pump End Assembly

MAINTENANCE & REPAIRPAGE E - 10

Page 34

PAH SERIES

OM-06602

PARTS LIST

46133-292 Pump End Assembly

ITEM NO.

1  PUMP CASING SEE NOTE BELOW 1

2 SUCTION HEAD 38246-614 10000 1

3 O‐RING 25152-387 --- 1

3A O‐RING 25152-387 --- 1

4  PIPE PLUG P04 15079 1

5  PIPE PLUG P08 15079 3

6 REPAIR ROTATING ASSY 44163-510 --- 1

7  STUD C1211 15991 8

8 LOCK WASHER J12 15991 8

9 HEX NUT D12 15991 8 10 WEAR RING 38691-364 11010 1 11  STUD C1213 15991 4 12 ADJUSTING SCREW 31871-070 1500G 4 13 LOCK COLLAR 38115-551 15001 4 14 LOCK WASHER J06 15991 4 15 HEX HEAD CAP SCREW B0804 15991 4 16 BACK COVER NUT 31871-073 15000 4

 INCLUDED W/REPAIR PUMP CASING ASSY 46474-910 --- 1

PART NAME

PART NUMBER

MAT'L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 11

Page 35

OM-06602 PAH SERIES

ILLUSTRATION

Figure 6. 44163-510 Repair Rotating Assembly

MAINTENANCE & REPAIRPAGE E - 12

Page 36

PAH SERIES

OM-06602

PARTS LIST

44163-510 Repair Rotating Assembly

ITEM NO.

1 IMPELLER 38621-738 11010 1

2  SOCKET HEAD CAP SCREW BD1206 15991 1

3  IMPELLER WASHER 31167-042 17000 1

2  SOCKET HEAD CAP SCREW BD1006 15991 1

3  IMPELLER WASHER 31167-096 17000 1

4 ROLL PIN S2197 --- 1

5 SHIM SET 48261-033 --- 1

6 MECHANICAL SEAL 25285-822 --- 1

7 SHAFT SLEEVE 31163-022 17000 1

8 SHAFT SLEEVE O‐RING 25152-150 --- 1

9 SEAL PLATE 38272-272 10000 1 10 SEAL CAVITY SIGHT GAUGE S1471 --- 2

10A BEARING CAVITY SIGHT GAUGE S1471 --- 2

11 LIP SEAL 25227-856 --- 2 12 REDUCER PIPE BUSHING AP1202 15079 1 13 SEAL CAVITY AIR VENT S1530 --- 1

13A BEARING CAVITY AIR VENT S1530 --- 1

14 GASKET 38683-665 18000 1 15 LOCK WASHER J10 15991 8 16 HEX HEAD CAP SCREW B1007 15991 8 17 PEDESTAL 38257-210 10000 1 18 BEARING CAVITY FILL PLUG P12 15079 1

18A BEARING CAVITY DRAIN PLUG P12 15079 1 18B SEAL CAVITY DRAIN PLUG P12 15079 1

19 LIP SEAL 25258-845 --- 1 20 DRIVE FLANGE 38545-018 10000 1 21 GASKET 38683-664 19060 1 22 BEARING LOCKNUT 23962-015 --- 1 23 BEARING LOCK COLLAR 23962-515 --- 1 24 BALL BEARING 23422-417 --- 1 25  IMPELLER SHAFT 38512-530 16000 1 25  IMPELLER SHAFT SEE NOTE BELOW 1 26 IMPELLER KEY N0806 15990 1 27 ROLLER BEARING 23535-001 --- 1 28 DRIVE KEY N1020 15990 1

NOT SHOWN:

PART NAME

PIPE PLUG P12 15079 2 SEAL PLATE O‐RING 25152-387 --- 1 SHIPPING PLUG 11495B 15079 2 INSTRUCTION TAG 6588U --- 1

PART NUMBER

MAT'L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

 FOR PUMPS WITH S/N AFTER 1548482

 FOR PUMPS WITH S/N PRIOR TO 1548482

 FOR PUMPS WITH S/N PRIOR TO 1548482, ORDER IMPELLER SHAFT REPAIR KIT 48781-032

MAINTENANCE & REPAIR PAGE E - 13

Page 37

OM-06602 PAH SERIES

ILLUSTRATION

Figure 7. 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 - 14

QTY

Page 38

PAH SERIES

OM-06602

ILLUSTRATION

Figure 8. 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 - 15

PART NAME

-ORIFICE BUTTON 26688-021 --- 1

PART NUMBER

MAT'L CODE

QTY

Page 39

OM-06602 PAH SERIES

ILLUSTRATION

Figure 9. 44162-162 Drive Assembly

ITEM NO.

1 COUPLING KIT 48112-006 --- 1

2 -BUSHING 24131-492 --- 1

3 -COUPLING ASSEMBLY 24391-106 --- 1

4 LOCKWASHER 21171-536 --- 8

5  SOCKET HEAD CAPSCREW B0612 15991 8

5  SOCKET HEAD CAPSCREW 22645-174 --- 8

6  HEX HEAD CAPSCREW B0606 15991 10

6  HEX HEAD CAPSCREW 22645-166 --- 10

7  LOCKWASHER J06 15991 12

7  LOCKWASHER 21171-511 --- 12

8  STUD C0606 15991 2

8  STUD 26821-879 15991 2

9  HEX NUT D06 15991 2

9  HEX NUT 26821-932 --- 2

PART NAME

 USE FOR SAE APPLICATIONS  USE FOR METRIC APPLICATIONS

PART NUMBER

MAT'L CODE

QTY

MAINTENANCE & REPAIRPAGE E - 16

Page 40

PAH SERIES

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 9) and the corresponding Parts Lists. Maintenance and repair instructions for the engine are covered separately in specific literature available from the manufactur er.

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, 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 per sonnel to ensure that only safe, established main tenance procedures are used, and that any proce dures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such prac tices.

Some pump service functions may be performed without separating the pump end assembly from the engine. However, the priming chamber (2, Fig ure 4) and discharge check valve assembly (12, Figure 4) 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, shut down the engine and take precautions to ensure that it will remain inoperative. Close all valves in the suc tion and discharge lines and drain the pump cas ing by removing the lowermost pipe plug (5, Figure

5). Clean and reinstall the plug.

OM-06602

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 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 pump integrity are compromised by such practices.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Shut down the engine and discon nect the positive battery cable 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.

Death or serious personal injury and damage to the pump or components

MAINTENANCE & REPAIR PAGE E - 17

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PAH SERIESOM-06602

can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.

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.

Priming Chamber Removal And Disassembly

(Figure 7)

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 4)

Remove the hardware (not shown) securing the discharge check valve bracket to the base.

Support the discharge check valve assembly (12) 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.

Disconnect both the suction piping and the air dis charge tubing from the priming chamber assembly (2, Figure 4). Support the priming chamber assem bly using a sling and a suitable lifting device. Re move the hardware (6 and 7) and separate the priming chamber assembly, gasket (8) and baffle (9) from the spool (7, Figure 4).

(Figure 8)

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.

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

Suction Head and Wear Ring Removal

(Figure 5)

The wear ring (10) is easily accessible and may be serviced by removing the suction head (2). 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 (7, Figure 4) from the suction head unless replace ment of the spool, gasket (4, Figure 4) or suction head is required. To remove the suction spool, dis engage the hardware (5 and 6, Figure 4) securing it to the pump casing.

Remove the back cover nuts (16) and two diago nally opposing locking collars (13). Use the adjust ing screws (12) 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 3/4-10 UNC‐2B capscrews (not

MAINTENANCE & REPAIRPAGE E - 18

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OM-06602

supplied) in the tapped holes in the suction head and use the screws to press the wear ring out of the suction head. Remove the jacking screws.

Pump Casing Removal

(Figure 5)

Remove the uppermost pipe plug (5) from the pump casing and install a lifting eye in the hole. Be sure to screw the lifting eye tightly into the hole as far as it will go. Attach a sling and suitable lifting de vice to the lifting eye and support the pump casing.

Remove the hardware (8 and 9) and use the lifting device to pull the pump casing straight away from the rotating assembly (6).

Remove and discard the pump casing O‐ring (3A).

Draining Oil From Seal Cavity

(Figure 6)

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.

peller and seal plate (9). Tap the wedges evenly in an alternating pattern to “walk” the impeller off the shaft.

Position a clean container under the seal cavity drain plug (18B). Remove the plug and drain the oil from the seal cavity into the container. For shorter drain time, remove the air vent (13). When the oil is drained, clean and reinstall the drain plug and air vent. Inspect the oil for water, dirt or a cloudy condi tion which could indicate seal failure.

Impeller Removal

(Figure 6)

With the pump casing removed, use an impact wrench with a hex key to loosen the impeller caps crew (2). Remove the capscrew, impeller washer (3) and roll pin (4).

Use a suitable three‐jawed puller to remove the im peller (1) and key (26) from the shaft (25). Use cau tion when removing 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

MAINTENANCE & REPAIR PAGE E - 19

Page 43

PAH SERIESOM-06602

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.

Seal Removal

(Figures 6 and 10)

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 from the seal plate bore.

slide the coupling off the shaft. Remove the shaft key (28, Figure 6).

It is not necessary to remove the outer ring of the coupling from the engine flywheel unless the cou pling must be replaced. To remove the ring, disen gage the hardware (4 and 5) securing it to the fly wheel.

Move the pump end to a clean, well equipped shop area for further disassembly.

Shaft and Bearing Removal and Disassembly

(Figure 6)

When the pump is properly operated and main tained, the bearing housing should not require dis assembly. Disassemble the shaft and bearings only when there is evidence of wear or damage.

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 (17). 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.

If no further disassembly is required, refer to Seal

Installation.

Separating Pedestal and Drive Assembly From Engine

(Figure 9)

Support the pedestal using a hoist and sling and remove the hardware (6, 7 and 9) securing the drive flange (20, Figure 6) to the engine bellhou sing. Separate the assemblies by pulling the ped estal straight away from the engine.

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 (18A) and drain the lubricant. Clean and reinstall the drain plug.

If not removed with the seal assembly, remove the hardware (15 and 16) and separate the seal plate and gasket (14) from the pedestal (17).

Disengage the hardware (15 and 16) and remove the drive flange (20), gasket (21) and oil seal (19). Press the oil seal from the drive 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 seals (11) from the bearing housing.

As the assemblies separate, the flexible portion of the coupling assembly (3) 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

After removing the shaft and bearings, clean and inspect the bearings in place as follows.

To prevent damage during removal from

MAINTENANCE & REPAIRPAGE E - 20

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PAH SERIES

OM-06602

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.

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.

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 (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.

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.

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.

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 rollers and balls. If rotation is rough or the rollers or 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, 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.

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

MAINTENANCE & REPAIR PAGE E - 21

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PAH SERIESOM-06602

suitably sized sleeve and a press to reposition the bearings against the shaft shoulders.

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.

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.

the retaining ring on the outboard bearing seats against the pedestal. Remove the lip seal sleeve.

When installing the shaft and bearings into 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 (11) and press it into the pedestal with the lip positioned as shown in Figure 6. 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 (19) and press it into the drive flange (20) with the lip positioned as shown in Figure 6. The oil seal should be centered in the flange bore.

Install the gasket (21) 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 (19) 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.).

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 lockwash er 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 (11) and press it into the pedestal bore with the lip positioned as shown in Figure 6. 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

Lubricate the bearings as indicated in LUBRICA

TION at the end of this section.

Securing Pedestal And Drive Assembly To Engine

(Figure 9)

Install the shaft key (28, Figure 6) in the shaft key way. Position the flexible portion of the coupling as sembly (3) on the shaft as shown in Figure 9.

NOTE

The flexible portion of the coupling must be proper ly positioned on the shaft. The heads of the caps crews in the center of the coupling must be posi tioned away from the pump.

Align the keyway in the bushing (2) with the shaft key, and slide it onto the shaft until the face of the bushing is just flush with the end of the shaft. Ro tate the flexible portion of the coupling until the tapped holes for the two setscrews align with those in the bushing, and install the setscrews.

MAINTENANCE & REPAIRPAGE E - 22

Page 46

PAH SERIES

OM-06602

er substance which may soften or otherwise dam age the rubber.

Make certain that the flexible portion of the coupling is mounted as shown in Figure 9. This is critical. If the coupling is not prop erly positioned on the shaft, the coupling parts may not fully engage, or a pre‐load condition can cause premature bearing failure.

The end of the shaft must be extend 0.44 inch (11,2 mm) from the face of the bushing. This will allow the two portions of

the coupling to fully engage when the en gine bracket is secured to the engine bell housing 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 67 ft. lbs. (800 in. lbs. or 0,57 m. kg.).

If the complete coupling assembly is being re placed, apply `Loctite Retaining Compound No. 242' or equivalent to the threads of the hardware (4 and 5) and secure the outer ring of the coupling to the engine flywheel by torquing the hardware to 50 ft. lbs. (6,9 m. kg.).

Secure the drive flange (20, Figure 6) to the engine bellhousing with the previously removed hardware (6, 7 and 9).

Seal Reassembly and Installation

(Figures 6 and 10)

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.

Using a suitable lifting device, position the as sembled drive and rotating assembly so the flex ible portion of the coupling seats inside the outer ring attached to the engine flywheel.

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.

NOTE

To ease installation, lightly lubricate the rubber por tion of the coupling with a non‐petroleum based lubricant such as vegetable oil or glycerin, or a sili con‐based lubricant such as “WD40” or equivalent. Do not use petroleum‐based lubricants, or any oth

MAINTENANCE & REPAIR PAGE E - 23

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 10 for seal part identification.

Page 47

PAH SERIESOM-06602

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 10. Seal Assembly

This seal is not designed for operation at temperatures above 160F (71C). 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 6)

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 & REPAIRPAGE E - 24

Page 48

PAH SERIES

OM-06602

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 5)

Lubricate the O‐ring (3A) with light grease and in stall it in the groove in the O.D. of the seal plate. Install a lifting eye in the uppermost hole in the pump casing (1) for the pipe plug (5). Be sure to screw the lifting eye tightly into the hole as far as it will go. Attach a sling and suitable lifting device to the lifting eye and use the lifting device to position the pump casing over the rotating assembly. Install the hardware (8 and 9) on the studs (7) and use the hardware to fully seat the pump casing against the seal plate (9, Figure 6).

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 back cover nuts snugly against the adjusting screws.

Suction Head and Wear Ring Installation and Adjustment

(Figure 5)

If the wear ring (10) was removed, position the re placement wear ring in the suction head (2) 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 (11).

The clearance between the wear ring and the im peller is adjusted using the four back cover nuts (16) and locking collars (13). 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 (12) 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 (11) 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 4)

If the discharge check valve (12) 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 & REPAIR PAGE E - 25

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PAH SERIESOM-06602

moved hardware, secure the discharge check valve assembly and flange gasket to the pump as sembly (1). Secure the discharge check valve to its support bracket using the previously removed hardware.

Priming Chamber Assembly And Installation

(Figure 8)

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 (10). Clean and rein stall the vented plug. Check the oil level regularly and maintain it at the middle of the sight gauge.

Bearings

(Figure 6)

The bearing housing was fully lubricated when shipped from the factory. Check the oil level regu larly through the sight gauge (10A) and maintain it at the midpoint of the gauge. When lubrication is required, 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 bear ing 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 7)

Install the baffle and gasket (8 and 9) and use a sling and suitable lifting device to position the prim ing chamber assembly on the pump suction spool (7, Figure 4). Secure the priming chamber assem bly with the hardware (6 and 7).

Reconnect both the suction piping and the air dis charge tubing to the priming chamber assembly.

LUBRICATION

Seal Assembly

(Figure 6)

Before starting the pump, remove the vented plug (13) and fill the seal cavity with approximately 170

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.

Engine

Consult the literature supplied with the engine, or contact your local engine representative.

MAINTENANCE & REPAIRPAGE E - 26

Page 50

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