Gorman-Rupp Pumps PAV3A60C-B User Manual
ACDEU
OM-06525-01
February 10, 2012
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
PA SERIES PUMP
MODEL
PAV3A60C‐B
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
2012 The Gorman‐Rupp Company
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:
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 - 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................................................................
ELECTRICAL CONNECTIONS PAGE B - 5...............................................
Grouding Methods PAGE B - 6.....................................................
Field Wiring Connections (Incoming Power) PAGE B - 6...............................
Voltage Imbalance PAGE B - 7.....................................................
Power Cable Connections PAGE B - 7...............................................
Control Box Adjustment PAGE B - 7.................................................
ALIGNMENT PAGE B - 7..............................................................
AUTO‐START PAGE B - 8.............................................................
Float Switch Installation PAGE B - 8.................................................
Submersible Transducer Installation PAGE B - 9......................................
OPERATION - SECTION C PAGE C - 1......................................
STARTING AND OPERATION PAGE C - 1...............................................
Control Box Function PAGE C - 1...................................................
Component Function PAGE C - 1...................................................
Rotation PAGE C - 2..............................................................
Priming PAGE C - 2...............................................................
Leakage PAGE C - 2..............................................................
Pump Vacuum Check PAGE C - 3..................................................
Priming Chamber Discharge Line PAGE C - 3........................................
Liquid Temperature And Overheating PAGE C - 3.....................................
Strainer Check PAGE C - 3.........................................................
STOPPING PAGE C - 3................................................................
Manual Stopping PAGE C - 3.......................................................
i
TABLE OF CONTENTS
(continued)
Automatic Stopping PAGE C - 3....................................................
PERIODIC CHECKS PAGE C - 3.......................................................
Seal Cavity and Bearing Lubrication PAGE C - 3......................................
Bearing Temperature Check PAGE C - 3.............................................
Air Compressor Drive Belt PAGE C - 4...............................................
COLD WEATHER PRESERVATION PAGE C - 4...........................................
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..........................................................
Pump End Assembly PAGE E - 5...................................................
Repair Rotating Assembly PAGE E - 9...............................................
Priming Chamber Kit PAGE E - 10...................................................
Priming Chamber Assembly PAGE E - 11.............................................
Air Compressor Assembly PAGE E - 12...............................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 13.........................
Priming Chamber Removal And Disassembly PAGE C - 14..............................
Discharge Check Valve Removal and Disassembly PAGE C - 14.........................
Back Cover Plate and Wear Plate Removal PAGE C - 14................................
Separating Pump And Drive Assembly From Engine PAGE C - 14........................
Draining Oil From Seal Cavity PAGE C - 15............................................
Loosening Impeller PAGE C - 15.....................................................
Pump Casing Removal PAGE C - 15.................................................
Impeller Removal PAGE C - 16......................................................
Seal Removal PAGE C - 16..........................................................
Shaft and Bearing Removal and Disassembly PAGE C - 16.............................
Shaft and Bearing Reassembly and Installation PAGE C - 17............................
Seal Reassembly and Installation PAGE C - 18........................................
Impeller Installation And Adjustment PAGE C - 20......................................
Pump Casing Installation PAGE C - 20................................................
Securing Pump End To Power Source PAGE C - 20....................................
Wear Plate and Back Cover Installation And Adjustment PAGE C - 20....................
Discharge Check Valve Reassembly And Installation PAGE C - 21.......................
Priming Chamber Assembly And Installation PAGE C - 22...............................
LUBRICATION PAGE C - 22.............................................................
Seal Assembly PAGE C - 22.........................................................
Bearings PAGE C - 22..............................................................
ii
PA SERIES OM-06525
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 PA Series, priming‐assisted centrif
ugal model. The unit is designed for handling non‐
volatile, non‐flammable liquids containing speci
fied entrained solids. The basic material of con
struction is ductile iron, with stainless steel shaft
and ductile iron wearing parts.
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.
The following are used to alert maintenance per
sonnel to procedures which require special atten
tion, 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.
For information or technical assistance on the
power source, contact the power source manufac
turer's local dealer or representative.
If there are any questions regarding the pump or
its application which are not covered in this man
ual or in other literature accompanying this 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
describe the requirements and the possi
ble damage which could result from failure
to follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
PAGE I - 1INTRODUCTION
PA SERIES OM-06525
SAFETY - SECTION A
This information applies to PA 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.
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.
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 materials which may
damage the pump or endanger person
nel as a result of pump failure.
After the pump has been positioned,
make certain that the pump and all pip
ing connections are tight, properly sup
ported and secure before operation.
Do not operate the pump without the
guards in place over the rotating parts.
Exposed rotating parts can catch cloth
ing, fingers, or tools, causing severe in
jury to personnel.
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 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.
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 before servicing.
Do not operate the pump against a
closed discharge valve for long periods
of time. If operated against a closed dis
charge valve, pump components will
deteriorate, and the liquid could come
PAGE A - 1SAFETY
PA SERIESOM-06525
to a boil, build pressure, and cause the
pump casing to rupture or explode.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam
age to equipment. Suction and dis
charge hoses and piping must be re
moved from the pump before lifting.
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.
rials which could cause illness through
direct exposure or emitted fumes. Wear
adequate protective clothing when
working on the pump or piping.
This pump may be equipped with an op
tional automatic starting system, and
therefore subject to automatic restart.
Keep hands and clothing away from the
unit to prevent injury during automatic
operation. Disconnect the positive bat
tery cable before performing any main
tenance. Failure to do so may result in
serious personal injury.
This pump may be used to handle mate
Pumps and related equipment must be in
stalled and operated according to all na
tional, local and industry standards.
PAGE A - 2 SAFETY
INSTALLATION - SECTION B
OM-06525PA SERIES
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
OUTLINE DRAWING
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 PAV3A60C-B
PAGE B - 1INSTALLATION
OM-06525 PA SERIES
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.
Mounting
Only operate this pump in the direction in
dicated by the arrow on the pump body or
on the accompanying decal. Refer to RO
TATION 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.
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
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.
PAGE B - 2 INSTALLATION
OM-06525PA SERIES
Line Configuration
Keep suction and discharge lines as straight as
possible to minimize friction losses. Make mini
mum use of elbows and fittings, which substan
tially increase friction loss. If elbows are necessary,
use the long‐radius type to minimize friction loss.
Connections to Pump
Before tightening a connecting flange, align it ex
actly with the pump port. Never pull a pipe line into
place by tightening the flange bolts and/or cou
plings.
Lines near the pump must be independently sup
ported to avoid strain on the pump which could
cause excessive vibration, decreased bearing life,
and increased shaft and seal wear. If hose‐type
lines are used, they should have adequate support
to secure them when filled with liquid and under
pressure.
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.
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.
Fittings
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.
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
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
PAGE B - 3INSTALLATION
OM-06525 PA SERIES
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 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.
PAGE B - 4 INSTALLATION
Valves
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.
If the application involves a high discharge
OM-06525PA SERIES
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 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.
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 3).
Figure 3. Aligning Spider‐Type Couplings
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
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
Figure 4. 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 4).
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.
Drive Belts
When using drive belts, the power source and the
pump must be parallel. Use a straightedge along
PAGE B - 5INSTALLATION
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