GORMAN-RUPP PUMPS PA6C60-4045D/S1 Application guide

OM‐05362-OE01

April 9, 2002

Rev. B 07‐14‐03

THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO

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

www.gormanrupp.com.

Copyright by the Gorman‐Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

PA SERIES PUMP

MODEL

PA6C60-4045D /S1

Including

PA6C60-(SAE 4/10)/S1 Pump End

The engine exhaust from this

product contains chemicals

known to the State of California to

cause cancer, birth defects or

other reproductive harm.

TABLE OF CONTENTS

INTRODUCTION PAGE I - 1.................................................

SAFETY ‐ SECTION A PAGE A - 1............................................

INSTALLATION - SECTION B PAGE B - 1....................................

Pump Dimensions PAGE B - 1.....................................................

PREINSTALLATION INSPECTION PAGE B - 1............................................

Battery Installation PAGE B - 2.....................................................

POSITIONING PUMP PAGE B - 2.......................................................

Lifting PAGE B - 2.................................................................

Mounting PAGE B - 2.............................................................

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

Materials PAGE B - 3..............................................................

Line Configuration PAGE B - 3......................................................

Connections to Pump PAGE B - 3..................................................

Gauges PAGE B - 3...............................................................

SUCTION LINES PAGE B - 3...........................................................

Fittings PAGE B - 3...............................................................

Strainers PAGE B - 3..............................................................

Sealing PAGE B - 4...............................................................

Suction Line Positioning PAGE B - 4................................................

DISCHARGE LINES PAGE B - 5........................................................

Siphoning PAGE B - 5.............................................................

Valves PAGE B - 5................................................................

ALIGNMENT PAGE B - 5..............................................................

AUTO‐START PAGE B - 5.............................................................

Float Switch Installation PAGE B - 6.................................................

OPERATION - SECTION C PAGE C - 1......................................

OPERATION PAGE C - 1..............................................................

PRIMING PAGE C - 1.................................................................

STARTING PAGE C - 1................................................................

OPERATION PAGE C - 1..............................................................

Leakage PAGE C - 1..............................................................

Pump Vacuum Check PAGE C - 1..................................................

Liquid Temperature And Overheating PAGE C - 2.....................................

Strainer Check PAGE C - 2.........................................................

STOPPING PAGE C - 2................................................................

BEARING TEMPERATURE CHECK PAGE C - 2..........................................

Cold Weather Preservation PAGE C - 3..............................................

TROUBLESHOOTING - SECTION D PAGE D - 1..............................

PREVENTIVE MAINTENANCE PAGE D - 3...............................................

PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................

STANDARD PERFORMANCE CURVE PAGE E - 1........................................

TABLE OF CONTENTS

(continued)

PARTS LIST:

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

Pump Assembly PAGE E - 5.......................................................

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

Repair Rotating Assembly PAGE E - 9...............................................

Priming Chamber Assembly PAGE E - 10.............................................

Drive Assembly PAGE E - 11........................................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 12.........................

Priming Chamber Removal And Disassembly PAGE C - 12..............................

Discharge Check Valve Removal and Disassembly PAGE C - 13.........................

Draining Oil From Seal Cavity PAGE C - 13............................................

Separating Pump And Drive Assembly From Engine PAGE C - 13........................

Impeller Loosening PAGE C - 13.....................................................

Pump Casing And Wear Plate Removal PAGE C - 14...................................

Impeller Removal PAGE C - 14......................................................

Seal Removal PAGE C - 14..........................................................

Shaft and Bearing Removal and Disassembly PAGE C - 15.............................

Shaft and Bearing Reassembly and Installation PAGE C - 15............................

Securing Intermediate And Drive Assembly To Engine PAGE C - 16......................

Seal Reassembly and Installation PAGE C - 17........................................

Impeller Installation And Adjustment PAGE C - 20......................................

Pump Casing And Wear Plate Installation PAGE C - 20.................................

Discharge Check Valve Reassembly And Installation PAGE C - 20.......................

Priming Chamber Assembly And Installation PAGE C - 21...............................

LUBRICATION PAGE C - 21.............................................................

Seal Assembly PAGE C - 21.........................................................

Bearings PAGE C - 21..............................................................

Engine PAGE C - 21................................................................

OM-05362PA SERIES PUMPS

PAGE I - 1INTRODUCTION

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 Installation, Operation, and Mainte

nance manual is designed to help you achieve the

best performance and longest life from your Gor

man‐Rupp 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.

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

For information or technical assistance on the en

gine, contact the engine manufacturer's local

dealer or representative.

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.

PA SERIES OM-05362

PAGE A - 1SAFETY

SAFETY ‐ SECTION A

This information applies to Prime Aire

Series pumps. Refer to the manual ac

companying the engine or power

source before attempting to begin oper

ation.

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 and

take precautions to ensure that the

pump will remain inoperative.

3. Allow the pump to completely cool

if overheated.

4. Check the temperature and make

sure the pump is cool before 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 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.

Use lifting and moving equipment in

good repair and with adequate capacity

to prevent injuries to personnel or dam

age to equipment. Attach lifting equip

ment to the lifting device fitted to the

pump. If chains or cable are wrapped

around the pump to lift it, make certain

that they are positioned so as not to

damage the pump, and so that the load

will be balanced. The bail is intended for

use in lifting the pump assembly only.

Suction and discharge hoses and pip

ing must be removed from the pump be

fore lifting.

After the pump has been installed, make

certain that the pump and all piping or

hose connections are tight, properly

supported and secure before operation.

Do not operate the pump against a

closed discharge valve. If operated

against a closed discharge valve, pump

components will deteriorate, and the

liquid could come to a boil, build pres

sure, and cause the pump casing to rup

ture or explode. Momentary closure of a

discharge valve is acceptable only

when required for startup or shutdown

procedures.

Do not remove plates, covers, gauges,

pipe plugs, or fittings from an over

PA SERIESOM-05362

PAGE A - 2 SAFETY

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.

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.

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.

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. The maximum continuous

operating speed for this pump is 1900

RPM.

PA SERIES OM-05362

PAGE B - 1INSTALLATION

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

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.

OUTLINE DRAWING

Figure 1. Pump Model PA6C60-4045D /S1

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.

OM-05362 PA SERIES

PAGE B - 2 INSTALLATION

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.

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.

POSITIONING PUMP

Use lifting and moving equipment in

good repair and with adequate capacity

to prevent injuries to personnel or dam

age to equipment. Attach lifting equip

ment to the lifting device fitted to the

pump. If chains or cable are wrapped

around the pump to lift it, make certain

that they are positioned so as not to

damage the pump, and so that the load

will be balanced. The bail is intended for

use in lifting the pump assembly only.

Suction and discharge hoses and pip

ing must be removed from the pump be

fore lifting.

Lifting

Use lifting equipment with a capacity of at least

16,000 pounds (7257 kg). This pump weighs ap

proximately 3,200 pounds (1452 kg), not includ

ing the weight of accessories and optional wheel

kit. Customer installed equipment such as suction

and discharge piping must be removed before at

tempting to lift.

The pump assembly can be seriously

damaged if the chains or cables used to lift

and move the unit are improperly wrapped

around the pump.

Mounting

Locate the pump in an accessible place as close as

practical to the liquid being pumped. Level 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

PA SERIES OM-05362

PAGE B - 3INSTALLATION

the brake and blocking the wheels before attempt

ing to operate the pump.

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

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.

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.

If a strainer not furnished with the pump is installed

by the pump user, make certain that the total area

of the openings in the strainer is at least three or

four times the cross section of the suction line, and

that the openings will not permit passage of solids

larger than the solids handling capability of the

pump.

This pump is designed to handle up to 3 inch (76,2

mm) diameter spherical solids.

This manual suits for next models

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