GORMAN-RUPP PA6C60-4045T-ESP Installation, Operation And Maintenance Manual
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GORMAN-RUPP PA6C60-4045T-ESP Installation, Operation And Maintenance Manual

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ACDEU
OM-06341-02
February 18, 2010
Rev. A 07‐26‐10
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
PA SERIES PUMP
MODEL
PA6C60-4045T-ESP
THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO
www.grpumps.com
D
GORMAN‐RUPP OF CANADA LIMITED
ST. THOMAS, ONTARIO, CANADA
Printed in U.S.A.
e
2010 The Gorman‐Rupp Company

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Summary of Contents for GORMAN-RUPP PA6C60-4045T-ESP

  • Page 1 February 18, 2010 Rev. A 07‐26‐10 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST PA SERIES PUMP MODEL PA6C60-4045T-ESP THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO www.grpumps.com GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A. 2010 The Gorman‐Rupp Company...
  • Page 2 Register your new 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ..........PAGE I - 1 SAFETY ‐...
  • Page 4 TABLE OF CONTENTS (continued) PREVENTIVE MAINTENANCE ..........PAGE D - 3 PUMP MAINTENANCE AND REPAIR ‐...

  • Page 5: Introduction

    PA SERIES OM-06341 INTRODUCTION Thank You for purchasing a Gorman‐Rupp pump. The following are used to alert personnel to proce­ Read this manual carefully to learn how to safely dures which require special attention, to those install and operate your pump. Failure to do so which could damage equipment, and to those could result in personal injury or damage to the which could be dangerous to personnel:...

  • Page 6: Safety - Section A

    PA SERIES OM-06341 SAFETY ‐ SECTION A This information applies to Prime Aire damage the pump or endanger person­ Series pumps. Refer to the manual ac­ nel as a result of pump failure. companying the engine or power source before attempting to begin oper­ ation.
  • Page 7 OM-06341 PA SERIES 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 Do not operate an internal combustion servicing. engine in an explosive atmosphere. When operating an internal combustion engine in an enclosed area, make sure exhaust fumes are piped to the outside.

  • Page 8: Installation - Section B

    See Figure 1 for the approximate physical dimen­ some of the information such as mounting, line sions of this pump. OUTLINE DRAWING Figure 1. Pump Model PA6C60-4045T-ESP PREINSTALLATION INSPECTION a. Inspect the pump for cracks, dents, damaged threads, and other obvious damage.

  • Page 9: Battery Installation

    OM-06341 PA SERIES c. Carefully read all tags, decals, and markings POSITIONING PUMP on the pump assembly, and perform all duties indicated. Note that the pump shaft rotates in the required direction. Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or dam­...

  • Page 10: Suction And Discharge Piping

    PA SERIES OM-06341 the brake and blocking the wheels before attempt­ lines are used, they should have adequate support ing to operate the pump. to secure them when filled with liquid and under pressure. Gauges The pump is drilled and tapped for installing dis­ If the pump has been mounted on a mov­...

  • Page 11: Sealing

    OM-06341 PA SERIES Sealing air to escape from the liquid before it is drawn into the suction inlet. Since even a slight leak will affect priming, head, If two suction lines are installed in a single sump, and capacity, especially when operating with a the flow paths may interact, reducing the efficiency high suction lift, all connections in the suction line of one or both pumps.

  • Page 12: Discharge Lines

    PA SERIES OM-06341 Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity DISCHARGE LINES Siphoning If the application involves a high discharge head, gradually close the discharge Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a si­ throttling valve before stopping the pump.

  • Page 13: Float Switch Installation

    OM-06341 PA SERIES Float Switch Installation pipe is available, attach the float switch cable to the standpipe in the sump at the approxi­ The Float Switch autostart system employs either a mate desired liquid level. single or double float switch, where a bulb raises or lowers (floats) with the liquid level, thus activating b.

  • Page 14: Operation - Section C

    OM-06341 PA SERIES OPERATION - SECTION C Review all SAFETY information in Section A. cated (see LUBRICATION in MAINTENANCE AND REPAIR). Follow the instructions on all tags, labels and The pump will begin to prime upon startup. The air decals attached to the pump. in the suction line will be discharged from the educ­...

  • Page 15: Operation

    OM-06341 PA SERIES AL'. After the engine starts and the unit is fully Adjust the engine speed to achieve the desired primed, adjust the engine RPM until the desired output. Do not exceed the factory set engine speed flow rate is achieved. and system operating pressure.

  • Page 16: Pump Vacuum Check

    OM-06341 PA SERIES connections or fittings. Keep all line connections Strainer Check and fittings tight to maintain maximum pump effi­ ciency. 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 vacuum suction gauge readings regularly to detect Pump Vacuum Check strainer blockage.

  • Page 17: Bearing Temperature Check

    OM-06341 PA SERIES Safety Shutdown System PERIODIC CHECKS Seal Cavity And Bearing Lubrication The unit is equipped with a safety system to auto­ matically shut down the engine under certain con­ Both the seal and bearing cavities were fully lubri­ ditions.

  • Page 18: Cold Weather Preservation

    OM-06341 PA SERIES few hours, or if it has been pumping liquids con­ COLD WEATHER PRESERVATION taining a large amount of solids, drain the pump, and flush it thoroughly with clean water. To prevent In below freezing conditions, drain the pump to large solids from clogging the drain port and pre­...

  • Page 19: Troubleshooting - Section D

    OM-06341 PA SERIES TROUBLESHOOTING - SECTION D Review all SAFETY information in Section A. Before attempting to open or service the pump: 1. Familiarize yourself with this manual. 2. Shut down the engine, disconnect the positive battery cable and take precautions to ensure that the pump will remain inoperative.
  • Page 20 OM-06341 PA SERIES TROUBLE POSSIBLE CAUSE PROBABLE REMEDY Check strainer and clean if neces­ Strainer clogged. PUMP STOPS OR FAILS TO DELIVER sary. RATED FLOW OR Check and clean check valve. Discharge check valve clogged. PRESSURE (cont.) Suction intake not submerged at Check installation and correct proper level or sump too small.
  • Page 21 OM-06341 PA SERIES TROUBLE POSSIBLE CAUSE PROBABLE REMEDY BEARINGS RUN Bearing temperature is high, but Check bearing temperature regu­ TOO HOT within limits. larly to monitor any increase. Low or incorrect lubricant. Check for proper type and level of lubricant. Suction and discharge lines not prop­...
  • Page 22 OM-06341 PA SERIES Preventive Maintenance Schedule Service Interval* Item Daily Weekly Monthly Semi‐ Annually Annually General Condition (Temperature, Unusual Noises or Vibrations, Cracks, Leaks, Loose Hardware, Etc.) Pump Performance (Gauges, Speed, Flow) Bearing Lubrication Seal Lubrication (And Packing Adjustment, If So Equipped) V‐Belts (If So Equipped) Air Release Valve Plunger Rod (If So Equipped) Front Impeller Clearance (Wear Plate)
  • Page 23 PUMP MAINTENANCE AND REPAIR - SECTION E MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE. STANDARD PERFORMANCE FOR PUMP MODEL PA6C60-4045T-ESP Based on 70_F (21_C) clear water at sea level with minimum suction lift. Since pump installations are seldom identical, your performance may be dif­...
  • Page 24 OM-06341 PA SERIES PARTS PAGE Figure 1. Pump Model PA6C60-4045T-ESP PAGE E - 2 MAINTENANCE & REPAIR...
  • Page 25 OM-06341 PA SERIES Pump Model PA6C60-4045T-ESP PARTS LIST (From S/N 1450296 Up) ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE PA6C60-(SAE 4/10) 46133-667 --- BATT BOX LID ASSY 42113-012 24150 J.D. 4045T ENGINE 29224-308 ---...
  • Page 26 OM-06341 PA SERIES Figure 2. Pump Model PA6C60-4045T-ESP PAGE E - 4 MAINTENANCE & REPAIR...
  • Page 27 OM-06341 PA SERIES Pump Model PA6C60-4045T-ESP PARTS LIST (Cont'd) ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE J.D. 4045T ENGINE 29224-313 --- HEX NUT 15991 3 ' ENCLOSURE ASSY 42164-031 --- STUD MOUNT 24631-011 ---...
  • Page 28 OM-06341 PA SERIES Figure 3. Pump Model PA6C60-4045T-ESP PAGE E - 6 MAINTENANCE & REPAIR...
  • Page 29 OM-06341 PA SERIES Pump Model PA6C60-4045T-ESP PARTS LIST (Cont'd) ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE 3 ' ENCLOSURE ASSY 42164-031 --- BRACKET ASSY 41881-706 24150 HOSE CLAMP 26518-678 --- CROSS RAIL 34412-035 15080...
  • Page 30 OM-06341 PA SERIES Figure 4. Pump Model PA6C60-4045T-ESP PAGE E - 8 MAINTENANCE & REPAIR...
  • Page 31 OM-06341 PA SERIES Pump Model PA6C60-4045T-ESP PARTS LIST (Cont'd) ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE RED PIPE BUSHING AP2008 11999 PRESS RELIEF VALVE 26662-028 --- HOSE CLAMP 26518-641 --- BALL VALVE 26631-023 ---...
  • Page 32 OM-06341 PA SERIES Figure 5. PA6C60-(SAE 4/10) Pump Assembly PAGE E - 10 MAINTENANCE & REPAIR...
  • Page 33 OM-06341 PA SERIES PA6C60-(SAE 4/10) Pump Assembly PARTS LIST ITEM PART MAT'L PART NAME NUMBER CODE 66F60-(SAE 4/10) PUMP SUBASSEMBLY SEE FIGURE 6 6” CHECK VALVE KIT 48274-015 -CHECK VALVE 26642-126 -FLAPPER 26688-001 -COVER O‐RING 25152-377 -FLANGE GASKET 25113-036 PRIMING CHAMBER KIT 48275-005 NOT SHOWN: STRAINER...
  • Page 34 OM-06341 PA SERIES Figure 6. 66F60-(SAE 4/10) Pump Subassembly PAGE E - 12 MAINTENANCE & REPAIR...
  • Page 35 OM-06341 PA SERIES PARTS LIST 66F60-(SAE 4/10) Pump Subassembly ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE PUMP CASING 38218-303 11010 HEX HD CAPSCREW B0806 15991 LOCK WASHER 15991 REPAIR ROTATING ASSY 44163-430 DRIVE ASSY 44162-159 BLIND FLANGE ASSY 42111-349...
  • Page 36 OM-06341 PA SERIES Figure 7. 44163-430 Repair Rotating Assembly PAGE E - 14 MAINTENANCE & REPAIR...
  • Page 37 OM-06341 PA SERIES PARTS LIST 44163-430 Repair Rotating Assembly ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE RETAINING RING S720 IMPELLER 38615-092 11010 THRUST WASHER 31134-115 15000 SEAL ASSY 46512-149 SEAL PLATE 38272-256 10000 OUTER BALL BEARING 23422-414 OIL SEAL...
  • Page 38 OM-06341 PA SERIES Figure 8. 48275-005 Priming Chamber Kit ITEM PART MAT'L PART NAME NUMBER CODE PRIMING CHAMBER ASSY 46112-709 PIPE BUSHING AP1608 11999 STREET ELBOW RS08 11999 BALL VALVE 26631-052 STUD C0809 15991 HEX NUT 15991 LOCK WASHER 15991 GASKET 38687-053 19060...
  • Page 39 OM-06341 PA SERIES Figure 9. 46112-709 Priming Chamber Assembly PARTS LIST ITEM PART MAT'L PART NAME NUMBER CODE PRIMING VALVE 26664-007 -ORIFICE BUTTON 26688-021 HEX HD CAPSCREW B0806 15991 LOCKWASHER 15991 PRIMING VALVE GASKET 38683-657 19060 PRIMING CHAMBER 38343-020 10000 STRAINER ASSY 46641-222 17000...
  • Page 40 OM-06341 PA SERIES Figure 10. 44162-159 Drive Assembly ITEM PART MAT'L PART NAME NUMBER CODE COUPLING KIT 44165-016 BUSHING 24131-498 -KEY 24113-603 DRIVE FLANGE 38545-004 10000 IMPELLER SHAFT 38515-586 1706H LOCKWASHER 21171-536 SOC HD CAPSCREW BD0606 1/2 15991 SOC HD CAPSCREW 22644-220 HEX HD CAPSCREW B0605...
  • Page 41 OM-06341 PA SERIES PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Review all SAFETY information in Section A. This manual will alert personnel to known procedures which require spe­ Follow the instructions on all tags, label and de­ cial attention, to those which could cals attached to the pump.
  • Page 42 OM-06341 PA SERIES Discharge Check Valve Removal and direct exposure or emitted fumes. Wear Disassembly adequate protective clothing when working on the pump or piping. (Figure 5) Remove the hardware (not shown) securing the discharge check valve bracket to the base. Support the discharge check valve (2) using a sling Use only replacement parts provided or and a suitable lifting device.
  • Page 43 OM-06341 PA SERIES gine. Disconnect the discharge piping from the Remove the impeller capscrew and washer (26 pump casing. and 27). Install the shaft key (22) in the shaft keyway. Install Remove the hardware (8 and 9) securing the drive a lathe dog on the drive end of the shaft (23) with flange (4) to the engine bellhousing.
  • Page 44 OM-06341 PA SERIES side of the stationary seat until the seat and O‐ring death could result. Suction and dis­ can be removed. charge hoses and piping must be re­ moved from the pump before lifting. Remove the seal plate O‐ring (30). Support the pump casing using a suitable hoist Remove the shaft sleeve O‐ring (28).
  • Page 45 OM-06341 PA SERIES Shaft and Bearing Reassembly and Installation be replaced any time the shaft and bear­ ings are removed. (Figure 6) Clean the bearing housing, shaft and all compo­ Inspect the shaft for distortion, nicks or scratches, nent parts (except the bearings) with a soft cloth or for thread damage on the impeller end.
  • Page 46 OM-06341 PA SERIES movement has occurred, use a suitably sized Lubricate a new bearing housing O‐ring (31) with sleeve and a press to reposition the bearings grease and install it in the groove in the bearing against the shaft shoulders. housing.
  • Page 47 OM-06341 PA SERIES If the complete coupling assembly is being re­ Clean the seal cavity and shaft with a cloth soaked placed, apply `Loctite Retaining Compound No. in fresh cleaning solvent. Inspect the stationary 242' or equivalent to the threads of the hardware (6 seat bore in the seal plate for dirt, nicks and burrs, and 7), and secure the outer ring of the coupling to and remove any that exist.
  • Page 48 OM-06341 PA SERIES RETAINER SEAL PLATE SPRING O‐RINGS IMPELLER SLEEVE O‐RING IMPELLER SHIMS IMPELLER SHAFT INTEGRAL SHAFT ROTATING SLEEVE ELEMENT BELLOWS SPRING CENTERING WASHER STATIONARY SEAT DRIVE BAND Figure 12. Seal Assembly the O‐ring down the shaft until it seats against the shaft shoulder.
  • Page 49 OM-06341 PA SERIES Lubricate the O‐rings (16 and 25) with light grease and install them in the grooves in the wear plate and back cover. The shaft and impeller threads must be Clearance between the impeller and wear plate is adjusted using the four back cover nuts (31) and completely clean before reinstalling the im­...
  • Page 50 OM-06341 PA SERIES adjusting screws so the holes in the collars for the Install the cover O‐ring and secure the cover with locking screws align approximately with the holes the previously removed hardware. in the cover plate. Apply a small amount of light grease to the gasket Loosen the back cover nuts used to press the back to hold it in place and position it against the pump cover into the pump casing one full turn.
  • Page 51 OM-06341 PA SERIES LUBRICATION NOTE The white reflector in the sight gauge must be posi­ (Figure 6) tioned horizontally to provide proper drainage. Seal Assembly Under normal conditions, drain the bearing hous­ Fill the seal cavity through the hole for the vented ing once each year and refill with clean oil.
  • Page 52 For U.S. and International Warranty Information, Please Visit www.grpumps.com/warranty or call: U.S.: 419-755-1280 International: +1-419-755-1352 For Canadian Warranty Information, Please Visit www.grcanada.com/warranty or call: 519-631-2870 THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA...

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