GORMAN-RUPP PA6D60-4045T-SU Installation, Operation And Maintenance Manual
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GORMAN-RUPP PA6D60-4045T-SU Installation, Operation And Maintenance Manual

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U
OM-06356-01
June 16, 2010
Rev. A 04‐24‐14
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
PA SERIES PUMP
MODEL
PA6D60-4045T-SU
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
2008 The Gorman‐Rupp Company

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  • Page 1 June 16, 2010 Rev. A 04‐24‐14 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST PA SERIES PUMP MODEL PA6D60-4045T-SU THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO www.grpumps.com GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A. 2008 The Gorman‐Rupp Company...
  • Page 2 Register your new Gorman‐Rupp pump online at www.grpumps.com/register. 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) PARTS LISTS: Pump Model ............PAGE E - 3 Pump Assembly .

  • Page 5: Introduction

    PA SERIES OM-06356 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-06356 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-06356 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 PA6D60-4045T-SU PREINSTALLATION INSPECTION a. Inspect the pump for cracks, dents, damaged threads, and other obvious damage.

  • Page 9: Battery Installation

    OM-06356 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-06356 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-06356 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-06356 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-06356 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-06356 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: Automatic Starting

    OM-06356 PA SERIES AL'. After the engine starts and the unit is fully Liquid Temperature And Overheating primed, adjust the engine RPM until the desired The maximum liquid temperature for this pump is flow rate is achieved. 160_ F (71_C). Do not apply it at a higher operating temperature.

  • Page 16: Stopping

    OM-06356 PA SERIES vacuum suction gauge readings regularly to detect normal for bearings, and they can operate safely to strainer blockage. at least 180_F (82_C). Checking bearing temperatures by hand is inaccu­ Never introduce air or steam pressure into the rate.

  • Page 17: Troubleshooting - Section D

    OM-06356 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 and discon­ nect the positive battery cable to en­ sure that the pump will remain inop­...
  • Page 18 OM-06356 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 19: Preventive Maintenance

    OM-06356 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 20 OM-06356 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 21: Pump Maintenance And Repair - Section E

    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 PA6D60-4045T-SU Based on 70_F (21_C) clear water at sea level Contact the Gorman‐Rupp Company to verify per­...
  • Page 22 OM-06356 PA SERIES PARTS PAGE ILLUSTRATION Figure 1. Pump Model PA6D60-4045T-SU PAGE E - 2 MAINTENANCE & REPAIR...
  • Page 23 OM-06356 PA SERIES Pump Model PA6D60-4045T-SU PARTS LIST (From S/N 1453390 Up) ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE PA6D60-(SAE 4/10) 46133-708 FLAT WASHER KE06 15991 STUD MOUNT 24631-012 STUD MOUNT 24631-006 FUEL FILTER SUPPORT 33659-069...
  • Page 24 OM-06356 PA SERIES ILLUSTRATION Figure 2. Pump Model PA6D60-4045T-SU (Cont'd) PAGE E - 4 MAINTENANCE & REPAIR...
  • Page 25 OM-06356 PA SERIES Pump Model PA6D60-4045T-SU PARTS LIST (Cont'd) (From S/N 1453390 Up) ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE J.D. 4045T ENGINE 29224-308 HEX HD CAPSCREW B0806 15991 LOCK WASHER 15991 FLAT WASHER...
  • Page 26 OM-06356 PA SERIES ILLUSTRATION Figure 3. Pump Model PA6D60-4045T-SU (Cont'd) PAGE E - 6 MAINTENANCE & REPAIR...
  • Page 27 OM-06356 PA SERIES Pump Model PA6D60-4045T-SU PARTS LIST (Cont'd) (From S/N 1453390 Up) ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE SKID BASE ASSY 41565-599 PRIMING BRKT ASSY 41881-680 24150 RED PIPE BUSHING AP2016...
  • Page 28 OM-06356 PA SERIES ILLUSTRATION Figure 4. Pump Model PA6D60-4045T-SU (Cont'd) PAGE E - 8 MAINTENANCE & REPAIR...
  • Page 29 OM-06356 PA SERIES Pump Model PA6D60-4045T-SU PARTS LIST (Cont'd) (From S/N 1453390 Up) ITEM PART MAT'L PART NAME NUMBER CODE FLAT WASHER 15991 LOCK WASHER 15991 HEX HD CAPSCREW B0504 15991 ENCLOSURE ASSY 42164-030 NOT SHOWN: NOT SHOWN: G‐R DECAL...
  • Page 30 OM-06356 PA SERIES ILLUSTRATION Figure 5. PA6D60-(SAE 4/10) Pump Assembly PAGE E - 10 MAINTENANCE & REPAIR...
  • Page 31 OM-06356 PA SERIES PARTS LIST PA6D60-(SAE 4/10) Pump Assembly ITEM PART MAT'L PART NAME NUMBER CODE PUMP END ASSEMBLY 46133-707 HEX HD CAPSCREW B0806 15991 GASKET 38687-053 19060 PRIMING CHAMBER ASSEMBLY 46112-704 DRIVE ASSEMBLY 44162-159 REDUCER BUSHING AP1608 14100 BALL VALVE 26631-023 PIPE NIPPLE 14100...
  • Page 32 OM-06356 PA SERIES ILLUSTRATION Figure 6. 46133-709 Pump End Assembly PAGE E - 12 MAINTENANCE & REPAIR...
  • Page 33 OM-06356 PA SERIES 46133-709 Pump End Assembly PARTS LIST ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE PUMP CASING 38218-018 10000 PIPE PLUG 15079 STUD C1211 15991 PIPE NIPPLE T1622 15079 LOCK WASHER 15991 SEAL PLATE O‐RING 25154-381 HEX NUT...
  • Page 34 OM-06356 PA SERIES ILLUSTRATION Figure 7. 44163-469 Repair Rotating Assembly PAGE E - 14 MAINTENANCE & REPAIR...
  • Page 35 OM-06356 PA SERIES PARTS LIST 44163-469 Repair Rotating Assembly ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE DRIVE FLANGE 38545-004 10000 IMPELLER 38628-036 1102H INTERM GUARD ASSY 42381-509 24152 IMPELLER ADJ SHIM SET 48261-057 BRG HOUSING GSKT 38683-474 18000...
  • Page 36 OM-06356 PA SERIES ILLUSTRATION Figure 8. 46112-704 Priming Chamber Assembly PAGE E - 16 MAINTENANCE & REPAIR...
  • Page 37 OM-06356 PA SERIES PARTS LIST 46112-704 Priming Chamber Assembly ITEM PART MAT'L PART NAME NUMBER CODE PRIMING CHAMBER 38343-018 10000 FLOAT 38349-412 19220 HEX NUT D#10 17000 LOCK WASHER J#10 17000 GUIDE PLATE 33522-009 17000 VALVE STRAP PROTECTOR 33271-019 19000 FLAT WASHER KE06 17000...
  • Page 38 OM-06356 PA SERIES ILLUSTRATION Figure 9. 44162-159 Drive Assembly ITEM PART MAT'L PART NAME NUMBER CODE COUPLING KIT 44165-016 BUSHING 24131-498 -KEY 24113-603 IMPELLER SHAFT 38515-586 1706H DRIVE FLANGE 38545-004 10000 LOCKWASHER 21171-536 INSTALLATION DRAWING GL-05086 SOC HD CAPSCREW 22644-220 SOC HD CAPSCREW B0606-1/2 15991...
  • Page 39 OM-06356 PA SERIES PUMP AND SEAL DISASSEMBLY might occur during maintenance of the unit. Therefore, it is the responsibility of AND REASSEMBLY the owner/maintenance personnel to ensure that only safe, established main­ Review all SAFETY information in Section A. tenance procedures are used, and that Follow the instructions on all tags, label and de­...
  • Page 40 OM-06356 PA SERIES move the valve plate, disengage the hardware (15 and 18). Discharge Check Valve Disassembly Use only replacement parts provided or (Not Shown) approved by Gorman‐Rupp. Use of non‐ authorized parts may result in damage to The flapper and cover O‐ring are the only service­ the equipment and/or injury to personnel able parts of the check valve.
  • Page 41 OM-06356 PA SERIES justing screws and sealing washers (6) from the Loosening Impeller suction spool. (Figures 7 and 10) With the pump end separated from the engine, in­ Separating Pump And Drive Assembly From sert a block of wood through the pump discharge Engine and wedge it between the vanes of the impeller and the pump casing to prevent rotation.
  • Page 42 OM-06356 PA SERIES nating pattern until the pump casing is pushed off If no further disassembly is required, refer to Seal of the bearing housing. Remove the jacking Installation. screws. Shaft and Bearing Removal and Disassembly (Figure 7) Impeller Removal When the pump is properly operated and main­...
  • Page 43 OM-06356 PA SERIES To prevent damage during removal from Most cleaning solvents are toxic and the shaft, it is recommended that bearings flammable. Use them only in a well ven­ be cleaned and inspected in place. It is tilated area free from excessive heat, strongly recommended that the bearings sparks, and flame.
  • Page 44 OM-06356 PA SERIES race, balls, or ball cage. Press only on the inner race. Apply a light coating of oil to the lip of the inboard oil seal (26) and press it into the bearing housing with Most cleaning solvents are toxic and the lip positioned as shown in Figure 7.
  • Page 45 OM-06356 PA SERIES RETAINER SEAL PLATE SPRING O‐RING IMPELLER SLEEVE O‐RING IMPELLER SHIMS IMPELLER SHAFT SHAFT SLEEVE ROTATING ELEMENT BELLOWS SPRING CENTERING WASHER STATIONARY SEAT DRIVE BAND Figure 11. Seal Assembly continue to slide the O‐ring down the shaft until it seats against the shaft shoulder.
  • Page 46 OM-06356 PA SERIES that order and fully tighten the hex nuts. Do not over‐tighten the nuts. Over‐tightening the nuts can deform the wear plate, resulting in uneven clear­ ance with the impeller. The shaft and impeller threads must be completely clean before reinstalling the im­ Slide the assembled suction spool and wear plate peller.
  • Page 47 OM-06356 PA SERIES Align the keyway in the bushing (2) with the shaft If removed, install the intermediate guards (19, Fig­ key, and slide it onto the shaft to the dimension ure 7) and secure the intermediate to the engine shown in Figure 9.
  • Page 48 OM-06356 PA SERIES against the sealing washer. Install the check valve When proper clearance can no longer be achieved and small valve weight, and secure the assembly by adjusting the wear plate, loosen the jam nuts with the lockwasher and hex nut. and back the adjusting screws out of the suction spool approximately 1/4 inch (6,4 mm).
  • Page 49 OM-06356 PA SERIES sitioned horizontally to provide proper drainage. cant regularly for evidence of rust or mois­ ture condensation. This is especially im­ portant in areas where variable hot and Under normal conditions, drain the bearing hous­ cold temperatures are common. ing once each year and refill with clean oil.
  • 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 D MANSFIELD, OHIO GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA...

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