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GORMAN-RUPP PUMPS PA3A60-4045H/S1 Installation, Operation, And Maintenance Manual With Parts List

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U
OM−06208−02
April 5, 2011
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
PA SERIES PUMP
MODEL
PA3A60−4045H /S1
THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO
D
GORMAN-RUPP OF CANADA LIMITED
ST. THOMAS, ONTARIO, CANADA
Printed in U.S.A
www.grpumps.com.
E
2011 The Gorman-Rupp Company

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  • Page 1 OM−06208−02 April 5, 2011 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST PA SERIES PUMP MODEL PA3A60−4045H /S1 THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO GORMAN-RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A www.grpumps.com. 2011 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 −...
  • Page 4 TABLE OF CONTENTS (continued) PARTS LISTS: Pump Model ............PAGE E −...

  • Page 5: Introduction

    OM−06208 PA SERIES 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−06208 SAFETY - SECTION A This information applies to Prime Aire non-volatile, non-flammable liquids Series pumps. Refer to the manual ac- containing specified entrained solids. companying the engine or power Do not attempt to pump volatile, corro- source before attempting to begin oper- sive, or flammable liquids which may ation.
  • Page 7 OM−06208 PA SERIES when required for startup or shutdown stands and chock the wheels, if so procedures. equipped. Use caution when positioning the skid-mounted unit to prevent damage to the fuel tank. Do not remove plates, covers, gauges, pipe plugs, or fittings from an over- heated pump.

  • Page 8: Installation − Section Bpage B

    PA SERIES OM−06208 INSTALLATION − SECTION B Review all SAFETY information in Section A. configuration, and priming must be tailored to the specific application. Since the pressure supplied Since pump installations are seldom identical, this to the pump is critical to performance and safety, be sure to limit the incoming pressure to 50% of the section offers only general recommendations and maximum permissible operating pressure as...

  • Page 9: Battery Installation

    OM−06208 PA SERIES d. Check levels and lubricate as necessary. Re- use in lifting the pump assembly only. fer to LUBRICATION in the Maintenance and Suction and discharge hoses and pip- Repair Manual and perform duties as in- ing must be removed from the pump be- structed.

  • Page 10: Materials

    PA SERIES OM−06208 tion losses. See the performance curve and oper- SUCTION LINES ating range shown on Page E-1 to be sure your overall application allows pump to operate within To avoid air pockets which could affect pump prim- the safe operation range. ing, the suction line must be as short and direct as possible.

  • Page 11: Suction Line Positioning

    OM−06208 PA SERIES sump at a distance equal to 1 1/2 times the diame- Suction Line Positioning ter of the suction line. The depth of submergence of the suction line is If there is a liquid flow from an open pipe into the critical to efficient pump operation.

  • Page 12: Discharge Lines

    PA SERIES OM−06208 Refer to the information which follows for installa- DISCHARGE LINES tion details for the liquid level sensing system pro- vided with your pump. Siphoning Float Switch Installation 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.
  • Page 13 OM−06208 PA SERIES ENGINE (0.9) CONTROL (.76) (Emptying) (0.6) (Filling) (.46) OPERATING (0.3) RANGE CABLE (See Table Below) TETHER (.15) POINT (Emptying) (0.3) (0.6) (0.9) (1.2) APPROXIMATE FREE CORD LENGTH IN FT. (M) 1.25" Pipe (Filling) (Not Furnished) Figure 3. Float Switch Data PAGE B −...

  • Page 14: Operation − Section C

    OM−06208 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- tor discharge line.

  • Page 15: Automatic Starting

    OM−06208 PA SERIES AL’. After the engine starts and the unit is fully Liquid Temperature And Overheating primed, adjust the engine RPM until the desired flow rate is achieved. The maximum liquid temperature for this pump is 160_ F (71_C). Do not apply it at a higher operating temperature.

  • Page 16: Stopping

    OM−06208 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−06208 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 and take precautions to ensure that the pump will remain inoperative.
  • Page 18 OM−06208 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−06208 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- Check piping installation for proper erly supported.
  • Page 20 OM−06208 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

    OM−06208 PA SERIES 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 PA3A60−4045H /S1 Based on 70_F (21_C) clear water at sea level with minimum suction lift.
  • Page 22 OM−06208 PA SERIES ILLUSTRATION PARTS PAGE Figure 1. Pump Model PA3A60−4045H /S1 PAGE E − 2 MAINTENANCE & REPAIR...
  • Page 23 OM−06208 PA SERIES PARTS LIST Pump Model PA3A60−4045H /S1 (From S/N 1476739 Up) ITEM PART MAT’L PART NAME NUMBER CODE PUMP END ASSEMBLY 46133−752 −−− POWER UNIT KIT 46143−120 −−− BATTERY 29331−527 PUMP MOUNTING KIT 48157−008 −−− PRIME AIRE DECAL 38812−078 −−−...
  • Page 24 OM−06208 PA SERIES ILLUSTRATION Figure 2. 46143−120 Power Unit Kit PAGE E − 4 MAINTENANCE & REPAIR...
  • Page 25 OM−06208 PA SERIES PARTS LIST 46143−120 Power Unit Kit ITEM PART MAT’L PART NAME NUMBER CODE JOHN DEERE ENGINE 29224−375 −−− LIFTING BAIL KIT 48274−804 −−− .50" ID X 60" LG. HOSE 18513−113 −−− HOSE BARB FITTING 26523−047 −−− CONNECTOR S1598 −−−...
  • Page 26 OM−06208 PA SERIES ILLUSTRATION Figure 3. PA3A60−(SAE 4/10) /S1 Pump End Assembly PAGE E − 6 MAINTENANCE & REPAIR...
  • Page 27 OM−06208 PA SERIES PARTS LIST PA3A60−(SAE 4/10) /S1 Pump End Assembly ITEM PART MAT’L PART NAME NUMBER CODE PUMP ASSEMBLY CONSULT FACTORY SUCTION SPOOL 38642−409 10000 STUD C1212 15991 HEX NUT 15991 LOCK WASHER 15991 GASKET 25113−046 −−− CHECK VALVE KIT 48274−002 −−−...
  • Page 28 OM−06208 PA SERIES ILLUSTRATION Figure 4. Pump Assembly PAGE E − 8 MAINTENANCE & REPAIR...
  • Page 29 OM−06208 PA SERIES PARTS LIST Pump Assembly ITEM PART NAME PART MAT’L ITEM PART NAME PART MAT’L NUMBER CODE NUMBER CODE PUMP CASING 26835−252 −−− BREATHER VENT 26717−007 −−− LIP SEAL 26835−805 −−− IMPELLER 26835−204 −−− LIP SEAL SPRING 26835−796 −−−...
  • Page 30 OM−06208 PA SERIES ILLUSTRATION Figure 5. 44162−163 Drive Assembly ITEM PART MAT’L PART NAME NUMBER CODE COUPLING KIT 48112−007 −−− −BUSHING 24131−498 −−− −COUPLING ASSEMBLY 24391−103 −−− −LOCKWASHER 21171−536 −−− −SOCKET HEAD CAPSCREW BD0606−1/2 15991 −SOCKET HEAD CAPSCREW 22644−220 −−− HEX HEAD CAPSCREW B0605 15991...
  • Page 31 OM−06208 PA SERIES ILLUSTRATION Figure 6. 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...
  • Page 32 OM−06208 PA SERIES ILLUSTRATION Figure 7. 46112−709 Priming Chamber Assembly 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...
  • Page 33 OM−06208 PA SERIES ILLUSTRATION Figure 8. 48274−002 Check Valve Kit ITEM PART MAT’L PART NAME NUMBER CODE CHECK VALVE 26642−123 −−− −FLAPPER 26688−011 −−− −COVER GASKET 26688−012 −−− HEX HD CAPSCREW B1010 15991 HEX NUT 15991 LOCKWASHER 15991 FLAT WASHER 21161−442 −−−...
  • Page 34 OM−06208 PA SERIES PUMP AND SEAL DISASSEMBLY 4. Check the temperature before opening any covers, plates, or AND REASSEMBLY plugs. 5. Close the suction and discharge Review all SAFETY information in Section A. valves. Follow the instructions on all tags, label and de- 6.
  • Page 35 PA SERIES OM−06208 chamber assembly using a sling and a suitable lift- Pump Casing and Wear Ring Removal ing device. Remove the hardware (6 and 7) and (Figure 4) separate the priming chamber assembly, gasket (8) and baffle (9) from the spool (2, Figure 3). Before attempting to remove the pump casing, re- move the lowermost pipe plug (5) and drain any liq- (Figure 7)
  • Page 36 OM−06208 PA SERIES If no further disassembly is required, see Pump Press the seal stationary seat out of the back plate Casing and Wear Ring Installation. from the back side. Remove the V-ring (28). Impeller Removal If no further disassembly is required, refer to Seal (Figure 4) Installation.
  • Page 37 PA SERIES OM−06208 is not recommended. These operations should be performed only in a properly equipped shop by qualified personnel. Most cleaning solvents are toxic and NOTE flammable. Use them only in a well ven- The bearings in this pump are grease-lubricated. tilated area free from excessive heat, No provisions are made for draining the lubricant sparks, and flame.
  • Page 38 OM−06208 PA SERIES Slide the shaft and assembled bearing (17) into the frame (15) until the shaft shoulder seats squarely against the inner race of the bearing (13). Use caution when handling hot bearings to prevent burns. NOTE When installing the shaft and bearings into If a hot oil bath is used to heat the bearings, both the the bearing bore, push against the outer oil and the container must be absolutely clean.
  • Page 39 PA SERIES OM−06208 screws align with those in the bushing, and install Seal Reassembly and Installation the setscrews. (Figures 4 and 9) Clean the bore of the back plate (7) and shaft (19) with a cloth soaked in fresh cleaning solvent. Make certain that the flexible portion of the coupling is mounted as shown in Figure 5.
  • Page 40 OM−06208 PA SERIES small amount of oil, and apply a drop of light lubri- as follows (see Figure 9). cating oil on the finished faces. Assemble the seal O-RING SPRING RETAINER IMPELLER STATIONARY SEAT SHAFT SHAFT SLEEVE IMPELLER SHAFT SPRING HOLDER ROTATING ELEMENT...
  • Page 41 PA SERIES OM−06208 impeller onto the shaft until fully seated (do not use er No. 262" or equivalent compound, and install the impeller lock screw). Make sure the spring the impeller washer and lock screw. Immobilize the holder seats squarely inside the seal spring. impeller by inserting a soft metal bar or rod through the discharge opening as described in Pump Cas- ing Removal.
  • Page 42 OM−06208 PA SERIES Discharge Check Valve Assembly And (Figure 6) Installation Install the baffle (9) and gasket (8) and use a sling (Figure 8) and suitable lifting device to position the priming chamber assembly on the hopper spool (not The flapper and cover gasket are the only service- shown).
  • Page 43 PA SERIES OM−06208 bearings and into the bearing cavity. If too much grease is retained in the bearing cavity, the bear- ings can over-heat, resulting in premature bearing failure. Engine Consult the literature supplied with the engine, or contact your local engine representative. MAINTENANCE &...
  • Page 45 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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