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GORMAN-RUPP PUMPS PA6D60-4045D-SU Nstallation, Operation And Maintenance Manual

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U
OM-05984-02
July 26, 2006
Rev. B 04‐24‐14
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
PA SERIES PUMP
MODEL
PA6D60-4045D-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
Copyright by the Gorman‐Rupp Company

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Summary of Contents for GORMAN-RUPP PUMPS PA6D60-4045D-SU

  • Page 1 July 26, 2006 Rev. B 04‐24‐14 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST PA SERIES PUMP MODEL PA6D60-4045D-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. Copyright by 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) PARTS LISTS: Pump Model ............PAGE E - 3 Pump End Assembly .

  • Page 5: Introduction

    PA SERIES PUMPS OM-05984 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-05984 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-05984 PA SERIES 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 Do not operate an internal combustion low the pump to cool completely before engine in an explosive atmosphere.

  • 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 PA6D60-4045D-SU PREINSTALLATION INSPECTION a. Inspect the pump for cracks, dents, damaged threads, and other obvious damage.

  • Page 9: Battery Installation

    OM-05984 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. Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed.

  • Page 10: Suction And Discharge Piping

    PA SERIES OM-05984 Gauges able base, do not attempt to operate the pump unless the unit is level. Be sure The pump is drilled and tapped for installing dis­ the leveling stands are positioned on a charge pressure and vacuum suction gauges. It is solid surface, and the wheels are recommended that gauges be installed to monitor chocked.

  • Page 11: Suction Lines In Sumps

    OM-05984 PA SERIES high suction lift, all connections in the suction line If two suction lines are installed in a single sump, should be sealed with pipe dope to ensure an air­ the flow paths may interact, reducing the efficiency tight seal.

  • Page 12: Discharge Lines

    PA SERIES OM-05984 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...
  • Page 13 OM-05984 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 - 6 INSTALLATION...

  • Page 14: Operation - Section C

    OM-05984 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-05984 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-05984 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-05984 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-05984 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-05984 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-05984 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 PA6D60-4045D-SU Based on 70_F (21_C) clear water at sea level Contact the Gorman‐Rupp Company to verify per­...

  • Page 22: Section Drawing

    OM-05984 PA SERIES PARTS PAGE SECTION DRAWING Figure 1. Pump Model PA6D60-4045D-SU PAGE E - 2 MAINTENANCE & REPAIR...
  • Page 23 OM-05984 PA SERIES Pump Model PA6D60-4045D-SU PARTS LIST (From S/N 1343627 up) ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE PUMP END ASSY 46133-708 HEX HD CAPSCREW B0605 15991 J.D. 4045D ENGINE 29224-137 FLAT WASHER...
  • Page 24 OM-05984 PA SERIES SECTION DRAWING Figure 2. Pump Model PA6D60-4045D-SU PAGE E - 4 MAINTENANCE & REPAIR...
  • Page 25 OM-05984 PA SERIES Pump Model PA6D60-4045D-SU PARTS LIST (From S/N 1343627 up) ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE 280” LG. FOAM TAPE 18668-004 EXHAUST SILENCER 46211-501 HEX HD CAPSCREW B0505 15991 EXHAUST CLAMP...
  • Page 26 OM-05984 PA SERIES SECTION DRAWING Figure 3. Pump Model PA6D60-4045D-SU PAGE E - 6 MAINTENANCE & REPAIR...
  • Page 27 OM-05984 PA SERIES Pump Model PA6D60-4045D-SU PARTS LIST (From S/N 1343627 up) ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE HEX HD CAPSCREW B0405 15991 SWIVEL 26523-044 LOCK WASHER 15991 HOSE BARB FITTING 26523-386...
  • Page 28 OM-05984 PA SERIES SECTION DRAWING Figure 4. 46133-708 Pump End Assembly PAGE E - 8 MAINTENANCE & REPAIR...

  • Page 29: Parts List

    OM-05984 PA SERIES PARTS LIST 46133-708 Pump End Assembly ITEM PART MAT'L PART NAME NUMBER CODE PUMP ASSEMBLY 46133-707 HEX HD CAPSCREW B0806 15991 GASKET 38687-053 19060 PRIMING CHAMBER ASSEMBLY 46112-704 NOT SHOWN: LUBE DECAL 11421A OIL LEVEL STICKER 38816-123 G‐R DECAL GR-06 NAME PLATE...
  • Page 30 OM-05984 PA SERIES SECTION DRAWING SHAFT END VIEW Figure 5. 46133-707 Pump Assembly PAGE E - 10 MAINTENANCE & REPAIR...
  • Page 31 OM-05984 PA SERIES 46133-707 Pump Assembly PARTS LIST ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE PUMP CASING 38218-018 10000 NIPPLE T1622 15079 STUD C1211 15991 O‐RING 25154-381 LOCK WASHER 15991 O‐RING S1748 HEX NUT 15991 WEAR PLATE ASSY 46451-761...
  • Page 32 OM-05984 PA SERIES SECTION DRAWING DRIVE END VIEW Figure 6. 44163-469 Repair Rotating Assembly PAGE E - 12 MAINTENANCE & REPAIR...
  • Page 33 OM-05984 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 SEAL PLATE 38272-256 10000 IMPELLER 38628-036 1102H SOC HD CAPSCREW DM1004S 17090 SEAL ASSY 46512-149 IMPELLER WASHER 31514-015 17000 INBOARD BALL BEARING 23422-019...
  • Page 34 OM-05984 PA SERIES SECTION DRAWING Figure 7. 46112-704 Priming Chamber Assembly PAGE E - 14 MAINTENANCE & REPAIR...
  • Page 35 OM-05984 PA SERIES PARTS LIST Priming Chamber Assembly ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE PRIMING CHAMBER LID 38346-615 1300U VALVE STRAP 33276-041 19410 PEELER VALVE NECK 38349-413 10000 CHECK VALVE ASSY 46411-112 HEX HD CAPSCREW B0403-1/2 15991...
  • Page 36 OM-05984 PA SERIES SECTION DRAWING Figure 8. 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 B0606-1/2 15991 HEX HD CAPSCREW B0605 15991 LOCKWASHER...

  • Page 37: Pump And Seal Disassembly And Reassembly

    OM-05984 PA SERIES PUMP AND SEAL DISASSEMBLY lishing that neither personal safety nor pump integrity are compromised by AND REASSEMBLY such practices. Review all SAFETY information in Section A. Follow the instructions on all tags, label and de­ cals attached to the pump. Before attempting to open or service the This pump requires little service due to its rugged, pump:...
  • Page 38 OM-05984 PA SERIES Inspect the check valve components. If the check moved from the pump before lifting. Lift valve (20) requires replacement, remove the hard­ the pump or component only as high as ware (22, 24 and 26) securing the valve weights (23 necessary and keep personnel away and 25) to the check valve.
  • Page 39 OM-05984 PA SERIES and wear plate (24) from the volute as an assembly. Move the pump end to a clean, well equipped shop Remove and discard the gasket (9). area for further disassembly. Inspect the wear plate for excessive wear or scor­ Draining Oil From Seal Cavity ing.
  • Page 40 OM-05984 PA SERIES tion of the seal (consisting of the bellows, retainer, Turn and rotating element) off the shaft as a unit. Counterclockwise Apply oil to the sleeve and work it up under the rub­ ber bellows. Slide the rotating portion of the seal off the sleeve.
  • Page 41 OM-05984 PA SERIES Place a block of wood against the impeller end of Rotate the bearings by hand to check for rough­ the shaft (11) and tap the shaft and assembled ness or binding and inspect the bearing balls. If ro­ bearings from the intermediate.
  • Page 42 OM-05984 PA SERIES the oil has been previously used, it must be thor­ the oil seal should be just flush with the outer face oughly filtered. of the drive flange. Install the drive flange gasket (16). Apply “Loctite Heat the bearings to a uniform temperature no Retaining Compound No.
  • Page 43 OM-05984 PA SERIES ponents are worn, replace the complete seal; matter. never mix old and new seal parts. To ease installation of the seal, lubricate the O‐ rings and bellows with water or a very small If a replacement seal is being used, remove it from amount of oil, and apply a drop of light lubricating the container and inspect the precision finished oil on the finished faces.
  • Page 44 OM-05984 PA SERIES Slide the sleeve and subassembled seal onto the Suction Spool And Wear Plate Installation shaft until the seal faces contact. Continue to push (Figure 5) the sleeve through the seal until the undercut end seats against the O‐ring and shaft shoulder. It is recommended that the suction spool (5) and wear plate (24) be installed in the pump casing (1) Install the seal spring and centering washer.
  • Page 45 OM-05984 PA SERIES assembly mounting hardware (16 and 17). As­ With the flexible portion of the coupling and the semble the shims (18) into sets equalling this di­ bushing properly positioned on the shaft, tighten mension plus .010 to .012 inch (0,25 and 0,3 mm). the two setscrews in an alternating sequence until This will ensure the proper impeller‐to‐wear plate the bushing and coupling are fully secured.
  • Page 46 OM-05984 PA SERIES compound to the studs, and secure with the lock Discharge Check Valve Reassembly And nuts (28). Installation (Not Shown) Position the lid and preassembled valve strap com­ ponents on its side. Apply “Loctite Threadlocker The flapper and cover O‐ring are the only service­ No.
  • Page 47 OM-05984 PA SERIES cause the bearings to over‐heat, resulting in pre­ LUBRICATION mature bearing failure. Seal Assembly NOTE (Figure 5) The white reflector in the sight gauges must be po­ sitioned horizontally to provide proper drainage. Fill the seal cavity through the hole for the vented plug (12) with SAE No.
  • Page 48 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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