GORMAN-RUPP PUMPS PA12A60-B-6068T-ESP Installation, Operation And Maintenance Manual

ACDEU
OM−06057−01
October 9, 2007
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
PA SERIES PUMP
MODEL
PA12A60−B−6068T−ESP
THE GORMAN-RUPP COMPANY MANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA
www.grpumps.com.
Copyright by the Gorman-Rupp Company
Printed in U.S.A
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. Your Gorman-Rupp distributor
needs this information when you require parts or service.
Pump Model:
Serial Number:
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE I − 1
SAFETY - SECTION A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE A − 1
INSTALLATION − SECTION B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE B − 1
Pump Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREINSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POSITIONING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUCTION AND DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections to Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUCTION LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Line Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Siphoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTO-START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Float Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OPERATION − SECTION C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Temperature And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strainer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEARING TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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
i
TABLE OF CONTENTS
(continued)
PARTS LIST:
Pump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Model Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Model Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming Chamber Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
Priming Chamber Removal And Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge Check Valve Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Head And Wear Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Casing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pedestal Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Shaft and Bearing Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . .
Engine Drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Drive Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft and Bearing Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pedestal Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Casing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Head And Wear Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge Check Valve Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming Chamber Assembly And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
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OM−06057
PA SERIES
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 Maintenance manual is designed to help you achieve the
best performance and longest life from your Gorman-Rupp pump.
This pump is a sound-attenuated PA Series, priming-assisted environmental silent pump. The
centrifugal pump unit is designed for handling
non-volatile, non-flammable liquids containing
specified entrained solids. The basic material of
pump construction is ductile iron, with stainless
steel shaft and ductile iron wearing parts.
Because pump installations are seldom identical,
this manual cannot possibly provide detailed instructions and precautions for every aspect of
each specific application. Therefore, it is the responsibility 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 compromised by the installation. Pumps and related
equipment must be installed and operated according to all national, local and industry standards.
If there are any questions regarding the pump
which are not covered in this manual or in other literature accompanying the unit, please contact
your Gorman-Rupp distributor or the GormanRupp 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
The following are used to alert personnel to procedures 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 required 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 describe 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.
For information or technical assistance on the engine, contact the engine manufacturer’s local
dealer or representative.
INTRODUCTION
PAGE I − 1
PA SERIES
OM−06057
SAFETY - SECTION A
This information applies to Prime Aire
Series pumps. Refer to the manual accompanying the engine or power
source before attempting to begin operation.
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and precautions for each specific application.
Therefore, it is the owner/installer’s responsibility to ensure that applications
not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity
are compromised by the installation.
Before attempting to open or service the
pump:
1. Familiarize yourself with this manual.
2. Shut down the engine and disconnect the positive battery cable 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 opening any covers, plates, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.
This pump is equipped with an automatic starting system, and is subject to automatic restart. Keep hands and clothing away from the unit to prevent injury
during automatic operation. Disconnect
SAFETY
the positive battery cable before performing any maintenance. Failure to do
so may result in serious personal injury.
This pump is designed to handle most
non-volatile, non-flammable liquids
containing specified entrained solids.
Do not attempt to pump volatile, corrosive, or flammable liquids which may
damage the pump or endanger personnel as a result of pump failure.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or damage to equipment. Attach lifting equipment 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 piping must be removed from the pump before 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
PAGE A − 1
OM−06057
liquid could come to a boil, build pressure, and cause the pump casing to rupture 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 overheated pump. Vapor pressure within the
pump can cause parts being disengaged to be ejected with great force. Allow the pump to cool completely before
servicing.
This pump may be used to handle materials 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. Exposed rotating parts can catch clothing,
fingers or tools, causing severe injury to
personnel.
Make sure the pump is level. Lower jack
PAGE A − 2
PA SERIES
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 engines 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 running 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. Refer to the Performance
Curve in Section, Page E-1 for the maximum continuous operating speed for
this pump.
SAFETY
PA SERIES
OM−06057
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 arrange 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.
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
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
See Figure 1 for the approximate physical dimensions of this pump.
OUTLINE DRAWING
Figure 1. Pump Model PA12A60−B−6068T−ESP
PREINSTALLATION INSPECTION
a. Inspect the pump for cracks, dents, damaged
threads, and other obvious damage.
The pump assembly was inspected and tested before shipment from the factory. Before installation,
inspect the pump for damage which may have occurred during shipment. Check as follows:
b. Check for and tighten loose attaching hardware. Since gaskets tend to shrink after drying, check for loose hardware at mating surfaces.
INSTALLATION
PAGE B − 1
OM−06057
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 indicated by the arrow on the pump body
and on the accompanying decal. Otherwise, the impeller could become loosened
from the shaft and seriously damage the
pump.
d. Check levels and lubricate as necessary. Refer to LUBRICATION in the Maintenance and
Repair Manual and perform duties as instructed.
e. If the pump has been stored for more than 12
months, some of the components or lubricants may have exceeded their maximum
shelf life. These must be inspected or replaced 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 determine 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 charging instructions.
Before installing the battery, clean the positive and
negative cable connectors, and the battery terminals. Secure the battery by tightening the
holddown brackets. The terminals and clamps
may be coated with petroleum jelly to retard corrosion. Connect and tighten the positive cable first,
then the negative cable.
PAGE B − 2
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POSITIONING PUMP
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or damage to equipment. Attach lifting equipment 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 piping must be removed from the pump before lifting.
Lifting
Pump unit weights will vary depending on the
mounting and drive provided. Check the shipping
tag on the unit packaging for the actual weight, and
use lifting equipment with appropriate capacity.
Drain the pump and remove all customer-installed
equipment such as suction and discharge hoses
or piping before attempting to lift existing, installed
units.
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 mounting 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 positioned as level as possible to ensure sufficient lubrication and fuel supply to the engine.
If the pump has been mounted on a moveable
base, make certain the base is stationary by setting
INSTALLATION
PA SERIES
the brake and blocking the wheels before attempting to operate the pump.
OM−06057
lines are used, they should have adequate support
to secure them when filled with liquid and under
pressure.
Gauges
If the pump has been mounted on a movable 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 increased suction lift, discharge elevation, and friction losses. See the performance curve and operating 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, reinforced type to prevent collapse under suction. Using piping couplings in suction lines is not recommended.
Line Configuration
Keep suction and discharge lines as straight as
possible to minimize friction losses. Make minimum use of elbows and fittings, which substantially 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 exactly with the pump port. Never pull a pipe line into
place by tightening the flange bolts and/or couplings.
Lines near the pump must be independently supported to avoid strain on the pump which could
cause excessive vibration, decreased bearing life,
and increased shaft and seal wear. If hose-type
INSTALLATION
The pump is drilled and tapped for installing discharge 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 priming, 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 installed with the flat part of the reducers uppermost
to avoid creating air pockets. Valves are not normally used in suction lines, but if a valve is used,
install it with the stem horizontal to avoid air pockets.
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.
PAGE B − 3
OM−06057
Sealing
Since even a slight leak will affect priming, head,
and capacity, especially when operating with a
high suction lift, all connections in the suction line
should be sealed 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 In Sumps
If a single suction line is installed in a sump, it
should be positioned away from the wall of the
sump at a distance equal to 1 1/2 times the diameter of the suction line.
If there is a liquid flow from an open pipe into the
sump, the flow should be kept away from the suction inlet because the inflow will carry air down into
the sump, and air entering the suction line will reduce pump efficiency.
If it is necessary to position inflow close to the suction inlet, install a baffle between the inflow and the
suction inlet at a distance 1-1/2 times the diameter
of the suction pipe. The baffle will allow entrained
PAGE B − 4
PA SERIES
air to escape from the liquid before it is drawn into
the suction inlet.
If two suction lines are installed in a single sump,
the flow paths may interact, reducing the efficiency
of one or both pumps. To avoid this, position the
suction inlets so that they are separated by a distance equal to at least 3 times the diameter of the
suction pipe.
Suction Line Positioning
The depth of submergence of the suction line is
critical to efficient pump operation. Figure 2
shows recommended minimum submergence vs.
velocity.
Although not recommended, the vacuum assisted
priming feature allows the pump to be operated
temporarily in a slurping" application with varying
water levels.
NOTE
The pipe submergence required may be reduced
by installing a standard pipe increaser fitting at the
end of the suction line. The larger opening size will
reduce the inlet velocity. Calculate the required
submergence using the following formula based
on the increased opening size (area or diameter).
INSTALLATION
PA SERIES
OM−06057
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
DISCHARGE LINES
Siphoning
Do not terminate the discharge line at a level lower
than that of the liquid being pumped unless a siphon breaker is used in the line. Otherwise, a siphoning action causing damage to the pump
could result.
Valves
This pump is designed with a check valve in the
discharge line.
If a throttling valve is desired in the discharge line,
use a valve as large as the largest pipe to minimize
friction losses. Never install a throttling valve in a
suction line.
With high discharge heads, it is recommended that
a throttling valve be installed in the discharge line
to protect the pump from excessive shock pressure and reverse rotation when it is stopped.
INSTALLATION
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
ALIGNMENT
The alignment of the pump, air compressor and
engine is critical for trouble-free mechanical operation. See Section E, Securing Intermediate And
Drive Assembly To Engine in MAINTENANCE
AND REPAIR, for details.
AUTO-START
The standard pump is equipped with an auto-start
control system which allows the pump to start and
stop as the liquid level in the wet well or sump rises
and falls.
Refer to the information which follows for installation details for the liquid level sensing system provided with your pump.
PAGE B − 5
OM−06057
PA SERIES
Float Switch Installation
The Float Switch autostart system employs either a
single or double float switch, where a bulb raises or
lowers (floats) with the liquid level, thus activating
an enclosed miniature switch. The floats are
equipped with a socket type connector that plugs
into a matching receptacle on the auto-start control
box.
Standard floats are equipped with 50 feet (15,2 m)
of cable.
When installing the floats, note the following:
a. Be sure to provide sufficient room in the wet
well or sump so that floats do not get obstructed or drawn into the suction line. If a flexible suction hose is used, it may be extended
to lay along the bottom of the wet well or sump
and the float can be attached to the hose
above the point where it bends along the bottom. Direct the suction line toward the flow,
and the float(s) away from the flow. If a stand-
b. In a single float system, the cable can be tethered to the suction line or standpipe approximately 6 inches (152 mm) above the float.
This setting allows approximately 9 inches
(229 mm) of liquid rise between pump start/
stop. The start/stop interval may be increased
by extending the float end of the cable. The
liquid level in the sump will increase approximately 8 inches (203 mm) between start/stop
intervals for every 6 inches (152 mm) of cable
increase.
c. If a double float switch system is used, position the Start" float at the desired high water
level in the sump, and the Stop" float at the
desired low water level in the pump.
d. Refer to Figure 3 for additional float switch
data.
3.0
(0.9)
ENGINE
CONTROL
BOX
ON
(Emptying)
OFF
(Filling)
OPERATING
RANGE
CABLE
TETHER (See Table Below)
POINT
OFF
(Emptying)
1.25" Pipe
(Not Furnished)
pipe is available, attach the float switch cable
to the standpipe in the sump at the approximate desired liquid level.
ON
(Filling)
2.5
(.76)
2.0
(0.6)
1.5
(.46)
1.0
(0.3)
0.5
(.15)
1.0
2.0
3.0
4.0
(0.3)
(0.6)
(0.9)
(1.2)
APPROXIMATE FREE CORD LENGTH IN FT. (M)
Figure 3. Float Switch Data
PAGE B − 6
INSTALLATION
OM−06057
PA SERIES
OPERATION − SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and
decals attached to the pump.
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.
The pump will begin to prime upon startup. The air
in the suction line will be discharged from the eductor discharge line. Complete priming is indicated
by a positive discharge pressure reading.
If full priming is not achieved, the discharge check
valve may be malfunctioning. If this occurs, shut
down the pump and consult Maintenance and
Repair, Section E for further details.
STARTING
Check the fuel level and oil levels in the engine, air
compressor, pump bearings and seal housing.
Make sure the pump is level. Lower the jack stands
and chock the wheels, if so equipped.
OPERATION
This pump is designed to handle most
non-volatile, non-flammable liquids
containing specified entrained solids.
Do not attempt to pump volatile, corrosive, or flammable liquids which may
damage the pump or endanger personnel as a result of pump failure.
Pump speed and operating condition
points must be within the continuous performance range shown on the performance curve in Section E on page E−1.
PRIMING
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.
This pump is equipped with automatic
liquid level controls, and is subject to
automatic restart. Keep hands and
clothing away from the unit to prevent
injury during automatic operation. Disconnect the positive battery cable before performing any maintenance. Failure to do so may result in serious personal injury.
Consult the engine operations manual before attempting to start the unit.
Manual Starting
Install the pump and piping as described in INSTALLATION. Make sure that the piping connections are tight, and that the pump is securely
mounted. Check that the pump is properly lubricated (see LUBRICATION in MAINTENANCE
AND REPAIR).
OPERATION
On initial start-up, set the engine speed at in the
half-throttle position. Turn the keyswitch to ‘MANUAL’. After the engine starts and the unit is fully
primed, adjust the engine RPM until the desired
flow rate is achieved.
PAGE C − 1
OM−06057
PA SERIES
Automatic Starting
With the float system installed, follow the procedures outlined for manual starting and throttle adjustment. Switch the keyswitch to ‘OFF’ until the
water level rises above the on point for the float system, then turn the keyswitch to the ‘AUTO’ setting.
The unit will run until the float signals the control
that the water in the wet well is at the float off point,
at which time the unit will shut down automatically.
When the float signals the control that the water in
the wet well is at the float on point, the unit will restart automatically, repeating the cycle.
OPERATION
Allow an over-heated pump to completely cool before servicing. Do not remove plates, covers, gauges, or fittings
from an overheated pump. Liquid within
the pump can reach boiling temperatures, and vapor pressure within the
pump can cause parts being disengaged to be ejected with great force. After the pump cools, drain the liquid from
the pump by removing the casing drain
plug. Use caution when removing the
plug to prevent injury to personnel from
hot liquid.
Leakage
Once the pump is fully primed, no leakage should
be visible at pump mating surfaces, or at pump
connections or fittings. Keep all line connections
and fittings tight to maintain maximum pump efficiency.
Pump Vacuum Check
Read the vacuum gauge with the pump primed
and at operation speed. Shut off the pump. The
vacuum gauge reading will immediately drop proportionate to static suction lift, and should then stabilize. If the vacuum reading falls off rapidly after
stabilization, an air leak exists. Before checking for
the source of the leak, check the point of installation of the vacuum gauge.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
160 F (71C). Do not apply it at a higher operating
temperature.
Overheating can occur if operated with the valves
in the suction or discharge lines closed. Operating
against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to rupture or explode. If overheating occurs, stop the
pump immediately and allow it to completely cool
before servicing it. Approach any over-heated
pump cautiously.
PAGE C − 2
As a safeguard against rupture or explosion due to
heat, this pump is equipped with a pressure relief
valve which will open if vapor pressure within the
pump casing reaches a critical point. If over-heating does occur, stop the pump immediately and allow it to cool before servicing it. Approach any
over-heated pump cautiously. It is recommended that the pressure relief valve assembly be
replaced at each overhaul, or any time the pump
casing over-heats and activates the valve. Never
replace this valve with a substitute which has not
been specified or provided by the Gorman-Rupp
Company.
Strainer Check
Check the strainer regularly, and clean it as necessary. The strainer should also be checked if pump
flow rate begins to drop. Monitor and record the
vacuum suction gauge readings regularly to detect
strainer blockage.
Never introduce air or steam pressure into the
pump casing or piping to remove a blockage. This
could result in personal injury or damage to the
equipment. If backflushing is absolutely necessary, liquid pressure must be limited to 50% of the
maximum permissible operating pressure shown
on the pump performance curve.
STOPPING
Never halt the flow of liquid suddenly. If the liquid
being pumped is stopped abruptly, damaging
OPERATION
OM−06057
PA SERIES
Reduce the throttle speed slowly and allow the engine to idle briefly before stopping.
A sudden increase in bearing temperatures is a
warning that the bearings are at the point of failing
to operate properly. Make certain that the bearing
lubricant is of the proper viscosity and at the correct level (see LUBRICATION in the Maintenance
and Repair Manual). Bearing overheating can also
be caused by shaft misalignment and/or excessive
vibration.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
When pumps are first started, the bearings may
seem to run at temperatures above normal. Continued operation should bring the temperatures
down to normal levels.
After stopping the pump, switch off the engine ignition and remove the key to ensure that the pump
will remain inoperative.
Cold Weather Preservation
shock waves can be transmitted to the pump and
piping system. Close all connecting valves slowly.
BEARING TEMPERATURE CHECK
Bearings normally run at higher than ambient temperatures because of heat generated by friction.
Temperatures up to 160F (71C) are considered
normal for bearings, and they can operate safely to
at least 180F (82C).
Checking bearing temperatures by hand is inaccurate. Bearing temperatures can be measured accurately by placing a contact-type thermometer
against the housing. Record this temperature for
future reference.
OPERATION
In below freezing conditions, drain the pump to
prevent damage from freezing. Also, clean out any
solids by flushing with a hose. Operate the pump
for approximately one minute; this will remove any
remaining liquid that could freeze the pump rotating parts. If the pump will be idle for more than a
few hours, or if it has been pumping liquids containing a large amount of solids, drain the pump,
and flush it thoroughly with clean water. To prevent
large solids from clogging the drain port and preventing the pump from completely draining, insert
a rod or stiff wire in the drain port, and agitate the
liquid during the draining process. Clean out any
remaining solids by flushing with a hose.
PAGE C − 3
OM−06057
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 disconnect the positive battery cable to ensure that the pump will remain inoperative.
3. Allow the pump to completely cool if
overheated.
4. Check the temperature and make
sure pump is cool before opening
any covers, plates, or plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.
TROUBLE
POSSIBLE CAUSE
PROBABLE REMEDY
PUMP FAILS TO
PRIME
Discharge check valve contaminated, damaged, or unable to seat.
Clean or replace check valve.
Air compressor head 180 out.
Consult factory.
Air leak in suction line.
Correct leak.
Lining of suction hose collapsed.
Replace suction hose.
Leaking or worn seal or pump gasket.
Check pump vacuum. Replace
leaking or worn seal or gasket.
Suction lift or discharge head too high.
Check piping installation and install
bypass line if needed. See INSTALLATION.
Air compressor damaged or belts broken.
Check and repair/replace.
Strainer clogged.
Check strainer and clean if necessary.
Eductor clogged.
Check and clean eductor.
Air leak in suction line.
Correct leak.
Lining of suction hose collapsed.
Replace suction hose.
Leaking or worn seal or pump gasket.
Check pump vacuum. Replace
leaking or worn seal or gasket.
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
TROUBLESHOOTING
PAGE D − 1
OM−06057
TROUBLE
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE (cont.)
PUMP REQUIRES
TOO MUCH
POWER
PUMP CLOGS
FREQUENTLY
EXCESSIVE NOISE
PAGE D − 2
PA SERIES
POSSIBLE CAUSE
PROBABLE REMEDY
Strainer clogged.
Check strainer and clean if necessary.
Discharge check valve clogged.
Check and clean check valve.
Suction intake not submerged at
proper level or sump too small.
Check installation and correct
submergence as needed.
Impeller or other wearing parts worn
or damaged.
Replace worn or damaged parts.
Check that impeller is properly
centered and rotates freely.
Impeller clogged.
Free impeller of debris.
Discharge head too high.
Install bypass line.
Suction lift too high.
Measure lift w/vacuum gauge. Reduce lift and/or friction losses in
suction line.
Pump speed too slow.
Check engine output; consult engine operation manual.
Belt or flexible coupling broken.
Check and replace as necessary.
Pump speed too high.
Check engine output.
Extreme ambient temperature.
Reduce pump output.
Discharge head too low.
Fuel filter clogged.
Adjust discharge valve.
Check & replace often in extreme
operating conditions.
Liquid solution too thick.
Dilute if possible.
Fuel contaminated.
Check and replace as required.
Pump or jack shaft bearing(s) frozen.
Disassemble, check and replace
bearing(s) as required..
Discharge flow too slow.
Open discharge valve fully to increase flow rate, and run engine at
maximum governed speed.
Suction check valve or foot valve
clogged or binding.
Clean valve.
Liquid solution too thick.
Dilute if possible.
Cavitation in pump.
Reduce suction lift and/or friction
losses in suction line. Record vacuum and pressure gauge readings
and consult local representative or
factory.
Pumping entrained air.
Locate and eliminate source of air
bubble.
Pump or drive not securely mounted.
Secure mounting hardware.
Impeller clogged or damaged.
Clean out debris; replace damaged
parts.
TROUBLESHOOTING
OM−06057
PA SERIES
TROUBLE
BEARINGS RUN
TOO HOT
POSSIBLE CAUSE
Bearing temperature is high, but
within limits.
Check bearing temperature regularly to monitor any increase.
Low or incorrect lubricant.
Check for proper type and level of
lubricant.
Suction and discharge lines not properly supported.
Check piping installation for proper
support.
Drive misaligned.
Align drive properly.
Excessive tension on drive belt.
Check belt tension. Adjust as
required.
PREVENTIVE MAINTENANCE
Since pump applications are seldom identical, and
pump wear is directly affected by such things as
the abrasive qualities, pressure and temperature
of the liquid being pumped, this section is intended
only to provide general recommendations and
practices for preventive maintenance. Regardless
of the application however, following a routine preventive maintenance schedule will help assure
trouble-free performance and long life from your
Gorman-Rupp pump. For specific questions concerning your application, contact your GormanRupp distributor or the Gorman-Rupp Company.
Record keeping is an essential component of a
good preventive maintenance program. Changes
in suction and discharge gauge readings (if so
TROUBLESHOOTING
PROBABLE REMEDY
equipped) between regularly scheduled inspections can indicate problems that can be corrected
before system damage or catastrophic failure occurs. The appearance of wearing parts should also
be documented at each inspection for comparison
as well. Also, if records indicate that a certain part
(such as the seal) fails at approximately the same
duty cycle, the part can be checked and replaced
before failure occurs, reducing unscheduled down
time.
For new applications, a first inspection of wearing
parts at 250 hours will give insight into the wear rate
for your particular application. Subsequent inspections should be performed at the intervals shown
on the chart below. Critical applications should be
inspected more frequently.
PAGE D − 3
OM−06057
PA SERIES
Preventive Maintenance Schedule
Service Interval*
Item
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)
Rear Impeller Clearance (Seal Plate)
Check Valve
Pressure Relief Valve (If So Equipped)
Pump and Driver Alignment
Shaft Deflection
Bearings
Bearing Housing
Piping
Driver Lubrication − See Mfgr’s Literature
Daily
Weekly
Monthly
Semi- Annually
Annually
I
I
I
R
I
R
I
I
C
I
I
I
C
I
I
I
I
I
Legend:
I = Inspect, Clean, Adjust, Repair or Replace as Necessary
C = Clean
R = Replace
* Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually.
Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.
PAGE D − 4
TROUBLESHOOTING
OM−06057
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 PA12A60−B−6068T−ESP
Based on 70F (21C) clear water at sea level
with minimum suction lift. Since pump installations
are seldom identical, your performance may be different due to such factors as viscosity, specific
gravity, elevation, temperature, and impeller trim.
If your pump serial number is followed by an N",
your pump is NOT a standard production model.
MAINTENANCE & REPAIR
Contact the Gorman-Rupp Company to verify performance or part numbers.
Pump speed and operating condition
points must be within the continuous performance range shown on the curve.
PAGE E − 1
OM−06057
PA SERIES
PARTS PAGE
SECTION DRAWING
Figure 1. Pump Model PA12A60−B−6068T−ESP
PAGE E − 2
MAINTENANCE & REPAIR
OM−06057
PA SERIES
PARTS LIST
Pump Model PA12A60−B−6068T−ESP
(From S/N 1378838 Up)
If your pump serial number is followed by an N", your pump is NOT a standard production model. Contact
the Gorman-Rupp Company to verify part numbers.
ITEM PART NAME
PART
NO.
NUMBER
1
PUMP MODEL ASSY
46133−726
2
J.D. 6068T ENGINE
29224−236
3
BASE ASSY
41565−591
4
BAIL/GUARD ASSY
42358−001
5
CONTROL PANEL
29284−028
6
CONT PANEL SUPPORT 34812−001
7
HEX NUT
D08
8
LOCK WASHER
J08
9
HEX HD CAPSCREW
B0804
10
HEX HD CAPSCREW
B1209
11
HEX NUT
D12
12
LOCK WASHER
J12
13
12" SPOOL
46353−844
14
GASKET
4991G
15
HEX HD CAPSCREW
B1415
16
LOCK WASHER
J14
17
HEX NUT
D14
18
CHK VLV SUPPORT ASSY 41881−968
19
FLAT WASHER
K12
20
PUMP SUPPORT ASSY
41581−041
21
RED PIPE BUSHING
AP2416
22
RED PIPE BUSHING
AP1608
23
THREADED ROD
31345−090
MAT’L
CODE
−−−
−−−
24150
−−−
−−−
15120
15991
15991
15991
15991
15991
15991
−−−
18000
15991
15991
15991
−−−
15991
−−−
11999
11999
15000
QTY
1
1
1
1
1
1
6
6
2
12
24
20
2
2
24
24
24
1
28
1
1
1
2
ITEM PART NAME
NO.
24
HEX JAM NUT
25
HOSE CLAMP
26
HOSE BARB FITTING
27
.62" ID X 36" LG HOSE
28
HEX HD CAPSCREW
29
BATT BOX ASSY
30
BATTERY
31
HEX HD CAPSCREW
32
LOCK WASHER
33
HEX NUT
34
.62" ID X 56" LG HOSE
35
ENGINE RAIL
36
FLAT WASHER
37
ENGINE RAIL
38
.62" ID X 52" LG HOSE
39
.38" ID X 48" LG HOSE
40
RED PIPE BUSHING
41
HOSE BARB FITTING
42
PLUG CONNECTOR
43
FLANGED CAPSCREW
44
CABLE
45
FLANGED CAPSCREW
46
FLANGED HEX NUT
47
ENCLOSURE ASSY
PART
MAT’L
NUMBER
CODE
AT12
15991
26518−642 −−−
26523−391 −−−
18513−304 −−−
B1210
15991
42432−003 −−−
SEE OPTIONS
B1008
15991
J10
15991
D10
15991
18513−304 −−−
34458−054 15080
K10
15991
34458−055 15080
18513−304 −−−
18513−302 −−−
AP0806
15079
26523−389 −−−
27261−301 −−−
21634−505 −−−
18141−147 −−−
21634−515 −−−
21765−314 −−−
42164−020 −−−
QTY
2
8
5
1
8
1
8
8
8
1
1
12
1
1
1
1
1
1
6
1
19
5
1
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR
PAGE E − 3
OM−06057
PA SERIES
SECTION DRAWING
Figure 2. Pump Model PA12A60−B−6068T−ESP (Cont’d)
PAGE E − 4
MAINTENANCE & REPAIR
OM−06057
PA SERIES
PARTS LIST
Pump Model PA12A60−B−6068T−ESP (Cont’d)
(From S/N 1378838 Up)
ITEM
NO.
PART NAME
PART
NUMBER
MAT’L
CODE
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
INTAKE TUBE ASSY
HOSE BARB FITTING
.75" ID X 52" LG HOSE
AIR INTAKE ELBOW
AIR INTAKE ELBOW
FLEX EXHAUST PIPE
EXHAUST ELBOW
U-BOLT
WEATHER CAP
EXHAUST PIPE
FLAT WASHER
HEX HD CAPSCREW
HOSE BARB FITTING
CONNECTOR
FUEL TANK ASSY
HOSE BARB FITTING
HOSE CLAMP
PRESS RELIEF VALVE
HOSE ASSY
CONNECTOR
PIPE TEE
VACUUM HOSE ASSY
PIPE COUPLING
RED PIPE BUSHING
PIPE COUPLING
STREET ELBOW
VENTURI
VENTURI MUFFLER
BUSHING
SPROCKET
PUMP DRIVE BELT
DRIVE ASSEMBLY
LOCK WASHER
HEX NUT
HALF PIPE COUPLING
46671−501
24150
26523−392
−−−
18513−305
−−−
SUPPLIED W/ENGINE
SUPPLIED W/ENGINE
29334−408
−−−
29334−330
−−−
SUPPLIED W/ENGINE
SUPPLIED W/ENGINE
SUPPLIED W/ENGINE
K08
15991
B0808
15991
26523−015
−−−
S1447
−−−
46711−094
24150
26523−386
−−−
26518−641
−−−
26662−028
−−−
46341−026
−−−
26351−065
−−−
U08
11999
46341−021
−−−
AE12
15079
AP1208
15079
AE16
15079
AGS16
11999
26817−001
−−−
29334−091
−−−
24131−535
−−−
24271−003
−−−
24154−001
−−−
44162−179
−−−
J04
15991
D04
15991
AES06
15070
QTY
1
1
1
1
4
8
4
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
4
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR
PAGE E − 5
OM−06057
PA SERIES
SECTION DRAWING
Figure 3. Pump Model PA12A60−B−6068T−ESP (Cont’d)
PAGE E − 6
MAINTENANCE & REPAIR
OM−06057
PA SERIES
PARTS LIST
Pump Model PA12A60−B−6068T−ESP (Cont’d)
(From S/N 1378838 Up)
ITEM
NO.
83
84
85
86
87
88
89
90
91
92
93
94
95
NOT SHOWN:
PART NAME
PART
NUMBER
MAT’L
CODE
QTY
RED PIPE BUSHING
CONNECTOR
.38" ID X 56" LG HOSE
.19" ID X 40" LG HOSE
POS BATTERY CABLE
NEG BATTERY CABLE
T-BOLT CLAMP
POLLAK PLATE
SOCKET CONNECTOR
T-BOLT CLAMP
HOSE BARB FITTING
ADAPTOR
ADAPTOR
AP0604
26351−059
18513−302
18513−301
47311−111
47311−185
26518−165
33541−066
27263−001
26518−163
26523−045
26523−192
26523−172
14100
−−−
−−−
−−−
−−−
−−−
−−−
13000
−−−
−−−
−−−
−−−
−−−
1
1
1
1
1
1
3
1
1
1
1
1
1
FLOAT SWITCH
1/8" X 1" FOAM TAPE
WARNING DECAL
WARNING DECAL
WARNING DECAL
PRIME AIRE DECAL
PUMP DRAIN LABEL
FUEL TANK DRAIN LABEL
RADIATOR DRAIN LABEL
OIL DRAIN LABEL
GRD WARNING STICKER
LUBE DECAL
BATTERY TAG
ENGINE STARTUP TAG
ACCESS PANEL DECAL
48312−980
18668−001
38816−330
38816−218
38816−203
38812−078
38816−320
38816−321
38816−322
38816−323
38816−063
38816−085
38818−506
38816−269
38817−089
−−−
−−−
−−−
−−−
−−−
−−−
−−−
−−−
−−−
−−−
−−−
−−−
−−−
−−−
−−−
1
1
2
4
4
2
1
1
1
1
1
1
1
1
1
MAINTENANCE & REPAIR
PAGE E − 7
OM−06057
PA SERIES
SECTION DRAWING
Figure 4. 46133−726 Pump Model Assembly
PAGE E − 8
MAINTENANCE & REPAIR
OM−06057
PA SERIES
PARTS LIST
46133−726 Pump Model Assembly
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PART NAME
PART
NUMBER
MAT’L
CODE
QTY
PUMP ASSMEBLY
HEX HD CAPSCREW
LOCKWASHER
HEX NUT
12" CHECK VALVE
−FLAPPER
−COVER GASKET
FLANGE GASKET
PIPE PLUG
12" SPOOL
BLIND FLANGE GASKET
4" BLIND FLANGE ASSY
LOCKWASHER
HEX HD CAPSCREW
HEX HD CAPSCREW
NAME PLATE
DRIVE SCREW
PRIMING CHAMBER KIT
612M60−B
B1415
J14
D14
26642−128
26688−003
26688−004
4991G
P04
38642−617
25113−034
42111−358
J10
B1007
B1413
38818−127
BM#04−03
48275−006
−−−
15991
15991
15991
−−−
−−−
−−−
18000
15079
10000
−−−
−−−
15991
15991
15991
13000
17000
−−−
1
12
24
24
1
1
1
1
1
1
1
1
8
8
12
REF
REF
1
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR
PAGE E − 9
OM−06057
PA SERIES
SECTION DRAWING
SEE FIG. 6
Figure 5. 612M60−B Pump Model Assembly
PAGE E − 10
MAINTENANCE & REPAIR
OM−06057
PA SERIES
PARTS LIST
612M60−B Pump Model Assembly
ITEM PART NAME
PART
MAT’L
NO.
NUMBER
CODE
1
PUMP CASING
38219−305 10010
2
IMP/WEAR RING ASSY
46151−022 24110
−IMPELLER
NOT AVAILABLE
−WEAR RING
4182A
11030
SEAL ASSEMBLY
46512−109 −−−
3
4
STUD
C1013
15991
5
STUD
C1011
15991
6
GASKET
38674−434 18000
7
SOCKET HD CAPSCREW BD1206
15990
8
IMPELLER WASHER
31167−022 15030
9
ROLL PIN
S2197
−−−
10
HOSE CLAMP
26518−642 −−−
11
MALE CONNECTOR
26523−409 −−−
12
BOTTLE OILER BRKT
41881−811 24150
13
FLAT WASHER
K10
15991
14
LOCK WASHER
J10
15991
15
HEX NUT
D10
15991
16
MACHINE SCREW
X0405
15991
17
LOCK WASHER
J04
15991
18
SIGHT GAUGE
S1471
−−−
19
VENTE PIPE PLUG
38649−009 15079
20
PEDESTAL
38257−520 10000
21
PIPE PLUG
P04
15079
22
HEX HD CAPSCREW
B0605
15991
23
OIL SEAL
25258−845 −−−
24
BEARING CAP
38322−429 10000
25
O-RING
25152−249 −−−
26
BEARING ADJ SHIM SET 48261−055 −−−
27
BEARING LOCKNUT
23962−015 −−−
28
BEARING LOCK WASHER 23962−515 −−−
29
BEARING CAP GASKET
4184G
18000
30
BALL BEARING
23413−015 −−−
SHAFT KEY
N1016
15990
31
32
IMPELLER SHAFT
38512−522 17040
33
IMPELLER KEY
N0809
15990
QTY
ITEM PART NAME
NO.
PART
NUMBER
MAT’L
CODE
QTY
1
1
1
1
1
3
9
1
1
1
1
2
2
1
1
22
24
2
2
2
1
1
1
12
3
1
1
1
1
1
1
2
1
1
1
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
ROLLER BEARING
BEARING CAP
AIR VENT
BEARING CAP O-RING
PIPE COUPLING
PIPE NIPPLE
SEAL PLATE
PIPE PLUG
IMP ADJ SHIM SET
PIPE PLUG
CASING DRAIN PLUG
SEAL PLATE COVER
HEX HD CAPSCREW
LOCK WASHER
.38" ID X 11" LG HOSE
SUCTION HEAD
SPIRAL PIN
WEAR RING
GASKET
STUD
BOTTLE OILER
SNAP RING
DRIVE SCREW
NAME PLATE
23528−005
38322−425
S1730
25151−266
AE06
T0608
38272−717
P12
48261−033
P06
P24
38242−708
B0503−1/2
J05
18513−054
4180
21137−123
4181A
4180G
C1009
26713−004
24124−057
BM#04−03
38818−127
−−−
1
10010
1
−−−
1
−−−
1
15079
1
15079
1
10000
1
15079
2
−−− REF
15079
2
10009
1
10000
1
15991
6
15991
6
−−−
1
10010
1
−−−
3
140001 1
18000
1
15991 12
−−−
1
−−−
1
17000
4
13000
1
NOT SHOWN:
SUCTION STICKER
ROTATION DECAL
STRAINER
G-R DECAL
WARNING DECAL
PAPER INSTR TAG
LUBRICATION DECAL
PAPER INSTR TAG
OIL LEVEL DECAL
DISCHARGESTICKER
6588AG
2613M
46641−012
GR−03
2613FE
38817−024
38816−079
38817−011
38816−123
6588BJ
−−−
−−−
24150
−−−
−−−
−−−
−−−
−−−
−−−
−−−
1
1
1
1
1
1
2
1
1
1
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR
PAGE E − 11
OM−06057
PA SERIES
SECTION DRAWING
SEE FIG. 5
Figure 6. 612M60−B Pump Model Assembly (Cont’d)
PAGE E − 12
MAINTENANCE & REPAIR
OM−06057
PA SERIES
PARTS LIST
612M60−B Pump Model Assembly (Cont’d)
ITEM PART NAME
PART
MAT’L
NO.
NUMBER
CODE
1
PUMP CASING
38219−305 10010
2
IMP/WEAR RING ASSY
46151−022 24110
−IMPELLER
NOT AVAILABLE
−WEAR RING
4182A
11030
SEAL ASSEMBLY
46512−109 −−−
3
4
STUD
C1013
15991
5
STUD
C1011
15991
6
GASKET
38674−434 18000
7
SOCKET HD CAPSCREW BD1206
15990
8
IMPELLER WASHER
31167−022 15030
9
ROLL PIN
S2197
−−−
10
HOSE CLAMP
26518−642 −−−
11
MALE CONNECTOR
26523−409 −−−
12
BOTTLE OILER BRKT
41881−811 24150
13
FLAT WASHER
K10
15991
14
LOCK WASHER
J10
15991
15
HEX NUT
D10
15991
16
MACHINE SCREW
X0405
15991
17
LOCK WASHER
J04
15991
18
SIGHT GAUGE
S1471
−−−
19
VENTE PIPE PLUG
38649−009 15079
20
PEDESTAL
38257−520 10000
21
PIPE PLUG
P04
15079
22
HEX HD CAPSCREW
B0605
15991
23
OIL SEAL
25258−845 −−−
24
BEARING CAP
38322−429 10000
25
O-RING
25152−249 −−−
26
BEARING ADJ SHIM SET 48261−055 −−−
27
BEARING LOCKNUT
23962−015 −−−
28
BEARING LOCK WASHER 23962−515 −−−
29
BEARING CAP GASKET
4184G
18000
30
BALL BEARING
23413−015 −−−
SHAFT KEY
N1016
15990
31
32
IMPELLER SHAFT
38512−522 17040
33
IMPELLER KEY
N0809
15990
QTY
ITEM PART NAME
NO.
PART
NUMBER
MAT’L
CODE
QTY
1
1
1
1
1
3
9
1
1
1
1
2
2
1
1
22
24
2
2
2
1
1
1
12
3
1
1
1
1
1
1
2
1
1
1
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
ROLLER BEARING
BEARING CAP
AIR VENT
BEARING CAP O-RING
PIPE COUPLING
PIPE NIPPLE
SEAL PLATE
PIPE PLUG
IMP ADJ SHIM SET
PIPE PLUG
CASING DRAIN PLUG
SEAL PLATE COVER
HEX HD CAPSCREW
LOCK WASHER
.38" ID X 11" LG HOSE
SUCTION HEAD
SPIRAL PIN
WEAR RING
GASKET
STUD
BOTTLE OILER
SNAP RING
DRIVE SCREW
NAME PLATE
23528−005
38322−425
S1730
25151−266
AE06
T0608
38272−717
P12
48261−033
P06
P24
38242−708
B0503−1/2
J05
18513−054
4180
21137−123
4181A
4180G
C1009
26713−004
24124−057
BM#04−03
38818−127
−−−
1
10010
1
−−−
1
−−−
1
15079
1
15079
1
10000
1
15079
2
−−− REF
15079
2
10009
1
10000
1
15991
6
15991
6
−−−
1
10010
1
−−−
3
140001 1
18000
1
15991 12
−−−
1
−−−
1
17000
4
13000
1
NOT SHOWN:
SUCTION STICKER
ROTATION DECAL
STRAINER
G-R DECAL
WARNING DECAL
PAPER INSTR TAG
LUBRICATION DECAL
PAPER INSTR TAG
OIL LEVEL DECAL
DISCHARGESTICKER
6588AG
2613M
46641−012
GR−03
2613FE
38817−024
38816−079
38817−011
38816−123
6588BJ
−−−
−−−
24150
−−−
−−−
−−−
−−−
−−−
−−−
−−−
1
1
1
1
1
1
2
1
1
1
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR
PAGE E − 13
OM−06057
PA SERIES
SECTION DRAWING
Figure 7. 48275−006 Priming Chamber Kit
ITEM
NO.
PART NAME
PART
NUMBER
MAT’L
CODE
QTY
1
2
3
4
5
6
7
8
BALL VALVE
STREET ELBOW
PRIMING CHAMBER ASSEMBLY
HEX NUT
LOCK WASHER
STUD
BAFFLE
GASKET
26631−054
RS16
36112−709
D08
J08
C0809
31113−011
38687−053
−−−
11999
−−−
15991
15991
15991
17000
19060
1
1
1
4
4
4
1
1
INDICATES PARTS RECOMMENDED FOR STOCK
PAGE E − 14
MAINTENANCE & REPAIR
OM−06057
PA SERIES
SECTION DRAWING
Figure 8. 46112−709 Priming Chamber Assembly
ITEM
NO.
1
2
3
4
5
6
PART NAME
PART
NUMBER
MAT’L
CODE
QTY
PRIMING VALVE
−ORIFICE BUTTON
HEX HD CAPSCREW
LOCKWASHER
PRIMING VALVE GASKET
PRIMING CHAMBER
STRAINER ASSY
26664−007
26688−021
B0806
J08
38683−657
38343−020
46641−222
−−−
−−−
15991
15991
19060
10000
17000
1
REF
8
8
1
1
1
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR
PAGE E − 15
OM−06057
PA SERIES
SECTION DRAWING
Figure 9. 44162−179 Engine Drive Assembly
ITEM
NO.
PART NAME
PART
NUMBER
MAT’L
CODE
QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
RETAINING RING
RETAINING RING
BALL BEARING
OUTPUT SHAFT
KEY
BEARING HOUSING
SOCKET HEAD CAPSCREW
LOCK WASHER
ALLEN HEAD SETSCREW
BUSHING
COUPLING
BALL BEARING
KEY
SPROCKET
TAPER LOCK BUSHING
24121−075
S215
23282−012
38512−051
N0612
38251−001
BD0606−1/2
J06
GA0703−1/2
24131−496
24391−103
23431−012
N0807
24271−004
24131−526
−−−
−−−
−−−
1706H
15990
11010
15991
15991
15990
−−−
−−−
−−−
15990
−−−
−−−
1
4
1
1
1
1
8
8
REF
1
1
1
1
1
1
INDICATES PARTS RECOMMENDED FOR STOCK
PAGE E − 16
MAINTENANCE & REPAIR
OM−06057
PA SERIES
SECTION DRAWING
IMPELLER
WEAR RING
NOTE: UNLESS
OTHERWISE
SPECIFIED,
MACHINED SURFACES TO BE 125 RMS.
Figure 10. Impeller Assembly Machining Tolerances
MAINTENANCE & REPAIR
PAGE E − 17
OM−06057
PUMP AND SEAL DISASSEMBLY
AND REASSEMBLY
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and decals attached to the pump.
This pump requires little service due to its rugged,
minimum-maintenance design. However, if it becomes necessary to inspect or replace the wearing
parts, follow these instructions which are keyed to
the sectional views (see Figures 1 through 10) and
the accompanying parts list.
This manual will alert personnel to known procedures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel. However,
this manual cannot possibly anticipate and provide
detailed precautions for every situation that might
occur during maintenance of the unit. Therefore, it
is the responsibility of the owner/maintenance personnel to ensure that only safe, established maintenance procedures are used, and that any procedures not addressed in this manual are performed
only after establishing that neither personal safety
nor pump integrity are compromised by such practices.
Before attempting to service the pump, shut down
the engine and take precautions to ensure that the
pump will remain inoperative. Close all valves in the
suction and discharge lines.
For engine disassembly and repair, consult the literature supplied with the engine, or contact your
local engine representative.
PA SERIES
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.
This pump may be used to handle materials which could cause illness through
direct exposure or emitted fumes. Wear
adequate protective clothing when
working on the pump or piping.
No instructions are provided in this manual
for disassembly and/or removal of the
pump enclosure. If removal of the enclosure is required for pump service, be sure
to use safe shop practices so as not to endanger personnel, and use caution to prevent damage to the enclosure.
Priming Chamber Removal And Disassembly
(Figure 7)
Disconnect both the suction piping and the air discharge tubing from the priming valve assembly (3).
Support the priming valve assembly using a sling
and a suitable lifting device. Disengage the hardware (4 and 5) and separate the priming valve assembly, gasket (8) and baffle (7) from the spool (8,
Figure 4).
(Figure 8)
Before attempting to open or service the
pump:
1. Familiarize yourself with this manual.
2. Shut down the engine and disconnect the postiive battery cable to
ensure that the pump will remain
inoperative.
3. Allow the pump to completely cool
if overheated.
PAGE E − 18
Remove the hardware (2 and 3) securing the priming valve (1) to the priming chamber (6). Carefully
lift the valve components from the priming chamber. Remove the gasket (4) and clean the mating
surfaces.
If the priming valve float is stuck or the strainer (6) is
clogged, it can usually be cleaned without further
disassembly.
The only serviceable part of the priming valve is the
orifice button (not shown). If liquid continues to byMAINTENANCE & REPAIR
PA SERIES
pass through the priming chamber after adjusting
the orifice button (see Priming Chamber Reassembly and Installation for adjustment), the button may require replacement. To replace the orifice
button, remove one of the e-clips" from the pivot
pin closest to the orifice button and remove the pivot pin. This will allow the linkage to be raised high
enough to access the orifice button.
Remove the hex nut and lockwasher securing the
orifice button to the linkage bar and unscrew the
orifice button from the linkage bar.
OM−06057
three holes horizontally, 180 apart, through the
wear ring between each of the spiral pins. Use a
chisel or other suitable tool to complete the cuts
through the wear ring. Use caution not to damage
the suction head bore. Remove the wear ring sections from the suction head. Pull the spiral pins
from the suction head.
If no further disassembly is required, see Suction
Head and Wear Ring Installation.
Pump Casing Removal
(Figure 5)
Discharge Check Valve Removal and
Disassembly
Support the pump casing using a suitable hoist
and sling.
(Figure 4)
Support the discharge check valve assembly (5)
using a sling and a suitable lifting device. Remove
the hardware (3 and 4) and separate the discharge
check valve assembly and gasket (6) from the
pump assembly (1).
The flapper and cover gasket are the only serviceable parts of the check valve. If the flapper requires
replacement, remove the hardware securing the
cover. Separate the valve cap and remove the flapper and gasket.
Suction Head And Wear Ring Removal
(Figure 5)
Unless replacment of the spool gasket (6, Figure 4)
is required, the suction head (49) may be removed
without separating it from the spool. However, if the
spool gasket must be replaced, support the spool
with a suitable hoist and sling, remove the hardware (3 and 4, Figure 4) and separate the suction
spool and gasket from the suction head.
Remove the hardware securing the suction head
(49) to the base. Support the suction head using a
suitable hoist and sling. Disengage the hardware
(14 and 15) and separate the suction head and
wear ring (51) from the pump casing. Remove the
suction head gasket (52) and clean the mating surfaces.
Inspect the wear ring for excessive wear or scoring.
The wear ring is a press fit into the suction head
and is additionally secured with the spiral pins (50).
If replacement is required, use a small bit to drill
MAINTENANCE & REPAIR
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or damage to equipment. If slings or chains are
used to move the pump or components,
make sure that the load is balanced;
otherwise serious personal injury or
death could result. Suction and discharge hoses and piping must be removed from the pump before lifting.
NOTE
When removing the pump casing, use a wire to secure the assembled bottle oiler (54, Figure 6) and
bracket (12, Figure 6) above the level of the oil in the
seal cavity. This will prevent oil from leaking out of
the oiler during disassembly.
If the impeller (2) is to be removed, the impeller
screw (7) should be loosened before removing the
pump casing. Immobilize the impeller by inserting
a wood block through the pump discharge and
into the impeller vanes. Remove the impeller screw
and washer (8). Remove the wood block from the
pump discharge.
Remove the hardware (13, 14 and 15, Figure 6) securing the pump casing and bottle oiler bracket to
the pedestal (20, Figure 6).
Pull the pump casing straight away from the pedestal to prevent binding on the impeller. Remove
PAGE E − 19
OM−06057
the casing gasket (6) and clean the contacting surfaces.
Impeller Removal
(Figure 5)
Before removing the impeller, loosen the hose
clamp (10, Figure 6) and remove the hose (48, Figure 6) from the lower connector (11, Figure 6). Remove the bottle oiler and bracket assembly and
drain the seal cavity. This will prevent the oil in the
oiler from escaping when the impeller is removed.
With the impeller screw and washer removed as
described in Pump Casing Removal, insert a pair
of wedges 180 apart between the impeller and the
seal plate (40, Figure 6). Tap the wedges alternately to force the impeller off the shaft. Retain the impeller key (33, Figure 6).
Inspect the impeller wear ring for excessive wear or
scoring.
PA SERIES
uid being pumped leaks past the oil seal, both
seals should be replaced immediately.
Remove the impeller shims (42). Tie and tag the
shims for ease of reassembly. Remove the seal
spring. Slide the rotating portion of the seal (consisting of the shaft sleeve and O-ring, bellows and
retainer, and rotating element) off the shaft as a
unit.
Apply oil to the sleeve and work it up under the rubber bellows. Slide the bellows and retainer off the
sleeve. Remove the sleeve O-ring.
Slide the seal plate and remaining seal components off the shaft. Disengage the hardware (46
and 47, Figure 6) and separate the seal plate cover
and O-ring (37, Figure 6) from the seal plate.
Use a suitably sized dowel to press the stationary
portion of the seal out of the seal plate. Press the oil
seal out of the seal plate cover.
If no further disassembly is required, refer to Seal
Installation.
Pedestal Assembly Removal
(Figure 1)
Proper replacement of the impeller wear
ring requires machining and dynamic balancing the impeller assembly after the new
wear ring is welded to the impeller. Failure
to properly install the new wear ring and
machine and balance the impeller assembly can result in premature shaft, seal or
bearing failure, or other damage to the
pump.
Disassembly of the pedestal requires separation of
the pump and driver. Disengage the hardware securing the belt guard to the lifting bail and remove
the guard.
Loosen, but do not remove, the hardware (10, 11,
12 and 19) securing the pump support assembly
(20) to the base.
(Figures 5 and 12)
Loosen the outer hardware (11 and 19) on the
threaded rods (23). Unscrew the jam nuts (24) until
they engage the adjusting brackets. Continue to
unscrew the jam nuts in an alternating sequence to
push" the pump assembly (1) and pump support
toward the discharge check valve. When sufficient
clearance is obtained, remove the pump drive belt
(78, Figure 3) from the sprocket and drive assembly (77 and 79, Figure 3).
This pump is designed with two seals; a primary
mechanical seal (3) located directly behind the impeller and a secondary oil seal (23, Figure 6) located in the seal plate cover (45, Figure 6). If the liq-
Remove the hardware (11, 12 and 28) securing the
pedestal to the pump support assembly (20). Use
a suitable hoist and sling to remove the pedestal
assembly.
To replace the wear ring, grind off the three weld
spots securing the wear ring to the impeller. Use
caution not to damage the impeller. Pry or carefully
grind the wear ring off the impeller.
Seal Removal
PAGE E − 20
MAINTENANCE & REPAIR
PA SERIES
Pump Shaft
Disassembly
OM−06057
and
Bearing
Removal
and
Place a block of wood against the impeller end of
the shaft (32) and tap the shaft and assembled
bearings (30 and 34) out of the pedestal.
(Figure 2)
When the pump is properly operated and maintained, the pedestal should not require disassembly. Disassemble the shaft and bearings only
when there is evidence of wear or damage.
Shaft and bearing disassembly in the field
is not recommended. These operations
should be performed only in a properly
equipped shop by qualified personnel.
The sprocket and bushing (76 and 77) must be removed from the drive end of the shaft before disassembling the pedestal (20, Figure 6). To remove
the sprocket, remove the screws securing the
sprocket to the hub, then reinstall the screws in the
tapped holes in the sprocket. Tighten the screws in
an alternating sequence to press against the hub
shoulder and jack" the sprocket off the hub.
With the sprocket removed, the hub can be pulled
or pried off the shaft. Remove the shaft key.
(Figure 6)
Before disassembling the pedestal, remove the
pedestal drain plug (21) and drain the oil from the
pedestal. Clean and reinstall the pipe plug.
Disengage the capscrews (22) and and remove
the outboard bearing cap (24), O-ring (25) and oil
seal (23). Remove the bearing shims (26). Press
the oil seal from the bearing cap.
Straighten the tab on the washer (28) securing the
bearing lock nut (27). Use a spanner wrench to remove the lock nut. Remove the tab washer.
Disengage the capscrews (22) and remove the inboard bearing cap (35) and oil seal (23). Remove
the bearing cap gasket (29) and clean the mating
surfaces. Press the oil seal from the bearing cap.
MAINTENANCE & REPAIR
After removing the shaft and bearings, clean and
inspect the bearings in place as described in
Bearing Cleaning And Inspection.
The bearing tolerances provide a tight press fit
onto the shaft and a snug slip fit into the pedestal.
Replace the bearings, shaft, or pedestal if the
proper bearing fit is not achieved.
If bearing replacement is required, remove the retaining ring (55) and use a bearing puller to remove
the inboard and outboard bearings from the shaft.
Engine Drive Disassembly
(Figure 9)
This engine is equipped with a jackshaft type drive
assembly as shown in Figure 9.
To remove the sprocket (14), remove the capscrews securing the taperlock bushing (15) to the
sprocket. Reinstall the capscrews in the tapped
holes in the bushing and use a suitable puller to
pull the bushing and sprocket off the output shaft
(4). Retain the key (13).
Further disassembly requires separating the remaining drive components from the engine. Remove the hardware (not shown, supplied with the
engine) securing the bearing housing (16) to the
engine. Pull the shaft and bearing housing straight
away from the engine. The rubber drive element of
the coupling (11) will separate from the drive ring
secured to the engine flywheel with the hardware
(7 and 8). Disengage the hardware to remove the
drive ring from the flywheel.
To remove the flexible portion of the coupling from
the output shaft, unscrew the two allen head setscrews (9) from the bushing (10). Screw one of the
setscrews into the hole on the circumference of the
bushing to separate the coupling and bushing.
When the parts separate, remove the bushing, and
slide the coupling off the shaft. Remove the key (5).
When properly operated and maintained, the output shaft and bearings should not require disassembly. Disassemble the shaft and bearings only
when there is evidence of wear or damage.
PAGE E − 21
OM−06057
Shaft and bearing disassembly in the field
is not recommended. These operations
should be performed only in a properly
equipped shop by qualified personnel.
To remove the shaft and bearings (3 and 12), use
snap ring pliers to remove the retaining ring (1).
Use a wood block to tap the shaft and bearings
from the bearing housing from the driven end.
PA SERIES
Most cleaning solvents are toxic and
flammable. Use them only in a well ventilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent containers.
Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.
After removing the shaft and bearings, clean and
inspect the bearings in place as described in
Bearing Cleaning And Inspection.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and bearings are removed.
Bearings must be kept free of all dirt and
foreign material. Failure to do so will greatly shorten bearing life. Do not spin dry
bearings. This may scratch the balls or
races and cause premature bearing failure.
Rotate the bearings by hand to check for roughness or binding. Inspect the bearing balls (or rollers) on open-type bearings. If rotation is rough or
the balls or rollers are discolored, replace the bearings.
The bearing tolerances provide a tight press fit
onto the shaft and a snug slip fit into the bearing
housing. Replace the bearings, shaft, or bearing
housing if the proper bearing fit is not achieved.
Engine Drive Reassembly
If bearing replacement is required, remove the outboard retaining rings (2) and use a bearing puller to
remove the inboard (3) and outboard (12) bearings
from the shaft.
Inspect the output shaft for distortion, nicks,
scratches, damaged keyways or galling on the
bearing seating surfaces. Dress small nicks and
burrs with a fine file or emery cloth. Replace the
shaft if defective.
(Figure 9)
It is not necessary to remove the inboard bearing
retaining rings unless replacement is required.
Use snap ring pliers to remove the retaining rings
as required.
If removed, install the inboard bearing retaining
rings (2) on the output shaft (4).
Bearing Cleaning And Inspection
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and bearings are removed.
Clean the pedestal, bearing housing, shafts and all
component parts (except the bearings) with a soft
cloth soaked in cleaning solvent. Inspect the parts
for wear or damage and replace as necessary.
PAGE E − 22
MAINTENANCE & REPAIR
PA SERIES
OM−06057
The bearings may be heated to ease installation.
An induction heater, hot oil bath, electric oven, or
hot plate may be used to heat the bearings. Bearings should never be heated with a direct flame or
directly on a hot plate.
NOTE
If a hot oil bath is used to heat the bearings, both the
oil and the container must be absolutely clean. If
the oil has been previously used, it must be thoroughly filtered.
Heat the bearings to a uniform temperature no
higher than 250F (120C), and slide the bearings
onto the shaft, one at a time, until they are fully
seated. This should be done quickly, in one continuous motion, to prevent the bearings from cooling and sticking on the shaft.
Use caution when handling hot bearings to
prevent burns.
After the bearings have been installed and allowed
to cool, check to ensure that they have not moved
in shrinking. If movement has occurred, use a suitably sized sleeve and a press to reposition the
bearings.
If heating the bearings is not practical, use a suitably sized sleeve and an arbor (or hydraulic) press
to install the bearings on the shaft.
Slide the shaft and assembled bearings into the
bearing housing until the outboard bearing is fully
seated against the bearing housing shoulder.
Install the key (5) in the output shaft keyway. Position the flexible portion of the coupling assembly
(3) on the shaft as shown in Figure 9.
NOTE
The flexible portion of the coupling must be properly positioned on the shaft. The heads of the capscrews in the center of the coupling must be positioned toward the drive end of the shaft.
Align the keyway in the bushing (10) with the shaft
key, and slide the bushing onto the shaft. Rotate
the flexible portion of the coupling until the tapped
holes for the two setscrews align with those in the
bushing and install the setscrews. Position the
coupling to the dimension shown in Figure 8.
Make certain that the flexible portion of the
coupling is mounted as shown in Figure 9.
The end of the shaft must protrude 1.06 to
1.19 inches (26,9 to 30,2 mm) from the face
of the bushing. This dimension is critical.
If the coupling is not properly positioned
on the shaft, the coupling parts may not fully engage, or a pre-load condition can
cause premature bearing failure.
With the flexible portion of the coupling and the
bushing properly positioned on the shaft, tighten
the two setscrews in an alternating sequence until
the bushing and coupling are fully secured. Torque
the setscrews to 23 ft. lbs. (280 in. lbs. or 3,2 m. kg.)
maximum.
Position the key (13) in the shaft keyway. Position
the drive sprocket over the shaft. Align the keyway
in the taperlock bushing (15) with the shaft key and
slide the bushing onto the shaft. Align the holes in
the bushing with those in the sprocket, and install
the bushing capscrews.
When installing the shaft and bearings into
the bearing bore, push against the outer
race. Never hit the balls or ball cage.
Position the sprocket on the shaft to the dimension
shown in Figure 9 and tighten the bushing capscrews in an alternating sequence until the bushing
and coupling are fully secured. Torque the setscrews to 60 ft. lbs. (720 in. lbs. or 8.3 m. kg.).
Secure the shaft and bearings in the bearing housing with the bearing retaining ring (1).
If the complete coupling assembly is being replaced, apply ‘Loctite Retaining Compound No.
MAINTENANCE & REPAIR
PAGE E − 23
OM−06057
PA SERIES
242’ or equivalent compound to the threads of the
hardware (7and 9), and secure the outer ring of the
coupling to the engine flywheel by torquing the
hardware to 45 ft. lbs. (540 in. lbs. or 6,2 m. kg.).
Position the drive assembly so the flexible portion
of the coupling seats inside the drive ring attached
to the engine flywheel. Secure the bearing housing
(6) to the engine bellhousing with the previously removed hardware.
Use caution when handling hot bearings to
prevent burns.
NOTE
If a hot oil bath is used to heat the bearings, both the
oil and the container must be absolutely clean. If
the oil has been previously used, it must be thoroughly filtered.
NOTE
To ease installation, lightly lubricate the rubber portion of the coupling with a non-petroleum based
lubricant such as vegetable oil or glycerin, or a silicon-based lubricant such as WD40" or equivalent.
Do not use petroleum-based lubricants, or any other substance which may soften or otherwise damage the rubber.
Pump Shaft and Bearing Reassembly and
Installation
(Figure 6)
Inspect the impeller shaft (32) for distortion, nicks
or scratches, or damaged keyways. Dress small
nicks and burrs with a fine file or emery cloth. Replace the shaft if defective.
Heat the bearings to a uniform temperature no
higher than 250F (120C) Slide the roller bearing
(34) onto the shaft until fully seated against the
shaft shoulder. This should be done quickly, in one
continuous motion, to prevent the bearings from
cooling and sticking on the shaft.
After the bearing has been installed and allowed to
cool, check to ensure that it has not moved away
from the shaft shoulder in shrinking. If movement
has occurred, use a suitably sized sleeve and a
press to reposition the bearing against the shaft
shoulder.
Secure the roller bearing on the shaft with the bearing retaining ring (55).
Slide the heated outboard bearings (30) onto the
shaft, one at a time, with the larger inner races of
each bearing positioned away from each other as
shown in Figure 6.
If heating the bearings is not practical, use a suitably sized sleeve and an arbor (or hydraulic) press
to install the bearings on the shaft.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and bearings are removed.
The bearings may be heated to ease installation.
An induction heater, hot oil bath, electric oven, or
hot plate may be used to heat the bearings. Bearings should never be heated with a direct flame or
directly on a hot plate.
PAGE E − 24
When installing the bearings onto the
shaft, never press or hit against the outer
race, balls, or ball cage. Press only on the
inner race.
After the bearings have been installed and allowed
to cool, check to ensure that they have not moved
away from the shaft shoulders in shrinking. If
movement has occurred, use a suitably sized
sleeve and a press to reposition the bearings
against the shaft shoulder.
MAINTENANCE & REPAIR
PA SERIES
Secure the assembled shaft and bearings by
clamping on the surface between the bearings.
Use caution not to scratch or mar the part number
etched into the shaft in this area. Install the tab
washer (28) and bearing lock nut (27). Torque the
lock nut to 150 ft. lbs. (1800 in. lbs. or 20,7 m. kg.).
Locate the tab on the lockwasher that aligns with a
slot in the lock nut, and bend the tab over into the
slot.
OM−06057
Position the hub and sprocket to the dimensions
shown in Figure 11 and torque the mounting capscrews to 75 ft. lbs. (900 in. lbs. or 10.4 m. kg.)
Slide the shaft and assembled bearings into the
pedestal from the drive end until the retaining inboard bearing (30) seats against the pedestal
bore.
When installing the shaft and bearings into
the bearing bore, push against the outer
race. Never hit the balls or ball cage.
Press the oil seal (23) into the bearing cap (24) with
the lip positioned as shown in Figure 6. Lubricate
and install a new bearing cap O-ring (25) and secure the bearing cap with the capscrews (22). Use
caution not to cut or roll the lip of the oil seal when
installing the bearing cap.
Press the oil seal (23) into the bearing cap (35) with
the lip positioned as shown in Figure 6. Replace
the bearing cap gasket (29) and secure the bearing cap with the capscrews (22). Use caution not to
cut or roll the lip of the oil seal when installing the
bearing cap.
Lubricate the pedestal as indicated in LUBRICATION.
Install the sprocket and hub onto the impeller shaft
as follows.
(Figures 2 and 11)
Install the key (31, Figure 6) in the shaft keyway.
Align the keyway in the hub with the shaft key, and
slide the hub onto the shaft with the shoulder positioned toward the pedestal.
Slide the sprocket over the hub, align the mounting
screw holes and install the mounting screws.
MAINTENANCE & REPAIR
Figure 11. Hub and Sprocket Installation
Make certain that the hub and sprocket are
mounted as shown in Figure 11. This is
critical. If the sprocket is not properly positioned on the shaft, the pump drive belt will
not be properly aligned, which can cause
premature belt or bearing failure.
Pedestal Assembly Installation
(Figure 1)
Use a suitable hoist and sling to position the pedestal assembly on the pump support assembly
(20). Secure the pedestal to the pump support assembly using the previously removed hardware
(11, 12 and 28).
Install the pump drive belt (76) after assembling the
remaining pump components.
To adjust the drive belt tension, find the center of
the belt span between the pump and engine
sprockets. Use a belt deflection gauge to measure
deflection across the width of the belt at this
point. Use the hardware (11 and 19) to adjust belt
tension to 3/8 inch (9,5 mm) of deflection at 30 lbs.
(13,6 kg.) of pressure. Do not over-tighten the
drive belt.
PAGE E − 25
OM−06057
PA SERIES
Install a new O-ring (37) in the groove in the seal
plate and secure the seal plate cover to the seal
plate with the hardware (46 and 47).
The inner edge of the pump pulley must be
aligned with the outer edge of the drive
pulley in order to prevent side wear of the
cog belt.
Do not over-tighten the drive belt. Overtightening will cause premature belt and/or
bearing failure.
After tensioning, secure the pump support assembly by tightening the jam nuts (24) and remaining
hardware (10, 11, 12 and 19).
Seal Reassembly and Installation
(Figures 5, 6 and 12)
Clean the bore of the seal plate (40), the seal plate
cover (45) and the shaft (32) with a cloth soaked in
fresh cleaning solvent.
Most cleaning solvents are toxic and
flammable. Use them only in a well ventilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent containers.
Lay the seal plate cover on a flat surface with the
inner side facing up. Press the oil seal (23) into the
seal plate cover with the lip positioned as shown in
Detail E, Figure 6.
PAGE E − 26
Since the mechanical seal is the primary seal in the
pump, special consideration should be given to
ensure proper installation.
The seal is not normally reused because wear patterns on the finished faces cannot be realigned
during reassembly. This could result in premature
failure. If necessary to reuse an old seal in an emergency, carefully wash all metallic parts in fresh
cleaning solvent and allow to dry thoroughly.
Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate precision
finished faces; even fingerprints on the faces can
shorten seal life. If necessary, clean the faces with a
non-oil based solvent and a clean, lint-free tissue.
Wipe lightly in a concentric pattern to avoid
scratching the faces.
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leakage. Clean and polish the shaft sleeve, or replace it
if there are nicks or cuts on either end. If any components are worn, replace the complete seal;
never mix old and new seal parts.
If a replacement seal is being used, remove it from
the container and inspect the precision finished
faces to ensure that they are free of any foreign
matter.
To ease installation of the seal, lubricate the bellows and stationary seat O-rings with water or a
very small amount of oil, and apply a drop of light
lubricating oil on the finished faces. Assemble the
seal as follows, (see Figure 12).
MAINTENANCE & REPAIR
PA SERIES
OM−06057
SPRING
RETAINER
SEAL PLATE
IMPELLER
SHAFT
KEY
STATIONARY
ELEMENT
SLEEVE
O-RING
IMPELLER
SHAFT
ROTATING
ELEMENT
O-RINGS
SHAFT
SLEEVE
BELLOWS
STATIONARY
SEAT
IMPELLER
SHIMS
Figure 12. Seal Assembly
the pedestal with three 1/2-inch by 2-inch long
capscrews and nuts (not supplied).
The standard seal is not designed for operation at temperatures above 160F (71C).
Do not use at higher operating temperatures.
Lubricate the outboard stationary seat O-ring with
water or light oil. Position the seal plate with the impeller side up and press the stationary subassembly (consisting of the stationary seat, O-rings
and stationary element) into the front of the seal
plate until it seats squarely against the bore shoulder.
Slide the seal plate and stationary portion of the
seal over the shaft until it is seated against the pedestal (20). Be careful not to damage the stationary
element or roll or cut the lip of the oil seal (23) on the
shaft keyway. Temporarily secure the seal plate to
MAINTENANCE & REPAIR
Lubricate the seal sleeve O-ring with a small
amount of light oil and install it in the groove in the
I.D. of the sleeve.
Lubricate the seal sleeve with a small amount of
light oil and slide the rotating subassembly (consisting of rotating element, bellows and retainer),
onto the sleeve until the rotating element is just
flush with the turned end of the sleeve.
Slide the sleeve and subassembled seal onto the
shaft until the seal faces contact and the sleeve
seats against the shaft shoulder.
Install the seal spring. Lubricate the seal as indicated in LUBRICATION after the impeller, remaining pump components, bottle oiler and piping are
installed.
PAGE E − 27
OM−06057
Impeller Installation
(Figure 5)
Proper wear ring replacement requires
machining and dynamic balancing the impeller assembly after the wear ring is
welded to the impeller. Failure to properly
install the wear ring and machine and balance the impeller assembly can result in
premature shaft, seal or bearing failure, or
other damage to the pump.
Inspect the impeller, and replace it if cracked or
badly worn. If the impeller wear ring was removed,
chill the impeller by refrigeration and use an induction heater or oven to heat the new wear ring. Slide
the wear ring onto the impeller until fully seated
against the shoulder and allow it to cool.
PA SERIES
A clearance of approximately .015 inch (0,38 mm)
between the impeller and the seal plate is recommended for maximum pump efficiency. Measure
this clearance, and add or remove impeller adjusting shims as required.
After the impeller clearance has been set, align the
pin (9) in the impeller washer (8) with the hole in the
impeller and install the washer. Apply NeverSeez" or equivalent compound on the threads of
the impeller capscrew (7). Immobilize the shaft and
secure the the impeller by torquing the capscrew
to 225 ft. lbs. (2700 in. lbs. or 31 m. kg.).
Pump Casing Installation
(Figure 5)
Install the casing gasket (6) over the pump casing
studs (4 and 5). Remove the hardware temporarily
securing the seal plate to the pedestal. Use a suitable hoist and sling to position the volute over the
impeller and slide the studs through the seal plate
and pedestal mounting holes.
(Figure 6)
The wear ring must seat squarely on the
impeller; otherwise binding and/or excessive wear will occur. Use caution when handling hot parts to prevent burns.
Install the bottle oiler bracket (12) over the volute
studs. Secure the bracket and volute casing with
the hardware (13, 14,and 15). Reconnect the hose
(48) to the connector (11) in the seal plate and secure it with the hose clamp (10).
Suction Head And Wear Ring Installation
Spot weld the wear ring to the impeller at three
places, equally spaced at the vanes. After welding,
machine the wear ring as shown in Figure 10.
The impeller assembly must be machined
and balanced as shown in Figure 10.
Otherwise, premature shaft, seal or bearing failure, or other damage to the pump
may occur.
After machining, dynamically balance the impeller
assembly per plane 1.05 oz./in. (11.7 g/cm).
Install the same thickness of impeller adjusting
shims (42) as previously removed. Install the shaft
key (33, Figure 6) and press the impeller assembly
onto the shaft until fully seated.
PAGE E − 28
(Figure 5)
If the wear ring (51) was removed, chill the wear
ring by refrigeration and heat the suction head.
Slide the wear ring into the suction head until fully
seated and allow it to cool.
The wear ring must seat squarely in the
suction head; otherwise binding and/or excessive wear will occur. Use caution when
handling hot parts to prevent burns.
The wear ring is secured to the suction head with
the spiral pins (50). Drill three evenly spaced
3/16-inch diameter x 3/4-inch deep holes through
the wear ring and into the suction head. Tap the
spiral pins into the holes until fully seated.
MAINTENANCE & REPAIR
PA SERIES
OM−06057
Install the suction head gasket (52). Position the
suction head over the studs (53) and secure it with
the hardware (14 and 15).
threads on the orifice button. When adjustment is
complete, install and tighten the lock washer and
hex nut securing the orifice button.
Turn the impeller shaft by hand and check for any
scraping or binding and correct it before putting
the pump into service.
Install the strainer (6) and priming valve gasket (4).
Discharge Check Valve Assembly and
Installation
(Figure 4)
The flapper and gasket are the only serviceable
parts of the check valve. If the flapper requires replacement, remove the hardware securing the
cover and gasket. Separate the valve cap and replace the flapper.
Install the valve cap gasket and secure the cap with
the previously removed hardware.
Support the discharge check valve assembly (5)
using a sling and a suitable lifting device. Secure
the discharge check valve assembly and gasket
(6) to the pump assembly (1) using the hardware
(2, 3 and 4).
See Figure 1, reinstall the spool and gasket (13 and
14) and secure them to the check valve and support (18) with the hardware (15, 16 and 17).
Lower the float into the priming chamber (5) and
secure the priming valve with the previously removed hardware (1 and 2).
(Figure 7)
Install the baffle (7) and gasket (8) and use a sling
and suitable lifting device to position the priming
chamber assembly against the pump suction
flange. Secure the priming chamber assembly with
the hardware (4 and 5).
Reconnect both the suction piping and the air discharge tubing to the priming chamber assembly.
LUBRICATION
Seal Assembly
(Figure 6)
Fill the bottle oiler (54) and seal cavity with approximately 85 ounces (2,5 liters) of SAE No. 30 non-detergent oil. Check the oil level regularly and refill as
required.
Bearings
(Figure 6)
Priming Chamber Assembly And Installation
(Figure 8)
Clean and inspect the components of the priming
valve (1). Inspect the linkage and ensure the orifice
button squarely engages the valve seat. Replace
the orifice button if required (see Priming Chamber Removal and Disassembly for orifice button
removal).
If the orifice button was removed, screw the new
orifice button into the linkage bar until fully seated.
Align the hole in the linkage bar with the holes in the
bracket and reinstall the pivot pin. Secure the pivot
pin with the previously removed e-clip".
Adjust the orifice button seating as necessary by
screwing the orifice button into or out of the linkage
bar. Proper adjustment is achieved when the orifice button fully seats against the orifice before the
linkage bar on the float bottoms against the
MAINTENANCE & REPAIR
The pedestal was fully lubricated when shipped
from the factory. Check the oil level regularly
through the sight gauges (18) and maintain it at the
midpoint of the gauges. When lubrication is required, remove the vented plug (19) and add SAE
No. 30 non-detergent oil through the opening.
Clean and reinstall the vented plug. Do not over-lubricate. Over-lubrication can cause the bearings to
over-heat, resulting in premature bearing failure.
NOTE
The white reflector in the sight gauge must be positioned horizontally to provide proper drainage.
Under normal conditions, drain the bearing housing once each year and refill with approximately 14
ounces (0,4 liter) of clean oil. Change the oil more
frequently if the pump is operated continuously or
installed in an environment with rapid temperature
change.
PAGE E − 29
OM−06057
PA SERIES
For cold weather operation, consult the factory or a
lubricant supplier for the recommended grade of
oil.
Monitor the condition of the bearing lubricant regularly for evidence of rust or moisture condensation. This is especially important in areas where variable hot and
cold temperatures are common.
PAGE E − 30
Engine
Consult the literature supplied with the engine, or
contact your local engine representative.
MAINTENANCE & REPAIR
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 D ST. THOMAS, ONTARIO, CANADA