GORMAN-RUPP PUMPS PRIME-AIRE PA6D User manual

PUBLICATION NUMBER MR--05112
June 5, 2000
Rev. B 01-10-03
Use With: OM--04402
THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
www.gormanrupp.com
ECopyright by the Gorman-Rupp Company
PRIME-AIRER
RR
RSERIES
PA6D Pumps

The engine exhaust from this
product contains chemicals
known tothe State ofCaliforniato
cause cancer, birth defects or
other reproductive harm.

MR--05112 PA SERIES PUMPS
PAGE I -- 1
INTRODUCTION
INTRODUCTION
Thank You for purchasing a Gorman-Rupp Prime-
AireRSeries priming-assisted pump. Read this
manual carefully to learn how to safely maintain
and service your pump. Failure to do so could re-
sult in personal injury or damage to the pump.
A set of three manuals accompanies your pump.
TheInstallation/OperationManualcontainsessen-
tial information on installing and operating the
pump, and on making electrical connections. The
Parts List Manual provides performance curve(s),
a pump model cross-section drawing, and parts
listforyourpump.
This Maintenance and Repair Manual provides
troubleshooting instructions required to properly
diagnose operational problems. Maintenance in-
structions within this manual are limited to the
pump hydraulic and drive components only. For
maintenance and repair of the engine or air com-
pressor,consulttheseparateliteratureprovidedby
the manufacturers.
This pump is a PA SeriesR, priming-assisted cen-
trifugal model. The unit is designed for handling
non-volatile, non-flammable liquids containing
specified entrained solids. For specific service,
contact your Gorman-Rupp distributor or the Gor-
man-Rupp Company.
As described on the following page, this manual
willalert personnelto known procedures which re-
quire specialattention, to those which could dam-
age equipment, and to those which could be dan-
gerous topersonnel. However, this manualcannot
possibly anticipate and provide detailed precau-
tions for every situation that might occur during
maintenanceofthe unit.Therefore,itistherespon-
sibilityof the owner/maintenance personnel to en-
sure that only safe, established maintenance pro-
ceduresareused,andthatanyproceduresnotad-
dressedinthismanualareperformedonlyafteres-
tablishingthatneitherpersonalsafetynorpumpin-
tegrity are compromised by such practices.
If there are any questions regarding the pump
which are not covered in this manual orin other lit-
erature accompanying the unit, please contact
your Gorman-Rupp distributor or the Gorman-
Rupp Company:
The Gorman-Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901--1217
Phone: [phone]
or
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: [phone]
CONTENTS
SAFETY -- SECTION A
TROUBLESHOOTING -- SECTION B
PUMP MAINTENANCE AND REPAIR -- SECTION C
DRAWINGS AND IDENTIFICATION LISTS PAGES C --- 2 THRU C---11..........................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE C --- 12...........................
Priming Chamber Removal and Disassembly PAGE C --- 13................................
Discharge Check Valve Removal and Disassembly PAGE C --- 13...........................
Suction Spool And Wear Plate Removal PAGE C --- 13.....................................
Separating Pump End From Power Source PAGE C --- 14..................................
Draining Oil From Seal Cavity PAGE C --- 14..............................................
Loosening Impeller PAGE C --- 14.......................................................
Pump Casing Removal PAGE C --- 15....................................................
Impeller Removal PAGE C --- 15.........................................................
Seal Removal PAGE C --- 15............................................................
Shaft and Bearing Removal And Disassembly PAGE C --- 15................................
Shaft and Bearing Reassembly and Installation PAGE C --- 16...............................

MR--05112PA SERIES PUMPS
PAGE I -- 2 INTRODUCTION
CONTENTS (Cont’d)
Seal Reassembly and Installation PAGE C --- 17...........................................
Impeller Installation And Adjustment PAGE C --- 19........................................
Suction Spool And Wear Plate Installation PAGE C --- 19...................................
Pump Casing Installation PAGE C --- 19..................................................
Securing Pump End to Power Source PAGE C --- 20.......................................
Priming Chamber Assembly And Installation PAGE C --- 20.................................
Discharge Check Valve Assembly And Installation PAGE C --- 21............................
Wear Plate Adjustment PAGE C --- 21....................................................
LUBRICATION PAGE C --- 22..............................................................
Seal Assembly PAGE C --- 22...........................................................
Bearings PAGE C --- 22................................................................
Power Unit PAGE C --- 22...............................................................
RECORDING MODEL AND
SERIAL NUMBERS
Please record the pump model and serial number
in the spaces provided below. Your Gorman-Rupp
distributorneedsthisinformationwhenyourequire
parts or service.
Pump Model:
Serial Number:
WARRANTY INFORMATION
The warranty provided with your pump is part of
Gorman-Rupp’s support program for customers
who operate and maintain their equipment as de-
scribed in this and the other accompanying litera-
ture. Please note that should the equipment be
abused or modified to change its performance be-
yond the original factory specifications, the war-
ranty will become void and any claim will be de-
nied.
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 resultin
severe personal injury or death. These
instructions describe the procedure re-
quired 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.
HazardsorunsafepracticeswhichCOULD
resultinminorpersonalinjuryorproductor
property damage. These instructions de-
scribe 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.

MR--05112 PA SERIES PUMPS
PAGE A -- 1
SAFETY
SAFETY --- SECTION A
The following information applies
throughout this manual to Gorman-
Rupp Prime AireRSeries pumps.
This manual will alert personnel to
known procedures which require spe-
cial attention, to those which could
damage equipment, and to those which
could be dangerous to personnel. How-
ever,thismanualcannotpossiblyantici-
pate and provide detailed instructions
and precautions for every situation that
might occur during maintenance of the
unit.Therefore,it isthe responsibilityof
the owner/maintenance personnel to
ensurethatonlysafe, established main-
tenance procedures are used, and that
any procedures not addressed in this
manual are performed only after estab-
lishing that neither personal safety nor
pump integrity are compromised by
such practices.
Before attempting to install, operate, or
service this pump, familiarize yourself
with this manual, and with all other liter-
ature shipped with the pump. Unfamil-
iarity with all aspects of pumpoperation
coveredin thismanualcouldleadtode-
struction of equipment, injury, or death
to personnel.
Beforeattemptingtoopenorservicethe
pump:
1. Familiarize yourself with this man-
ual.
2. Shut down the engine and discon-
nect the positive battery cable (en-
gine driven units) or lock out and
tag out incoming power tothe con-
trol box (electric motor driven
units) and take precautions to en-
sure that the pump will remain in-
operative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau-
tiously.
7. Drain the pump.
Thispump ismaybe usedto handlema-
terials which could cause illness
through direct exposure or emitted
fumes. Wear adequate protective cloth-
ing when working on the pump or pip-
ing.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam-
age to equipment. Attach lifting equip-
ment 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
willbe balanced.Thebailisintendedfor
use in lifting the pump assembly only.
Suction and discharge hoses and pip-
ing must beremovedfromthe pumpbe-
fore lifting.

PA SERIES PUMPS MR--05112
PAGE A-- 2 SAFETY
Afterthepump hasbeen installed,make
certain that the pump and all piping or
hose connections are tight, properly
supportedandsecurebeforeoperation.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over-
heatedpump. Vaporpressure withinthe
pump can cause parts being disen-
gaged to be ejected withgreat force.Al-
low the pump to cool before servicing.
Overheated pumps can cause severe
burns and injuries,and produce explo-
sive fumes. If overheating of the pump
occurs:
1. Stop the pump immediately.
2. Ventilate the area.
3. Allowthepumptocompletelycool.
4. Check the temperature and make
sure it is cool before opening any
covers, plates, gauges, or plugs.
5. Vent the pump slowly and cau-
tiously.
6. Refer to instructions in the manu-
als accompanying the pump be-
fore restarting the pump.
Do not operate the pump without the
guards in place over the rotating parts.
Exposed rotating parts can catch cloth-
ing, fingers, or tools, causing severe in-
jury to personnel.
Use only replacement parts provided or
approved by Gorman-Rupp. Use of non-
authorized parts may result in damage to
the equipment and/or injury to personnel
and will invalidate the warranty.
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.
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating an internalcombustion
engine in an enclosed area, make sure
exhaust fumes are piped to the outside.
These fumescontain carbon monoxide,
a deadly gas that is colorless, tasteless
and odorless.
Fuel used by internal combustion en-
gines presents an extreme explosion
andfirehazard.Makecertainthatallfuel
linesaresecurelyconnectedandfreeof
leaks. Never refuel a hot or running en-
gine. Avoid overfilling the fuel tank. Al-
ways use the correct type of fuel.
Never tamper with the governor to gain
more power. The governor establishes

MR--05112 PA SERIES PUMPS
PAGE A -- 3
SAFETY
safe operating limits that should not be
exceeded. Refer to the pump Perfor-
mance Curve for the maximum continu-
ous operating speed.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO
PRIME
Strainer clogged. Check strainer and clean if neces-
sary.
Suction lift or discharge head too high. Check piping installation and install
bypass line if needed. See INSTAL-
LATION.
Leakingor worn seal or pumpgasket. Check pump vacuum. Replace
leakingorwornsealorgasket.
Lining of suction hose collapsed. Replace suction hose.
Air leak in suction line. Correct leak.
Discharge check valve contami-
nated, damaged, or unable to seat. Clean or replace check valve.
Aircompressorhead180_out. Consult factory.
Air compressor damaged or belts bro-
ken. Check and repair/replace.
Eductor safety valve leaking. Check and replace safety valve.
Pump speed too slow (engine driven
units). Check driver output; consult driver
operation manual.
Eductor clogged. Check and clean eductor.
PA SERIES PUMPS MR--05112
TROUBLESHOOTING PAGE B -- 1
TROUBLESHOOTING --- SECTION B
Review all SAFETY information in Section A.
Beforeattemptingtoopenorservicethe
pump:
1. Familiarize yourselfwith thismanual.
2. Shut down the engine and discon-
nect the positive battery cable (en-
gine driven units) or lock out and tag
out incoming power to the control
box (electric motor driven units) and
take precautions 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 REQUIRES
TOO MUCH
POWER
PUMP CLOGS
FREQUENTLY
Impellerorotherwearingpartsworn
or damaged.
Free impeller of debris.Impeller clogged.
Replace worn or damaged parts.
Check that impeller is properly
centered and rotates freely.
Discharge head too high.
Measure lift w/vacuum gauge. Re-
duce lift and/or friction losses in
suction line.
Suction lift too high.
Install bypass line.
Pump speed too slow (engine driven
units). Check driver output; consult driver
operation manual.
Pump speed too high (engine driven
units). Check driver output.
Discharge head too low.
Dilute if possible.Liquid solution too thick.
Adjust discharge valve.
Pump or jack shaft bearing(s) frozen. Disassemble, check and replace
bearing(s) as required..
Liquid solution too thick.
Open discharge valve fully to in-
crease flow rate, and run engine at
maximum governed speed.
Discharge flow too slow.
Dilute if possible.
Suction check valve or foot valve
clogged or binding. Clean valve.
Suction intake not submerged at
proper level or sump too small. Check installation and correct submergence as needed.
Discharge check valve clogged. Check and clean check vavle.
Strainer clogged. Check strainer and clean if neces-
sary.
Belt or flexible coupling broken. Check and replace as necessary.
Extreme ambient temperature. Reduce pump output.
Fuel filter clogged (engine driven
units. Check & replace often in extreme operating conditions.
Check and replace as required.
Fuel contaminated (engine driven
units).
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE Air leak in suction line. Correct leak.
Lining of suction hose collapsed. Replace suction hose.
Leakingor worn seal or pumpgasket. Check pump vacuum. Replace
leakingorwornsealorgasket.
Eductor clogged. Check and clean eductor.
MR--05112 PA SERIES PUMPS
TROUBLESHOOTINGPAGE B -- 2

PA SERIES PUMPS MR--05112
TROUBLESHOOTING PAGE B -- 3
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
BEARINGS RUN
TOO HOT Bearing temperature is high, but
within limits.
Align drive properly.Drive misaligned.
Checkpipinginstallationforproper
support.
Suction and discharge lines not prop-
erly supported.
Check for proper type and level of
lubricant.
Low or incorrect lubricant.
Check bearing temperature regu-
larly to monitor any increase.
Check belt tension. Adjust as
required.
Excessivetensionondrivebelt.
EXCESSIVE NOISE Cavitation in pump. Reduce suction lift and/or friction
losses in suction line. Record vac-
uum and pressure gauge readings
and consult local representative or
factory.
Clean out debris; replace damaged
parts.
Impeller clogged or damaged.
Secure mounting hardware.Pump or drive not securely mounted.
Locate and eliminate source of air
bubble.
Pumping entrained air.
PREVENTIVE MAINTENANCE
Sincepumpapplicationsareseldomidentical,and
pump wear is directly affected by such things as
the abrasive qualities, pressure and temperature
oftheliquidbeingpumped, thissectionisintended
only to provide general recommendations and
practices for preventive maintenance. Regardless
of the application however, following a routine pre-
ventive maintenance schedule will help assure
trouble-free performance and long life from your
Gorman-Rupp pump. For specific questions con-
cerning your application, contact your Gorman-
Rupp 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
equipped) between regularly scheduled inspec-
tions can indicate problems that can be corrected
before system damage or catastrophic failure oc-
curs.Theappearanceofwearingpartsshouldalso
bedocumentedateach inspectionforcomparison
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
beforefailureoccurs,reducingunscheduleddown
time.
For new applications, a first inspection of wearing
partsat250hourswillgiveinsightintothewearrate
foryourparticularapplication.Subsequentinspec-
tions should be performed at the intervals shown
on the chart below. Critical applications should be
inspected more frequently.

MR--05112 PA SERIES PUMPS
TROUBLESHOOTINGPAGE B -- 4
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.) I
Pump Performance (Gauges, Speed, Flow) I
Bearing Lubrication I R
Seal Lubrication (And Packing Adjustment,
If So Equipped) I R
V-Belts (If So Equipped) I
Air Release Valve Plunger Rod (If So Equipped) I C
Front Impeller Clearance (Wear Plate) I
Rear Impeller Clearance (Seal Plate) I
Check Valve I
Pressure Relief Valve (If So Equipped) C
Pump and Driver Alignment I
Shaft Deflection I
Bearings I
Bearing Housing I
Piping I
Driver Lubrication --- See Mfgr’s Literature
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.
Preventive Maintenance Schedule
Item Daily Weekly Monthly Semi-
Annually Annually
Service Interval*

PA SERIES PUMPS MR--05112
TROUBLESHOOTING PAGE B -- 5
This page intentionally blank.

MR--05112
PA SERIES PUMPS
MAINTENANCE & REPAIR PAGE C -- 1
PUMP MAINTENANCE AND REPAIR --- SECTION C
Review all SAFETY information in Section A.
Followtheinstructionsonall tags,labelandde-
cals attached to the pump.
Before attempting to install, operate, or
service this pump, familiarize yourself
with this manual, and with all other liter-
ature shipped with the pump. Unfamil-
iarity with all aspects of operation or
maintenance could lead to destruction
of equipment, injury or death toperson-
nel.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam-
age to equipment. If slingsor chainsare
used to move the pump or components,
make sure that the load is balanced;
otherwise serious personal injury or
death could result. 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.
The maintenance and repair instructions in this
manual are keyed to the sectional views and the
corresponding parts identification lists on the fol-
lowingpages.RefertotheseparatePartsListMan-
ual for replacement parts.
This Maintenance and Repair Manual provides
troubleshooting instructions required to properly
diagnose operational problems. Maintenance in-
structions within this manual are limited to the
pump hydraulic, priming and drive components
only.Thepumpassemblymaybeclose-coupledto
either a factory-supplied or customer-supplied en-
gine or motor. Maintenance of engines, motors
and factory-supplied air compressors are detailed
in separate literature provided by the manufactur-
er(s).
Check TROUBLESHOOTING, Section B to deter-
mine causes and remedies of pump problems.
Disassemble the pump only as far as required.
As described in the SAFETY Section, this manual
willalert personnelto known procedures which re-
quire specialattention, to those which could dam-
age equipment, and to those which could be dan-
gerous topersonnel. However, this manualcannot
possibly anticipate and provide detailed precau-
tions for every situation that might occur during
maintenanceofthe unit.Therefore,itistherespon-
sibilityof the owner/maintenance personnel to en-
sure that only safe, established shop procedures
are used, and that any procedures not addressed
in this manual are performed only after establish-
ing that neither personal safety nor pump integrity
are compromised by such practices.
Select a suitable location, preferably indoors, to
perform required maintenance. All work must be
performed by qualified personnel.
Lifting
Use lifting equipment with a capacity of at least
five times the weight of the component being
lifted. When lifting the complete unit, the lifting
equipment must also be capable of lifting the
weight of any options or customer-installed acces-
sories. Suction and discharge hoses or piping
must be removed before attempting to lift the
pump.
For the approximate weight of your pump, refer to
the pump specification data sheet or contact your
Gorman-Rupp distributor or the Gorman-Rupp
Company.

PA SERIES PUMPSMR--05112
MAINTENANCE & REPAIRPAGE C -- 2
SECTION DRAWING
Figure C---1. PA6D60 Pump Model Assembly

ITEM PART NAME
NO.
NOTE: Maintenanceinstructions in thismanual are limited tothe pump hydrau-
lic, priming and drive components only. Maintenance of engines and
factory-supplied air compressors are detailed in separate literature pro-
vided by the manufacturer(s).
MR--05112
PA SERIES PUMPS
MAINTENANCE & REPAIR PAGE C -- 3
PA6D60 Pump Model Assembly
Part Identification List
Refer to the separate Parts List Manual for serviceable parts, part numbers and quantities.
1PUMPENDASSEMBLY
2 HEX HD CAPSCREW
3GASKET
4PRIMINGCHAMBERASSY

PA SERIES PUMPSMR--05112
MAINTENANCE & REPAIRPAGE C -- 4
SECTION DRAWING
SHAFT END VIEW
Figure C---2. PA6D60 Pump End Assembly

ITEM
NO. PART NAME ITEM NO. PART NAME
MR--05112
PA SERIES PUMPS
MAINTENANCE & REPAIR PAGE C -- 5
PA6D60 Pump End Assembly
Part Identification List
Refer to the separate Parts List Manual for serviceable parts, part numbers and quantities.
1PUMPCASING
2STUD
3LOCKWASHER
4HEXNUT
5 SUCTION SPOOL
6 SEALING WASHER
7JAMNUT
8 HEX HD CAPSCREW
9 SUCT SPOOL GASKET
10 PIPE PLUG
11 PIPE PLUG
12 VENTED PLUG
13 PIPE PLUG
14 SIGHT GAUGE
15 REPAIR ROTATING ASSY
16 HEX HD CAPSCREW
17 LOCKWASHER
18 ROT ASSY SHIM SET
19 PIPE PLUG
20 PIPE PLUG
21 NIPPLE
22 WEAR PLATE O-RING
23 WEAR PLATE O-RING
24 WEAR PLATE ASSY
25 BALL VALVE 1”
26 HEX NUT
27 LOCKWASHER
28 SEALING WASHER
29 FLAT WASHER
30 MOUNTING FOOT
31 STUD
32 LOCKWASHER
33 HEX NUT
34 MTG PAD GASKET
35 HEX HD CAPSCREW
36 LOCKWASHER
37 MOUNTING PAD
38 WEAR PLATE ADJ SHIM

PA SERIES PUMPSMR--05112
MAINTENANCE & REPAIRPAGE C -- 6
SECTION DRAWING
Figure C---3. PA6D60 Rotating Assembly

ITEM PART NAME
NO.
MR--05112
PA SERIES PUMPS
MAINTENANCE & REPAIR PAGE C -- 7
PA6D60 Rotating Assembly
Part Identification List
Refer to the separate Parts List Manual for serviceable parts, part numbers and quantities.
1 IMPELLER
2 SEAL ASSEMBLY
3INBOARDBEARING
4BEARINGHOUSING
5VENTEDPLUG
6AIRVENT
7 RED PIPE BUSHING
8OUTBOARDBEARING
9DRIVEFLANGE
10 KEY
11 IMPELLER SHAFT
12 OIL SEAL
13 SNAP RING
14 HEX HD CAPSCREW
15 LOCKWASHER
16 BRG HOUSING GASKET
17 OIL SEAL
18 HEX HD CAPSCREW
19 LOCKWASHER
20 SEAL PLATE
21 SOC HD CAPSCREW
22 IMPELLER WASHER
23 SIGHT GAUGE
24 BRG CVTY DRAIN PLUG
25 SEAL CVTY DRAIN PLUG
26 SIGHT GAUGE
27 INTERMEDIATE GUARD
28 SHAFT SLEEVE O-RING
29 IMP ADJ SHIM SET
30 SHAFT SLEEVE
31 SHIPPING PLUG
32 SHIPPING PLUG
33 ROTATING ASSY O-RING
34 SEAL PLATE O-RING
35 BRG HOUSING SHIM SET

PA SERIES PUMPSMR--05112
MAINTENANCE & REPAIRPAGE C -- 8
SECTION DRAWING
Figure C---4. Drive Assembly (Engine Driven Unit)