GORMAN-RUPP PUMPS PRIME-AIRE Series Operating instructions

PUBLICATION NUMBER MR−05861
April 4, 2006
Use With: OM−04402
THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
ECopyright by the Gorman-Rupp Company
PRIME-AIRERSERIES
PA6A Model Pumps
(Including Model 66E Pump End)

Register your new
Gorman-Rupp pump online at
www.grpumps.com/register.
Valid serial number and e-mail address required.
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:
The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects or
other reproductive harm.

MR−05861 PA SERIES PUMPS
PAGE I − 1INTRODUCTION
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.
The Installation/Operation Manual contains essen-
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
list for your pump.
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, consult the separate literature provided by
the manufacturers.
This pump is a PA Series, priming-assisted centrif-
ugal model. The unit is designed for handling non-
volatile, non-flammable liquids containing speci-
fied entrained solids. For specific service, contact
your Gorman-Rupp distributor or the Gorman-
Rupp Company.
As described on the following page, this manual
will alert personnel to known procedures which re-
quire special attention, to those which could dam-
age equipment, and to those which could be dan-
gerous to personnel. However, this manual cannot
possibly anticipate and provide detailed precau-
tions for every situation that might occur during
maintenance of the unit. Therefore, it is the respon-
sibility of the owner/maintenance personnel to en-
sure that only safe, established maintenance pro-
cedures are used, and that any procedures not ad-
dressed in this manual are performed only after es-
tablishing that neither personal safety nor pump in-
tegrity are compromised by such practices.
If there are any questions regarding the pump
which are not covered in this manual or in 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
or
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
CONTENTS
SAFETY − SECTION A
TROUBLESHOOTING − SECTION B
PUMP MAINTENANCE AND REPAIR − SECTION C
DRAWINGS AND IDENTIFICATION LISTS PAGES C − 2 THRU C−9. . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE C − 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor Drive Belt Tensioning For Deutz Engine Driven Models PAGE C − 11. . . . . . . . . .
Priming Chamber Removal and Disassembly PAGE C − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Casing And Wear Plate Removal PAGE C − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Oil From Seal Cavity PAGE C − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller Removal PAGE C − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Removal PAGE C − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separating Intermediate And Drive Assembly From Engine PAGE C − 13. . . . . . . . . . . . . . . . . . . .
Shaft and Bearing Removal And Disassembly PAGE C − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft and Bearing Reassembly and Installation PAGE C − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Securing Intermediate And Drive Assembly To Engine PAGE C − 15. . . . . . . . . . . . . . . . . . . . . . . . .
Seal Reassembly And Installation PAGE C − 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impeller Installation And Adjustment PAGE C − 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MR−04821 PA SERIES PUMPS
PAGE I − 2 INTRODUCTION
CONTENTS (Cont’d)
Pump Casing And Wear Plate Installation PAGE C − 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming Chamber Assembly And Installation PAGE C − 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION PAGE C − 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Assembly PAGE C − 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings PAGE C − 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Unit PAGE C − 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECORDING MODEL AND
SERIAL NUMBERS
Please record the 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:
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 result in
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.
Hazards or unsafe practices which COULD
result in minor personal injury or product or
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.

PA SERIES PUMPSMR−05861
SAFETY PAGE A − 1
SAFETY − SECTION A
The following information applies
throughout this manual to Gorman-
Rupp Prime AiretSeries 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, this manual cannot possibly antici-
pate and provide detailed instructions
and 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 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 pump operation
covered in this manual could lead to de-
struction of equipment, injury, or death
to personnel.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man-
ual.
2. Shut down the engine, disconnect
the positive battery cable and take
precautions to ensure that the
pump will remain inoperative.
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.
This pump is may be used to handle ma-
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
will be balanced. The bail is intended for
use in lifting the pump assembly only.
Suction and discharge hoses and pip-
ing must be removed from the pump be-
fore lifting.
After the pump has been installed, make

MR−05861PA SERIES PUMPS
PAGE A − 2 SAFETY
certain that the pump and all piping or
hose connections are tight, properly
supported and secure before operation.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over-
heated pump. Vapor pressure within the
pump can cause parts being disen-
gaged to be ejected with great force. Al-
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. Allow the pump to completely cool.
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 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 en-
gines 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 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
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.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
leaking or worn seal or gasket.
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.
Air compressor head 180_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. Check driver output; consult driver
operation manual.
Eductor clogged. Check and clean eductor.
PA SERIES PUMPS MR−05861
TROUBLESHOOTING PAGE B − 1
TROUBLESHOOTING − SECTION B
Review all SAFETY information in Section A.
Before attempting to open or service the
pump:
1. Familiarize yourself with this manual.
2. Shut down the engine and discon-
nect the positive battery cable and
take precautions to ensure that the
pump will remain inoperative.
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
Impeller or other wearing parts worn
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. Check driver output; consult driver
operation manual.
Pump speed too high. 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.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
leaking or worn seal or gasket.
Eductor clogged. Check and clean eductor.
MR−05861 PA SERIES PUMPS
TROUBLESHOOTINGPAGE B − 2

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
BEARINGS
RUN TOO HOT
Bearing temperature is high, but
within limits.
Align drive properly.Drive misaligned.
Check piping installation for proper
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.
Excessive tension on drive belt.
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.
PA SERIES PUMPS MR−05861
TROUBLESHOOTING PAGE B − 3

MR−05861
PA SERIES PUMPS
MAINTENANCE & REPAIR PAGE C − 1
PUMP MAINTENANCE AND REPAIR − SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and de-
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 to person-
nel.
Use lifting and moving equipment in
good repair and with adequate capacity
to prevent injuries to personnel or dam-
age 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. 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-
lowing pages. Refer to the separate Parts List Man-
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. The pump assembly may be close-coupled to
either a factory-supplied or customer-supplied en-
gine. Maintenance of engines and factory-supplied
air compressors are detailed in separate literature
provided by the manufacturer(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
will alert personnel to known procedures which re-
quire special attention, to those which could dam-
age equipment, and to those which could be dan-
gerous to personnel. However, this manual cannot
possibly anticipate and provide detailed precau-
tions for every situation that might occur during
maintenance of the unit. Therefore, it is the respon-
sibility of 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.