GORMAN-RUPP PRIME-AIRE PA4B Series Operating instructions

PUBLICATION NUMBER MR--04835
March 25, 1998
Rev. A 04/23/99
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-AIREr
rr
rSERIES
PA4B Model Pumps
(Including Model 64B Pump Ends)

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

MR--04835 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 manual covers high head PA Series priming-
assisted models, which incorporate a 60 Series
straight centrifugal pump end. The pump is de-
signed for high pressure distribution of non-vola-
tile, non-flammable liquids that do not contain
largeentrainedsolids. Forspecific service,contact
your Gorman-Rupp distributor or the Gorman-
Rupp Company.
As described on the following page, this manual
willalert personnel toknown 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
maintenanceoftheunit.Therefore,itistherespon-
sibility of 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
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---7...........................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE C --- 8............................
Air Compressor Drive Belt Tensioning For Deutz Engine Driven Models PAGE C --- 9...........
Priming Chamber Removal and Disassembly PAGE C --- 9.................................
Discharge Check Valve Removal and Disassembly PAGE C --- 9............................
Suction Head Removal PAGE C --- 9.....................................................
Impeller Removal PAGE C --- 10.........................................................
Seal Removal and Disassembly PAGE C --- 10............................................
Pump Casing Removal PAGE C --- 10....................................................
Separating Intermediate and Drive Assembly From Engine PAGE C --- 10....................
Shaft And Bearing Removal And Disassembly PAGE C --- 11................................
Shaft and Bearing Reassembly and Installation PAGE C --- 11...............................
Securing Intermediate And Drive Assembly To Engine PAGE C --- 12.........................

MR--04835PA SERIES PUMPS
PAGE I -- 2 INTRODUCTION
Pump Casing Installation PAGE C --- 14..................................................
Seal Reassembly and Installation PAGE C --- 14...........................................
Impeller Installation PAGE C --- 15.......................................................
Suction Head Installation PAGE C --- 16..................................................
Discharge Check Valve Assembly And Installation PAGE C --- 16............................
Priming Chamber Assembly And Installation PAGE C --- 17.................................
Final Pump Assembly PAGE C --- 17.....................................................
LUBRICATION PAGE C --- 17..............................................................
Seal Assembly PAGE C --- 17...........................................................
Bearings PAGE C --- 18................................................................
Engine PAGE C --- 18..................................................................
RECORDING MODEL AND
SERIAL NUMBERS
Please record the pump modeland 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 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.
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--04835 PA SERIES PUMPS
PAGE A -- 1
SAFETY
SAFETY --- SECTION A
The following information applies
throughout this manual to Gorman-
Rupp Prime Airer
rr
rSeries 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 responsibility of
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 pump operation
coveredinthismanual couldlead tode-
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 or
take other precautions to ensure
that the pump will remain inopera-
tive.
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 designed for high pres-
sure distribution of most non-volatile,
non-flammable liquids that do not con-
tain large entrained solids. Do not at-
tempt to pump volatile, flammable liq-
uidswhichmaydamagethepump oren-
danger 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 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
willbebalanced.Thebailisintendedfor
use in lifting the pump assembly only.
Suction and discharge hoses and pip-
ing must beremoved fromthe pumpbe-
fore lifting.
Afterthepumphasbeen installed,make
certain that the pump and all piping or

PA SERIES PUMPS MR--04835
PAGE A-- 2 SAFETY
hose connections are tight, properly
supportedandsecurebeforeoperation.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over-
heatedpump. Vaporpressure 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. 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
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 pump gasket. 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. Check driver output; consult driver
operation manual.
Eductor clogged. Check and clean eductor.
PA SERIES PUMPS MR--04835
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-
nectthepositivebatterycableortake
other 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. 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.
Leakingor worn seal or pump gasket. Check pump vacuum. Replace
leakingorwornsealorgasket.
Eductor clogged. Check and clean eductor.
MR--04835 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.
Checkpipinginstallation forproper
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.
PA SERIES PUMPS MR--04835
TROUBLESHOOTING PAGE B -- 3

MR--04835 PA SERIES PUMPS
TROUBLESHOOTINGPAGE B -- 4
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.
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*