GORMAN-RUPP PUMPS PA Series Application guide

OM-06440-01
April 11, 2011
Rev. A 04‐03‐15
GORMAN‐RUPP PUMPS
www.grpumps.com
2011 Gorman‐Rupp Pumps Printed in U.S.A.
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
PA SERIESPUMPS
MODELS
PA4A60C‐B‐E30 460/575/3
PA4A60C-B-(E30)

Register your new
Gorman‐Rupp pump online at
www.grpumps.com
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:

TABLE OF CONTENTS
i
INTRODUCTION PAGE I - 1.................................................
SAFETY ‐ SECTION A PAGE A - 1............................................
INSTALLATION - SECTION B PAGE B - 1....................................
Pump Dimensions PAGE B - 1.....................................................
PREINSTALLATION INSPECTION PAGE B - 2............................................
POSITIONING PUMP PAGE B - 2.......................................................
Lifting PAGE B - 2.................................................................
Mounting PAGE B - 2.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 3.........................................
Materials PAGE B - 3..............................................................
Line Configuration PAGE B - 3......................................................
Connections to Pump PAGE B - 3..................................................
Gauges PAGE B - 3...............................................................
SUCTION LINES PAGE B - 3...........................................................
Fittings PAGE B - 3...............................................................
Strainers PAGE B - 3..............................................................
Sealing PAGE B - 4...............................................................
Suction Lines In Sumps PAGE B - 4.................................................
Suction Line Positioning PAGE B - 4................................................
DISCHARGE LINES PAGE B - 5........................................................
Siphoning PAGE B - 5.............................................................
Valves PAGE B - 5................................................................
ELECTRICAL CONNECTIONS PAGE B - 5...............................................
Grouding Methods PAGE B - 6.....................................................
Field Wiring Connections (Incoming Power) PAGE B - 6...............................
Voltage Imbalance PAGE B - 7.....................................................
Power Cable Connections PAGE B - 7...............................................
Control Box Adjustment PAGE B - 7.................................................
ALIGNMENT PAGE B - 7..............................................................
AUTO‐START PAGE B - 8.............................................................
Float Switch Installation PAGE B - 8.................................................
Submersible Transducer Installation PAGE B - 9......................................
OPERATION - SECTION C PAGE C - 1......................................
STARTING AND OPERATION PAGE C - 1...............................................
Control Box Function PAGE C - 1...................................................
Component Function PAGE C - 1...................................................
Rotation PAGE C - 2..............................................................
Priming PAGE C - 2...............................................................
Leakage PAGE C - 2..............................................................
Pump Vacuum Check PAGE C - 3..................................................
Priming Chamber Discharge Line PAGE C - 3........................................
Liquid Temperature And Overheating PAGE C - 3.....................................
Strainer Check PAGE C - 3.........................................................
STOPPING PAGE C - 3................................................................
Manual Stopping PAGE C - 3.......................................................

TABLE OF CONTENTS
(continued)
ii
Automatic Stopping PAGE C - 3....................................................
PERIODIC CHECKS PAGE C - 3.......................................................
Seal Cavity and Bearing Lubrication PAGE C - 3......................................
Bearing Temperature Check PAGE C - 3.............................................
Air Compressor Drive Belt PAGE C - 4...............................................
COLD WEATHER PRESERVATION PAGE C - 4...........................................
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........................................
PARTS LISTS:
Pump Model PAGE E - 3..........................................................
Pump End Assembly PAGE E - 5...................................................
Repair Rotating Assembly PAGE E - 9...............................................
Priming Chamber Kit PAGE E - 10...................................................
Priming Chamber Assembly PAGE E - 11.............................................
Air Compressor Assembly PAGE E - 12...............................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 13.........................
Priming Chamber Removal And Disassembly PAGE C - 14..............................
Discharge Check Valve Removal and Disassembly PAGE C - 14.........................
Back Cover Plate and Wear Plate Removal PAGE C - 14................................
Separating Pump And Drive Assembly From Engine PAGE C - 14........................
Draining Oil From Seal Cavity PAGE C - 15............................................
Loosening Impeller PAGE C - 15.....................................................
Pump Casing Removal PAGE C - 15.................................................
Impeller Removal PAGE C - 16......................................................
Seal Removal PAGE C - 16..........................................................
Shaft and Bearing Removal and Disassembly PAGE C - 16.............................
Shaft and Bearing Reassembly and Installation PAGE C - 17............................
Seal Reassembly and Installation PAGE C - 18........................................
Impeller Installation And Adjustment PAGE C - 20......................................
Pump Casing Installation PAGE C - 20................................................
Securing Pump End To Power Source PAGE C - 20....................................
Wear Plate and Back Cover Installation And Adjustment PAGE C - 20....................
Discharge Check Valve Reassembly And Installation PAGE C - 21.......................
Priming Chamber Assembly And Installation PAGE C - 22...............................
LUBRICATION PAGE C - 22.............................................................
Seal Assembly PAGE C - 22.........................................................
Bearings PAGE C - 22..............................................................

PA SERIES OM-06440
PAGE I - 1INTRODUCTION
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.
Because pump installations are seldom identical,
this manual cannot possibly provide detailed in
structions and precautions for every aspect of
each specific application. Therefore, it is the re
sponsibility 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 com
promised by the installation. Pumps and related
equipment must be installed and operated ac
cording to all national, local and industry stan
dards.
If there are any questions regarding the pump or
its application which are not covered in this man
ual or in other literature accompanying this 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]
For information or technical assistance on the
power source, contact the power source manufac
turer's local dealer or representative.
HAZARD AND INSTRUCTION
DEFINITIONS
The following are used to alert maintenance per
sonnel to procedures which require special atten
tion, 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
describe the requirements and the possi
ble 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 OM-06440
PAGE A - 1SAFETY
SAFETY ‐ SECTION A
This information applies to Prime Airr
Series pumps. Refer to the manual ac
companying the engine or power
source before attempting to begin oper
ation.
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
wire the pump control box, familiarize
yourself with this manual, and with all
other literature shipped with the control
box. Unfamiliarity with all aspects of
control operation covered in this manu
al could lead to destruction of equip
ment, injury, or death to personnel.
Before connecting any cable to the con
trol box, be sure to ground the control
box. See Section B for suggested
grounding methods.
The control box provides overload pro
tection and power control. Do not con
nect the pump motor directly to the in
coming power lines. If the power circuit
breaker or overload relay is tripped dur
ing operation, correct the problem be
fore resetting or replacing.
The electrical power used to operate the
pump control box is high enough to
cause injury or death. Obtain the ser
vices of a qualified electrician to make
all electrical connections. Make certain
that the enclosure is properly
grounded; never use gas pipe as an
electrical ground. Be sure that the in
coming power matches the voltage and
phase of the control before connecting
the power source. Do not make electri
cal connections if the voltage is not
within the limits. If the overload unit is
tripped during operation, correct the
problem before restarting.
The electrical power used to operate the
pump control box is high enough to
cause injury or death. Make certain that
the control handle on the control box is
in the OFF position and locked out be
fore attempting to service the pump. Be
fore attempting to open or service the
control box, disconnect and/or lock out
the power supply to the control box. Tag
electrical circuits to prevent accidental
start‐up.

PA SERIESOM-06440
PAGE A - 2 SAFETY
Obtain the services of a qualified elec
trician to troubleshoot, test and/or ser
vice the electrical components of the
control box.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Lock out the power from the con
trol box 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 may be equipped with an op
tional automatic starting system, and
therefore subject to automatic restart.
Keep hands and clothing away from the
unit to prevent injury during automatic
operation. Lock out the power from the
control box to ensure that the pump will
remain inoperative. Failure to do so
may result in serious personal injury.
Do not attempt to disengage any part of
an overheated pump unit. Vapor pres
sure within the pump casing can eject
these parts with great force when they
are disengaged. Allow the pump to
completely cool before servicing it.
This pump is designed to handle most
non‐volatile, non‐flammable liquids
containing specified entrained solids.
Do not attempt to pump volatile, corro
sive, or flammable liquids which may
damage the pump or endanger person
nel as a result of pump failure.
Death or serious personal injury and
damage to the pump or components
can occur if proper lifting procedures
are not observed. Make certain that
hoists, chains, slings or cables are in
good working condition and of suffi
cient capacity and that they are posi
tioned so that loads will be balanced
and the pump or components will not be
damaged when lifting. Suction and dis
charge hoses and piping must be re
moved from the pump before lifting. Lift
the pump or component only as high as
necessary and keep personnel away
from suspended objects.
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
liquid could come to a boil, build pres
sure, and cause the pump casing to rup
ture or explode. Momentary closure of a

PA SERIES OM-06440
PAGE A - 3SAFETY
discharge valve is acceptable only
when required for startup or shutdown
procedures.
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 completely before
servicing.
Do not operate the pump without guards
in place over the rotating parts. Ex
posed rotating parts can catch clothing,
fingers or tools, causing severe injury to
personnel.
Pumps and related equipment must be in
stalled and operated according to all na
tional, local and industry standards.
Make sure the pump is level. Lower jack
stands and chock the wheels, if so
equipped.

PA SERIES OM-06440
PAGE B - 1INSTALLATION
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 ar
range 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.
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
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
See Figure 1 for the approximate physical dimen
sions of this pump.
OUTLINE DRAWING
Figure 1. Pump Model PA4A60C-B-E30 460/575/3

OM-06440 PA SERIES
PAGE B - 2 INSTALLATION
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be
fore shipment from the factory. Before installation,
inspect the pump for damage which may have oc
curred during shipment. Check as follows:
a. Inspect the pump for cracks, dents, damaged
threads, and other obvious damage.
b. Check for and tighten loose attaching hard
ware. Since gaskets tend to shrink after dry
ing, check for loose hardware at mating sur
faces.
c. Compare the amperes, phase, voltage and
hertz indicated on the pump motor nameplate
to the ratings indicated for the control box.
d. 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 in
dicated by the arrow on the pump body
and on the accompanying decal. Other
wise, the impeller could become loosened
from the shaft and seriously damage the
pump.
e. Check levels and lubricate as necessary. Re
fer to LUBRICATION in the Maintenance and
Repair Manual and perform duties as in
structed.
f. If the pump has been stored for more than 12
months, some of the components or lubri
cants may have exceeded their maximum
shelf life. These must be inspected or re
placed 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 deter
mine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.
POSITIONING PUMP
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.
Lifting
Death or serious personal injury and
damage to the pump or components
can occur if proper lifting procedures
are not observed. Make certain that
hoists, chains, slings or cables are in
good working condition and of suffi
cient capacity and that they are posi
tioned so that loads will be balanced
and the pump or components will not be
damaged when lifting. Suction and dis
charge hoses and piping must be re
moved from the pump before lifting. Lift
the pump or component only as high as
necessary and keep personnel away
from suspended objects.
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.