GORMAN-RUPP PUMPS PA Series User manual

OM-07208-01
November 27, 2018
GORMAN‐RUPP PUMPS
www.grpumps.com
e2018 Gorman‐Rupp Pumps Printed in U.S.A.
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
PA SERIESrPUMP
MODEL
PA4A60C-ZPP428-ESP

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 - 1............................................
Battery Specifications And Installation PAGE B - 2....................................
SAFETY AND CONFORMANCE PAGE B - 2.............................................
POSITIONING PUMP PAGE B - 3.......................................................
Lifting PAGE B - 3.................................................................
Mounting PAGE B - 3.............................................................
Clearance PAGE B - 3.............................................................
NATURAL GAS FUEL PAGE B - 3......................................................
LPG FUEL PAGE B - 3................................................................
FUEL TANK (LPG ONLY) PAGE B - 4....................................................
REGULATORS (NATURAL GAS) PAGE B - 4.............................................
REGULATORS (LP GAS) PAGE B - 4...................................................
CONNECTING FUEL SUPPLY LINE TO THE UNIT PAGE B - 5.............................
CHANGING FUEL TYPE PAGE B - 5....................................................
SUCTION AND DISCHARGE PIPING PAGE B - 5.........................................
Materials PAGE B - 5..............................................................
Line Configuration PAGE B - 5......................................................
Connections to Pump PAGE B - 5..................................................
Gauges PAGE B - 5...............................................................
SUCTION LINES PAGE B - 6...........................................................
Fittings PAGE B - 6...............................................................
Strainers PAGE B - 6..............................................................
Sealing PAGE B - 6...............................................................
Suction Lines In Sumps PAGE B - 6.................................................
Suction Line Positioning PAGE B - 6................................................
SUBMERSIBLE TRANSDUCER PAGE B - 7..............................................
DISCHARGE LINES PAGE B - 8........................................................
Siphoning PAGE B - 8.............................................................
Valves PAGE B - 8................................................................
OPERATION - SECTION C PAGE C - 1......................................
OPERATION PAGE C - 1..............................................................
STARTING PAGE C - 1................................................................
PRIMING PAGE C - 1.................................................................
OPTIONAL EPS CONTROL PAGE C - 2.................................................
Features PAGE C - 2..............................................................
Functional Description PAGE C - 2..................................................
EPS Functions PAGE C - 3.........................................................
EPS Calibration PAGE C - 4........................................................
Zero Adjustment PAGE C - 4.......................................................
Span Adjustment PAGE C - 4......................................................
Level Adjustment PAGE C - 4......................................................

TABLE OF CONTENTS
(continued)
ii
Horn Delay PAGE C - 4............................................................
ROUTINE OPERATION PAGE C - 4.....................................................
Lines With a Bypass PAGE C - 5....................................................
Lines Without a Bypass PAGE C - 5.................................................
OPERATION IN EXTREME HEAT PAGE C - 5............................................
OPERATIONAL CHECKS PAGE C - 5...................................................
Leakage PAGE C - 5..............................................................
Pump Vacuum Check PAGE C - 5..................................................
Liquid Temperature And Overheating PAGE C - 5.....................................
Strainer Check PAGE C - 6.........................................................
STOPPING PAGE C - 6................................................................
Manual Stopping PAGE C - 6.......................................................
Automatic Stopping PAGE C - 6....................................................
Safety Shutdown System PAGE C - 6...............................................
PERIODIC CHECKS PAGE C - 6.......................................................
Seal Cavity and Bearing Lubrication PAGE C - 6......................................
Bearing Temperature Check PAGE C - 6.............................................
Engine Fuel Filter PAGE C - 7......................................................
Engine Oil PAGE C - 7.............................................................
COLD WEATHER PRESERVATION PAGE C - 7...........................................
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 Model (Cont'd) PAGE E - 5...................................................
Pump End Assembly PAGE E - 7...................................................
Pump End Assembly PAGE E - 9...................................................
Repair Rotating Assembly PAGE E - 11...............................................
Priming Chamber Kit PAGE E - 12...................................................
Priming Chamber Assembly PAGE E - 13.............................................
Drive Assembly PAGE E - 14........................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 15.........................
Priming Chamber Removal And Disassembly PAGE E - 16..............................
Discharge Check Valve Removal and Disassembly PAGE E - 16.........................
Separating Pump And Drive Assembly From Engine PAGE E - 16........................
Draining Oil From Seal Cavity PAGE E - 17............................................
Loosening Impeller PAGE E - 17.....................................................
Pump Casing And Wear Plate Removal PAGE E - 17...................................
Impeller Removal PAGE E - 18......................................................
Seal Removal PAGE E - 18..........................................................
Shaft and Bearing Removal and Disassembly PAGE E - 18.............................
Shaft and Bearing Reassembly and Installation PAGE E - 19............................
Securing Bearing Housing And Drive Assembly To Engine PAGE E - 20..................
Seal Reassembly and Installation PAGE E - 21........................................
Impeller Installation And Adjustment PAGE E - 24......................................
Pump Casing And Wear Plate Installation PAGE E - 24.................................

TABLE OF CONTENTS
(continued)
iii
Discharge Check Valve Reassembly And Installation PAGE E - 24.......................
Priming Chamber Assembly And Installation PAGE E - 25...............................
LUBRICATION PAGE E - 25.............................................................
Seal Assembly PAGE E - 25.........................................................
Bearings PAGE E - 25..............................................................
Engine PAGE E - 25................................................................

PA SERIES OM-07208
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-07208
PAGE A - 1SAFETY
SAFETY ‐ SECTION A
This information applies to Prime Airer
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 pro
vide detailed instructions and precau
tions for each specific application or for
every situation that might occur during
maintenance of the unit. Therefore, it is
the responsibility of the owner, installer
and/or maintenance personnel to en
sure that applications and/or mainte
nance procedures not addressed in this
manual are performed only after estab
lishing that neither personal safety nor
pump integrity are compromised by
such applications or procedures.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Shut down the engine, remove the
key 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 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 equipped with an automat
ic starting system, and is subject to au
tomatic restart. Keep hands and cloth
ing away from the unit to prevent injury
during automatic operation. Disconnect
the positive battery cable before per
forming any maintenance. Failure to do
so may result in serious personal injury.
This pump is designed to handle dirty
water containing specified entrained
solids. Do not attempt to pump volatile,
corrosive, or flammable liquids which
may damage the pump or endanger per
sonnel 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 unit has been installed, make
certain that the pump and all piping or

PA SERIESOM-07208
PAGE A - 2 SAFETY
hose connections are tight, properly
supported and secure before operation.
Do not operate the pump against a
closed discharge valve for long periods
of time. If operated against a closed dis
charge valve, pump components will
deteriorate, and the liquid could come
to a boil, build pressure, and cause the
pump casing to rupture or explode.
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.
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating internal combustion
engines in an enclosed area, make cer
tain that exhaust fumes are piped to the
outside. These fumes contain carbon
monoxide, a deadly gas that is color
less, tasteless, and odorless.
Natural gas presents an extreme explo
sion and fire hazard. Follow all safety
precautions outlined by the National
Fire Protection Association when de
signing and installing the system. Make
certain that the regulators and fuel lines
are of the proper size and capacity for
the system, and that all fuel lines are se
curely connected and free of leaks.
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 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 E for the maximum con
tinuous operating speed for this pump.
Pumps and related equipment must be in
stalled and operated according to all na
tional, local and industry standards.

PA SERIES OM-07208
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
DISCHARGE:
4.00 NOMINAL WITH
8 HOLES .75/[19,0] DIA
EQUALLY SPACED
ON A 7.50/[190,5] DIA BC
POWERED BY: ZENITH ZPP428 NATURAL GAS / LP ENGINE
4.00/[101,6] X
10.00/[254,0]
FORK LIFT POCKET
2 PLACES
.75/[19,0] DIA
6 HOLES
SUCTION:
4.00 NOMINAL WITH
8 HOLES .75/[19,0] DIA
EQUALLY SPACED
ON A 7.50/[190,5] DIA BC
76.87
[ 1952,5]
APPROX
18.53
[ 470,6 ]
17.13
[ 435,1 ]
48.00
[ 1219,2 ]
53.00
[ 1346,2]
59.48
[ 1510,8] APPROX
60.19
[ 1528,8]
16.97
[ 431,0 ]
APPROX.
32.17
[ 817,1 ]
64.34
[ 1634,2]
26.12
[ 663,4 ]
23.01
[ 584,6 ]
102.76
[ 2610,0] APPROX
85.50
[ 2171,7]
31.88
[ 809,8 ]
1.00
[ 25,4 ]
51.00
[ 1295,4]
10°
DIMENSIONS:
INCHES
[MILLIMETERS]
Figure 1. Pump Model PA4A60C-ZPP428-ESP
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 assembly for cracks, dents,
damaged threads, and other obvious dam
age.
b. Check for and tighten loose attaching hard
ware. Since gaskets tend to shrink after dry

OM-07208 PA SERIES
PAGE B - 2 INSTALLATION
ing, check for loose hardware at mating sur
faces.
c. Carefully read all tags, decals, and markings
on the pump assembly, and perform all duties
indicated.
d. Check levels and lubricate as necessary. Re
fer to LUBRICATION in the MAINTENANCE
AND REPAIR section of this manual and per
form duties as instructed.
e. If the pump and engine have been stored for
more than 12 months, some of the compo
nents or lubricants may have exceeded their
maximum shelf life. These must be inspected
or replaced to ensure maximum pump serv
ice.
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.
Battery Specifications And Installation
Unless otherwise specified on the pump order, the
engine battery was not included with the unit.
When selecting a battery, refer to the specifications
on the paper tag attached to the battery box in or
der to ensure the proper size and electrical charac
teristics of the battery.
Before installing the battery, clean the positive and
negative cable connectors, and the battery termi
nals. Secure the battery by tightening the
holddown brackets. The terminals and clamps
may be coated with petroleum jelly to retard corro
sion. Connect and tighten the positive cable first,
then the negative cable.
SAFETY AND CONFORMANCE
All aspects of the design and installation of the fuel
supply system must be evaluated in terms of safety
to personnel and equipment, and conformance to
all applicable codes.
Natural Gas and Liquefied Petroleum
Gas (LPG) presents an extreme explo
sion and fire hazard. Follow all safety
precautions outlined by the National
Fire Protection Association when de
signing and installing the system. Make
certain that the regulators and fuel lines
are of the proper size and capacity for
the system, and that all fuel lines are se
curely connected and free of leaks.
Before installing the system:
1. Check all state and local codes pertaining to
installations of stationary combustion engines
and fuel systems.
2. Consult the following National Fire Protection
Association pamphlet:
NFPA No. 37 - Stationary Combustion
Engines/Gas Turbines
NFPA No. 54 - National Fuel Gas Code Hand
book.
NFPA No. 37 - Liquefied Petroleum Gas Stor
age and Handling.
Copies may be ordered from:
National Fire Protection Association
1 Batterymarch Park
Quincy, Massachusets 02269