GORMAN-RUPP PA4A60-4024T-ESP User manual

OM-06301-02
March 16, 2015
GORMAN‐RUPP PUMPS
www.grpumps.com
2015 Gorman‐Rupp Pumps Printed in U.S.A.
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
PA SERIESPUMP
MODEL
PA4A60-4024T-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:
The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects or
other reproductive harm.

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 Installation 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................................................................
ALIGNMENT PAGE B - 5..............................................................
AUTO‐START PAGE B - 5.............................................................
Float Switch Installation PAGE B - 6.................................................
OPERATION - SECTION C PAGE C - 1......................................
OPERATION PAGE C - 1..............................................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 1................................................................
Manual Starting PAGE C - 1........................................................
Automatic Starting PAGE C - 2.....................................................
Priming PAGE C - 2...............................................................
Routine Operation PAGE C - 2......................................................
Operation In Extreme Heat PAGE C - 2..............................................
OPERATIONAL CHECKS PAGE C - 2...................................................
Leakage PAGE C - 2..............................................................
Pump Vacuum Check PAGE C - 3..................................................
Liquid Temperature And Overheating PAGE C - 3.....................................
Strainer Check PAGE C - 3.........................................................
STOPPING PAGE C - 3................................................................
Manual Stopping PAGE C - 3.......................................................
Automatic Stopping PAGE C - 3....................................................
Safety Shutdown System PAGE C - 4...............................................

TABLE OF CONTENTS
(continued)
ii
PERIODIC CHECKS PAGE C - 4.......................................................
Seal Cavity and Bearing Lubrication PAGE C - 4......................................
Bearing Temperature Check PAGE C - 4.............................................
Air Compressor PAGE C - 4........................................................
Additional Checks PAGE C - 4......................................................
COLD WEATHER PRESERVATION PAGE C - 5...........................................
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..........................................................
Power Unit Kit PAGE E - 5.........................................................
Pump 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 - 15..............................
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.................................
Discharge Check Valve Reassembly And Installation PAGE E - 24.......................
Priming Chamber Assembly And Installation PAGE E - 24...............................
LUBRICATION PAGE E - 25.............................................................
Seal Assembly PAGE E - 25.........................................................
Bearings PAGE E - 25..............................................................
Engine PAGE E - 25................................................................

PA SERIES OM-06301
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.