Gorman-Rupp Pumps PA4A60C-4024T-ESP 1362521 and up User Manual

ACDEU OM-06027−OE01

February 28, 2007

Rev. B 01-08-10

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

PA SERIES PUMP

MODEL

PA4A60C−4024T−ESP

THE GORMAN-RUPP COMPANY MANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA

Printed in U.S.A

www.grpumps.com.

2007 The Gorman-Rupp Company

Register your new

Gorman-Rupp pump online at www.grpumps.com

Valid serial number and e-mail address required.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

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

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE I − 1

SAFETY - SECTION A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE A − 1

INSTALLATION − SECTION B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B − 1

Pump Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREINSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Installation

POSITIONING PUMP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION AND DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections to Pump

Gauges

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fittings

Strainers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Lines In Sumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Line Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISCHARGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Siphoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTO-START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Float Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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OPERATION − SECTION C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C − 1

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRIMING

STARTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ROUTINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION IN EXTREME HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATIONAL CHECKS

Leakage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature And Overheating

Strainer Check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Shutdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS

(continued)

PERIODIC CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Cavity and Bearing Lubrication

Bearing Temperature Check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Compressor Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COLD WEATHER PRESERVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TROUBLESHOOTING − SECTION D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE D − 1

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE D − 3

PUMP MAINTENANCE AND REPAIR - SECTION E . . . . . . . . . . . . . . . . . PAGE E − 1

STANDARD PERFORMANCE CURVE

PARTS LISTS:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Unit Kit

Pump Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Rotating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Assembly

Drive Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Removal And Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Discharge Check Valve Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .

Separating Pump And Drive Assembly From Engine . . . . . . . . . . . . . . . . . . . . . . . .

Draining Oil From Seal Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loosening Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Casing And Wear Plate Removal

Impeller Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft and Bearing Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft and Bearing Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing Bearing Housing And Drive Assembly To Engine . . . . . . . . . . . . . . . . . .

Seal Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Installation And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Casing And Wear Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Discharge Check Valve Reassembly And Installation . . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Assembly And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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PA SERIES OM−06027

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. This Installation, Operation, and Maintenance manual is designed to help you achieve the best performance and longest life from your Gorman-Rupp pump.

This pump is a PA Series, priming-assisted centrifugal model. The unit is designed for handling dirty water containing specified entrained solids and slurries. The basic material of construction is ductile iron, with stainless steel shaft and ductile iron wearing parts. The pump is surrounded by a sound-attenuating enclosure.

Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and precautions for every aspect of each specific application. Therefore, it is the responsibility 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 compromised by the installation. Pumps and related equipment must be installed and operated according to all national, local and industry standards.

If there are any questions regarding the pump which are not covered in this manual or in other literature accompanying the unit, please contact your Gorman-Rupp distributor or the Gorman-

Rupp Company:

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 required 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.

The Gorman-Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901−1217

Phone: (419) 755−1011 or:

Gorman-Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631−2870

Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. These instructions describe 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 .

For information or technical assistance on the engine, contact the engine manufacturer’s local dealer or representative.

INTRODUCTION PAGE I − 1


SAFETY - SECTION A

This information applies to Prime Aire r

Series pumps. Refer to the manual accompanying the engine before attempting to begin operation.

forming any maintenance. Failure to do so may result in serious personal injury.

Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and precautions for each specific application.

Therefore, it is the owner/installer’s responsibility to ensure that applications not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity are compromised by the installation.

Do not attempt to disengage any part of an overheated pump unit. Vapor pressure 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, corrosive, or flammable liquids which may damage the pump or endanger personnel as a result of pump failure.

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

2. Shut down the engine 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 and make sure the 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.

Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or damage to equipment. Attach lifting equipment 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 piping must be removed from the pump before lifting.

This pump is equipped with an automatic starting system, and is subject to automatic restart. Keep hands and clothing away from the unit to prevent injury during automatic operation. Disconnect the positive battery cable before per-

SAFETY

After the pump has been installed, make certain that the pump and all piping or

PAGE A − 1

OM−06027 PA SERIES hose connections are tight, properly supported and secure before operation.

fingers or tools, causing severe injury to personnel.

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 pressure, and cause the pump casing to rupture or explode. Momentary closure of a discharge valve is acceptable only when required for startup or shutdown procedures.

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 remove plates, covers, gauges, pipe plugs, or fittings from an overheated pump. Vapor pressure within the pump can cause parts being disengaged to be ejected with great force. Allow the pump to cool completely before servicing.

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.

This pump may be used to handle materials which could cause illness through direct exposure or emitted fumes. Wear adequate protective clothing when working on the pump or piping.

Fuel used by internal combustion engines 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 engine. Avoid overfilling the fuel tank. Always use the correct type of fuel.

Do not operate the pump without guards in place over the rotating parts. Exposed rotating parts can catch clothing,

Never tamper with the governor to gain more power. The governor establishes safe operating limits that should not be exceeded. The maximum continuous operating speed for this pump is 1950

RPM.

PAGE A − 2 SAFETY


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 arrange the pump and piping.

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.

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.

Pump Dimensions

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

See Figure 1 for the approximate physical dimensions of this pump.

OUTLINE DRAWING

Figure 1. Pump Model PA4A60C−4024T−ESP

PREINSTALLATION INSPECTION a. Inspect the pump for cracks, dents, damaged threads, and other obvious damage.

The pump assembly was inspected and tested before shipment from the factory. Before installation, inspect the pump for damage which may have occurred during shipment. Check as follows:

INSTALLATION b. Check for and tighten loose attaching hardware. Since gaskets tend to shrink after drying, check for loose hardware at mating surfaces.

PAGE B − 1

OM−06027 PA SERIES c. 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.

POSITIONING PUMP

Only operate this pump in the direction indicated by the arrow on the pump body and on the accompanying decal. Otherwise, the impeller could become loosened from the shaft and seriously damage the pump.

d. Check levels and lubricate as necessary. Refer to LUBRICATION in the Maintenance and

Repair Manual and perform duties as instructed.

e. If the pump has been stored for more than 12 months, some of the components or lubricants may have exceeded their maximum shelf life. These must be inspected or replaced 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 determine the repair or updating policy. Do not put the pump into service until appropriate action has been taken.

Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or damage to equipment. Attach lifting equipment 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 piping must be removed from the pump before lifting.

Lifting

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.

Battery Installation

Unless otherwise specified on the pump order, the engine battery is not included with engine driven units.

Refer to the information accompanying the battery and/or electrolyte solution for activation and charging instructions.

Before installing the battery, clean the positive and negative cable connectors, and the battery terminals. Secure the battery by tightening the holddown brackets. The terminals and clamps may be coated with petroleum jelly to retard corrosion. Connect and tighten the positive cable first, then the negative cable.

PAGE B − 2

The pump assembly can be seriously damaged if the chains or cables used to lift and move the unit are improperly wrapped around the pump.

Mounting

Locate the pump in an accessible place as close as practical to the liquid being pumped. Level mounting is essential for proper operation. The pump may have to be supported or shimmed to provide for level operation and eliminate vibration.

For engine driven units, the pump must be positioned as level as possible to ensure sufficient lubrication and fuel supply to the engine.

If the pump has been mounted on a moveable base, make certain the base is stationary by setting

INSTALLATION

PA SERIES OM−06027 the brake and blocking the wheels before attempting to operate the pump.

If the pump has been mounted on a movable base, do not attempt to operate the pump unless the unit is level. Be sure the leveling stands are positioned on a solid surface, and the wheels are chocked.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by increased suction lift, discharge elevation, and friction losses. See the performance curve and operating range shown on Page E-1 to be sure your overall application allows pump to operate within the safe operation range.

Materials

Either pipe or hose maybe used for suction and discharge lines; however, the materials must be compatible with the liquid being pumped. If hose is used in suction lines, it must be the rigid-wall, reinforced type to prevent collapse under suction. Using piping couplings in suction lines is not recommended.

Line Configuration

Keep suction and discharge lines as straight as possible to minimize friction losses. Make minimum use of elbows and fittings, which substantially increase friction loss. If elbows are necessary, use the long-radius type to minimize friction loss.

Connections to Pump

Before tightening a connecting flange, align it exactly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or couplings.

Lines near the pump must be independently supported to avoid strain on the pump which could cause excessive vibration, decreased bearing life, and increased shaft and seal wear. If hose-type

INSTALLATION lines are used, they should have adequate support to secure them when filled with liquid and under pressure.

Gauges

The pump is drilled and tapped for installing discharge pressure and vacuum suction gauges. It is recommended that gauges be installed to monitor pump performance. Seal the gauge threads with pipe dope to ensure an airtight seal. Follow the sealant manufacturer’s recommendations when selecting and applying the pipe dope. The pipe dope should be compatible with the liquid being pumped.

SUCTION LINES

To avoid air pockets which could affect pump priming, the suction line must be as short and direct as possible. When operation involves a suction lift, the line must always slope upward to the pump from the source of the liquid being pumped; if the line slopes down to the pump at any point along the suction run, air pockets will be created.

Fittings

Suction lines should be the same size as the pump inlet. If reducers are used in suction lines, they should be the eccentric type, and should be installed with the flat part of the reducers uppermost to avoid creating air pockets. Valves are not normally used in suction lines, but if a valve is used, install it with the stem horizontal to avoid air pockets.

Strainers

Be certain to use the strainer furnished with the pump; any spherical solids which pass through the strainer will also pass through the pump itself.

If a strainer not furnished with the pump is installed by the pump user, make certain that the total area of the openings in the strainer is at least three or four times the cross section of the suction line, and that the openings will not permit passage of solids larger than the solids handling capability of the pump.

This pump is designed to handle up to 3 inch (76,2 mm) diameter spherical solids.

PAGE B − 3

OM−06027 PA SERIES

Sealing

Since even a slight leak will affect priming, head, and capacity, especially when operating with a high suction lift, all connections in the suction line should be sealed with pipe dope to ensure an airtight seal. Follow the sealant manufacturer’s recommendations when selecting and applying the pipe dope. The pipe dope should be compatible with the liquid being pumped.

Suction Lines In Sumps

If a single suction line is installed in a sump, it should be positioned away from the wall of the sump at a distance equal to 1 1/2 times the diameter of the suction line.

If there is a liquid flow from an open pipe into the sump, the flow should be kept away from the suction inlet because the inflow will carry air down into the sump, and air entering the suction line will reduce pump efficiency.

If it is necessary to position inflow close to the suction inlet, install a baffle between the inflow and the suction inlet at a distance 1-1/2 times the diameter of the suction pipe. The baffle will allow entrained air to escape from the liquid before it is drawn into the suction inlet.

If two suction lines are installed in a single sump, the flow paths may interact, reducing the efficiency of one or both pumps. To avoid this, position the suction inlets so that they are separated by a distance equal to at least 3 times the diameter of the suction pipe.

Suction Line Positioning

The depth of submergence of the suction line is critical to efficient pump operation. Figure 2 shows recommended minimum submergence vs.

velocity.

Although not recommended, the vacuum assisted priming feature allows the pump to be operated temporarily in a slurping" application with varying water levels.

NOTE

The pipe submergence required may be reduced by installing a standard pipe increaser fitting at the end of the suction line. The larger opening size will reduce the inlet velocity. Calculate the required submergence using the following formula based on the increased opening size (area or diameter).

PAGE B − 4 INSTALLATION


Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

DISCHARGE LINES

Siphoning

Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a siphon breaker is used in the line. Otherwise, a siphoning action causing damage to the pump could result.

Valves

If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.

ALIGNMENT

The alignment of the pump, air compressor and engine is critical for trouble-free mechanical operation. See Section E, Securing Intermediate And

Drive Assembly To Engine in MAINTENANCE

AND REPAIR , for details.

This pump is designed with a check valve in the discharge line.

If a throttling valve is desired in the discharge line, use a valve as large as the largest pipe to minimize friction losses. Never install a throttling valve in a suction line.

With high discharge heads, it is recommended that a throttling valve be installed in the discharge line to protect the pump from excessive shock pressure and reverse rotation when it is stopped.

INSTALLATION

AUTO-START

The standard pump is equipped with an auto-start control system which allows the pump to start and stop as the liquid level in the wet well or sump rises and falls.

Refer to the information which follows for installation details for the liquid level sensing system provided with your pump.

PAGE B − 5

OM−06027

Float Switch Installation

The Float Switch autostart system employs either a single or double float switch, where a bulb raises or lowers (floats) with the liquid level, thus activating an enclosed miniature switch. The floats are equipped with a socket type connector that plugs into a matching receptacle on the auto-start control box.

Standard floats are equipped with 50 feet (15,2 m) of cable.

When installing the floats, note the following: a.

Be sure to provide sufficient room in the wet well or sump so that floats do not get obstructed or drawn into the suction line. If a flexible suction hose is used, it may be extended to lay along the bottom of the wet well or sump and the float can be attached to the hose above the point where it bends along the bottom. Direct the suction line toward the flow, and the float(s) away from the flow. If a stand-

PA SERIES pipe is available, attach the float switch cable to the standpipe in the sump at the approximate desired liquid level.

b. In a single float system, the cable can be tethered to the suction line or standpipe approximately 6 inches (152 mm) above the float.

This setting allows approximately 9 inches

(229 mm) of liquid rise between pump start/ stop. The start/stop interval may be increased by extending the float end of the cable. The liquid level in the sump will increase approximately 8 inches (203 mm) between start/stop intervals for every 6 inches (152 mm) of cable increase.

c. If a double float switch system is used, position the Start" float at the desired high water level in the sump, and the Stop" float at the desired low water level in the pump.

d. Refer to Figure 3 for additional float switch data.

ENGINE

CONTROL

BOX

ON

(Emptying)

OFF

(Filling)

CABLE

TETHER

POINT

OPERATING

RANGE

(See Table Below)

OFF

(Emptying)

1.25" Pipe

(Not Furnished)

ON

(Filling)

3.0

(0.9)

2.5

(.76)

2.0

(0.6)

1.5

(.46)

1.0

(0.3)

0.5

(.15)

1.0

(0.3)

2.0

(0.6)

3.0

(0.9)

APPROXIMATE FREE CORD LENGTH IN FT. (M)

4.0

(1.2)

Figure 3. Float Switch Data

PAGE B − 6 INSTALLATION



Follow the instructions on all tags, labels and decals attached to the pump.

OPERATION

OPERATION − SECTION C




cated (see LUBRICATION in MAINTENANCE

AND REPAIR ).

The pump will begin to prime upon startup. The air in the suction line will be discharged from the eductor discharge line. Complete priming is indicated by a positive discharge pressure reading.

If full priming is not achieved, the discharge check valve may be malfunctioning. If this occurs, shut down the pump and consult Maintenance and

Repair, Section E for further details.

STARTING

Check the fuel level and oil levels in the engine, air compressor, pump bearings and seal housing.

Make sure the pump is level. Lower the jack stands and chock the wheels, if so equipped.

This pump is designed to handle most non-volatile, non-flammable liquids containing specified entrained solids and corrosives. Do not attempt to pump volatile, corrosive, or flammable liquids which may damage the pump or endanger personnel as a result of pump failure.

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.

Pump speed and operating condition points must be within the continuous performance range shown on the performance curve in Section E on page E−1.

PRIMING

Install the pump and piping as described in IN-

STALLATION . Make sure that the piping connections are tight, and that the pump is securely mounted. Check that the pump is properly lubri-

OPERATION

This pump is equipped with automatic liquid level controls, and is subject to automatic restart. Keep hands and clothing away from the unit to prevent injury during automatic operation. Disconnect the positive battery cable before performing any maintenance. Failure to do so may result in serious personal injury.

Consult the engine operations manual before attempting to start the unit.

Manual Starting

On initial start-up, set the engine speed at in the half-throttle position. Turn the keyswitch to ‘MANU-

PAGE C − 1


AL’. After the engine starts and the unit is fully primed, adjust the engine RPM until the desired flow rate is achieved.

Pump speed and operating condition points must be within the continuous performance range shown on the curve on

Page E-1.


Adjust the engine speed to achieve the desired output. Do not exceed the factory set engine speed and system operating pressure. Do not operate below the recommended operating speed (if applicable).

Automatic Starting

With the float system installed, follow the procedures outlined for manual starting and throttle adjustment. Switch the keyswitch to ‘OFF’ until the water level rises above the on point for the float system, then turn the keyswitch to the ‘AUTO’ setting.

The unit will run until the float signals the control that the water in the wet well is at the float off point, at which time the unit will shut down automatically.

When the float signals the control that the water in the wet well is at the float on point, the unit will restart automatically, repeating the cycle.

Priming

The pump will begin to prime upon startup. The air in the suction line will be discharged from the eductor discharge line. Complete priming is indicated by a positive discharge pressure reading.

If full priming is not achieved, the discharge check valve may be malfunctioning. If this occurs, shut down the pump and consult the separate Maintenance and Repair manual for further details.

Routine Operation

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 the separate Parts List Manual for the maximum continuous operating speed for this pump.

Operation In Extreme Heat

The safety shutdown system will automatically stop the unit if engine operating temperature exceeds design limits. If engine over-temperature shutdown occurs, allow the unit to cool before restarting.

If engine overheating continues, check the engine lubricant level and viscosity. Consult the engine operation manual for the recommended lubricant for operation in extreme heat.

If the unit is being operated in the automatic mode, adjust the float(s) to allow shorter run and longer cooling periods, if possible.



PAGE C − 2

This pump is equipped with automatic liquid level controls, and is subject to automatic restart. Keep hands and clothing away from the unit to prevent injury during automatic operation. Disconnect the battery before performing any maintenance. Failure to do so may result in serious personal injury.

OPERATION


OPERATIONAL CHECKS

Leakage

Once the pump is fully primed, no leakage should be visible at pump mating surfaces, or at pump connections or fittings. Keep all line connections and fittings tight to maintain maximum pump efficiency.

Pump Vacuum Check

Read the vacuum gauge with the pump primed and at operation speed. Shut off the pump. The vacuum gauge reading will immediately drop proportionate to static suction lift, and should then stabilize. If the vacuum reading falls off rapidly after stabilization, an air leak exists. Before checking for the source of the leak, check the point of installation of the vacuum gauge.

Liquid Temperature And Overheating

The maximum liquid temperature for this pump is

160 F (71 C). Do not apply it at a higher operating temperature.

Overheating can occur if operated with the valves in the suction or discharge lines closed. Operating against closed valves could bring the liquid to a boil, build pressure, and cause the pump to rupture or explode. If overheating occurs, stop the pump immediately and allow it to completely cool before servicing it.

Approach any over-heated pump cautiously .

plug to prevent injury to personnel from hot liquid.

Strainer Check

Check the strainer regularly, and clean it as necessary. The strainer should also be checked if pump flow rate begins to drop. Monitor and record the vacuum suction gauge readings regularly to detect strainer blockage.

Never introduce air or steam pressure into the pump casing or piping to remove a blockage. This could result in personal injury or damage to the equipment. If backflushing is absolutely necessary, liquid pressure must be limited to 50% of the maximum permissible operating pressure shown on the pump performance curve.

STOPPING

Manual Stopping

Never halt the flow of liquid suddenly. If the liquid being pumped is stopped abruptly, damaging shock waves can be transmitted to the pump and piping system. Close all connecting valves slowly.

Reduce the throttle speed slowly and allow the engine to idle briefly before stopping.

In the manual mode, reduce the throttle speed slowly, and allow the engine to idle briefly before switching the HAND-OFF-AUTO switch to ‘OFF’.

Allow an over-heated pump to completely cool before servicing. Do not remove plates, covers, gauges, or fittings from an overheated pump. Liquid within the pump can reach boiling temperatures, and vapor pressure within the pump can cause parts being disengaged to be ejected with great force. After the pump cools, drain the liquid from the pump by removing the casing drain plug. Use caution when removing the

OPERATION

If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.

After stopping the pump, switch off the engine ignition and remove the key to ensure that the pump will remain inoperative.

Automatic Stopping

In the automatic mode, the pump will stop when the liquid in the wet well or sump lowers and activates the Off" float switch(s). The pump will restart

PAGE C − 3

OM−06027 PA SERIES automatically when the liquid rises and activates the On" float switch(s).

Safety Shutdown System

The unit is equipped with a safety system to automatically shut down the engine under certain conditions. The engine will automatically shut down:

1. If the engine exceeds its safe operating temperature.

2. If the engine oil pressure drops below design limits.

3. If the engine fails to start within a pre-set period of time.

4. If the engine speed exceeds the safe operating range.

5. If the engine fan belt breaks.

Lights on the control panel will indicate which of the safety features has caused the engine to shut down.

Should any of the safety features cause the engine to shut down, the cause must be determined and corrected before putting the unit back into service.

The engine will not restart until the key switch has been returned to the ‘OFF’ position for at least 10 seconds.

All safety shutdown features are pre-set at the factory for optimum performance and safety; do not attempt to adjust these settings.

Never disconnect any of the safety shutdown features; this will void the warranty and could result in serious damage to the unit and/or injury to personnel. Safety shutdown features are pre-set at the factory; do not attempt to adjust any of the settings. Determine the cause of shutdown before putting the unit back into service. Consult the factory for additional information.

PAGE C − 4

PERIODIC CHECKS

Seal Cavity And Bearing Lubrication

Both the seal and bearing cavities were fully lubricated at the factory. Check the lubrication levels before startup, and regularly thereafter as indicated in Section E, Maintenance and Repair .

When lubrication is required, use only SAE No. 30 non-detergent oil.

Bearing Temperature Check

Bearings normally run at higher than ambient temperatures because of heat generated by friction.

Temperatures up to 160 F (71 C) are considered normal for bearings, and they can operate safely to at least 180 F (82 C).

Checking bearing temperatures by hand is inaccurate. Bearing temperatures can be measured accurately by placing a contact-type thermometer against the housing. Record this temperature for future reference.

A sudden increase in bearing temperatures is a warning that the bearings are at the point of failing to operate properly. Make certain that the bearing lubricant is of the proper viscosity and at the correct level (see LUBRICATION in Section E, Maintenance and Repair ). Bearing overheating can also be caused by shaft misalignment and/or excessive vibration.

When pumps are first started, the bearings may seem to run at temperatures above normal. Continued operation should bring the temperatures down to normal levels.

Air Compressor

The air compressor was lubricated for test at the factory. However, always check the lubrication level before startup.

Consult the manual accompanying the air compressor and perform all duties and checks as indicated.

Additional Checks

See Page D−4 and perform all recommended preventive maintenance checks applicable to your particular unit.

OPERATION


Consult the manual accompanying the engine and perform any and all routine checks recommended by the engine manufacturer.

COLD WEATHER PRESERVATION

In below freezing conditions, drain the pump to prevent damage from freezing. Also, clean out any solids by flushing with a hose. Operate the pump for approximately one minute; this will remove any remaining liquid that could freeze the pump rotating parts. If the pump will be idle for more than a few hours, or if it has been pumping liquids containing a large amount of solids, drain the pump, and flush it thoroughly with clean water. To prevent large solids from clogging the drain port and preventing the pump from completely draining, insert a rod or stiff wire in the drain port, and agitate the liquid during the draining process. Clean out any remaining solids by flushing with a hose.

OPERATION PAGE C − 5


TROUBLESHOOTING − SECTION D




7. Drain the pump.



2. Turn the keyswitch to ‘OFF’, and disconnect the positive battery cable to ensure that the pump will remain inoperative.


4. Check the temperature before opening any covers, plates, or plugs.

This pump is equipped with an automatic starting system, and is subject to automatic restart. Keep hands and clothing away from the unit to prevent injury during automatic operation. Disconnect the positive battery cable before performing any maintenance. Failure to do so may result in serious personal injury.

TROUBLE

PUMP FAILS TO

PRIME

POSSIBLE CAUSE PROBABLE REMEDY

Discharge check valve contaminated, damaged, or unable to seat.

Air leak in suction line.

Lining of suction hose collapsed.

Clean or replace check valve.

Correct leak.

Replace suction hose.

Leaking or worn seal or pump gasket.

Check pump vacuum. Replace leaking or worn seal or gasket.

Suction lift or discharge head too high.

Check piping installation and install bypass line if needed. See INSTAL-

LATION .

Air compressor damaged or belts broken.

Strainer clogged.

Check and repair/replace.

Check strainer and clean if necessary.

PUMP STOPS OR

FAILS TO DELIVER

RATED FLOW OR

PRESSURE

Eductor clogged.

Check and clean eductor.

Air leak in suction line.

Lining of suction hose collapsed.

Correct leak.

Replace suction hose.

Leaking or worn seal or pump gasket.

Check pump vacuum. Replace leaking or worn seal or gasket.

TROUBLESHOOTING PAGE D − 1


TROUBLE

PUMP STOPS OR

FAILS TO DELIVER

RATED FLOW OR

PRESSURE (cont.)

PUMP REQUIRES

TOO MUCH

POWER

PUMP CLOGS

FREQUENTLY

POSSIBLE CAUSE

Strainer clogged.

Discharge check valve clogged.

Suction intake not submerged at proper level or sump too small.

Impeller or other wearing parts worn or damaged.

Impeller clogged.

Discharge head too high.

Suction lift too high.

Pump speed too slow.

Belt or flexible coupling broken.

Pump speed too high.

Extreme ambient temperature.

Discharge head too low.

Fuel filter clogged.

Liquid solution too thick.

Fuel contaminated.

Pump or jack shaft bearing(s) frozen.

Discharge flow too slow.

Suction check valve or foot valve clogged or binding.

Liquid solution too thick.

EXCESSIVE NOISE Cavitation in pump.

PROBABLE REMEDY

Check strainer and clean if necessary.

Check and clean check valve.

Check installation and correct submergence as needed.

Replace worn or damaged parts.

Check that impeller is properly centered and rotates freely.

Free impeller of debris.

Install bypass line.

Measure lift w/vacuum gauge. Reduce lift and/or friction losses in suction line.

Check engine output; consult engine operation manual.

Check and replace as necessary.

Check engine output.

Reduce pump output.

Adjust discharge valve.

Check & replace often in extreme operating conditions.

Dilute if possible.

Check and replace as required.

Disassemble, check and replace bearing(s) as required..

Open discharge valve fully to increase flow rate, and run engine at maximum governed speed.

Clean valve.

Pumping entrained air.

Pump or drive not securely mounted.

Impeller clogged or damaged.

Dilute if possible.

Reduce suction lift and/or friction losses in suction line. Record vacuum and pressure gauge readings and consult local representative or factory.

Locate and eliminate source of air bubble.

Secure mounting hardware.

Clean out debris; replace damaged parts.

PAGE D − 2 TROUBLESHOOTING


TROUBLE

BEARINGS RUN

TOO HOT

POSSIBLE CAUSE

Bearing temperature is high, but within limits.

Low or incorrect lubricant.

Suction and discharge lines not properly supported.

Drive misaligned.

Excessive tension on drive belt.

PROBABLE REMEDY

Check bearing temperature regularly to monitor any increase.

Check for proper type and level of lubricant.

Check piping installation for proper support.

Align drive properly.

Check belt tension. Adjust as required.

PREVENTIVE MAINTENANCE

Since pump applications are seldom identical, and pump wear is directly affected by such things as the abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however, following a routine preventive maintenance schedule will help assure trouble-free performance and long life from your

Gorman-Rupp pump. For specific questions concerning 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 inspections can indicate problems that can be corrected before system damage or catastrophic failure occurs. The appearance of wearing parts should also be documented at each inspection for comparison 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 before failure occurs, reducing unscheduled down time.

For new applications, a first inspection of wearing parts at 250 hours will give insight into the wear rate for your particular application. Subsequent inspections should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently.

TROUBLESHOOTING PAGE D − 3


Item

Preventive Maintenance Schedule

Daily

Service Interval*

Weekly Monthly Semi-

Annually

Annually

General Condition (Temperature, Unusual

Noises or Vibrations, Cracks, Leaks,

Loose Hardware, Etc.)

Pump Performance (Gauges, Speed, Flow)

Bearing Lubrication

Seal Lubrication (And Packing Adjustment,

If So Equipped)

V-Belts (If So Equipped)

Air Release Valve Plunger Rod (If So Equipped)

Front Impeller Clearance (Wear Plate)

Rear Impeller Clearance (Seal Plate)

Check Valve

Pressure Relief Valve (If So Equipped)

Pump and Driver Alignment

Shaft Deflection

Bearings

Bearing Housing

Piping

Driver Lubrication − See Mfgr’s Literature

I

I

I

I

I

I

C

I

I

R

R

I

I

I

C

I

I

I

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.

PAGE D − 4 TROUBLESHOOTING


PUMP MAINTENANCE AND REPAIR − SECTION E

MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK

OPERATING PERFORMANCE.

Based on 70

STANDARD PERFORMANCE FOR PUMP MODEL PA4A60C−4024T−ESP

F (21 C) clear water at sea level with minimum suction lift. Since pump installations are seldom identical, your performance may be different due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.

Contact the Gorman-Rupp Company to verify performance or part numbers.

If your pump serial number is followed by an N", your pump is NOT a standard production model.

Pump speed and operating condition points must be within the continuous performance range shown on the curve.

MAINTENANCE & REPAIR PAGE E − 1

OM−06027

PARTS PAGE

SECTION DRAWING

PA SERIES

PAGE E − 2


MAINTENANCE & REPAIR


ITEM

NO.

PART NAME

1 PUMP END ASSY

2 J.D. 4024T ENGINE

3 HEX HD CAPSCREW

4 FLAT WASHER

5 MOUNTING BRACKET

6 CONTROL PANEL

7 BRACKET

8 HOISTING BAIL ASSY

9 AIR INTAKE PIPE

10 T-BOLT CLAMP

11 AIR INTAKE ELBOW

12 EXHAUST BLANKET

13 FLEX EXH PIPE ASSY

14 MUFFFLER CLAMP

46133−695 −−− 1

29224−153 −−− 1

B0605

K06

15991

15991

10

10

34621−320 13000 1

29284−012 −−− 1

34184−007 15120 1

44715−038 24150 1

31417−065 15000 2

26518−164 −−− 3

29284−033 −−− 1

29334−297 −−− 1

46241−013 −−− 1

29334−261 −−− 3

15 MUFFLER MTG BRKT

16 MUFFLER

17 WEATHER CAP

18 EXHAUST PIPE

19 HEX HD CAPSCREW

20 HEX NUT

21 LOCK WASHER

29334−298 −−− 1

29334−106 −−− 1

S1710 −−− 1

31912−039 15000 1

B0504

D05

J05

15991

15991

15991

3

3

14

22 FLAT WASHER

23 LOCK WASHER

K06

J06

15991 14

15991 12

24 MUFFLER MOUNT ASSY 41824−010 24150 1

25 HEX HD CAPSCREW B1006 15991 10

26 FLAT WASHER

27 LOCK WASHER

28 HEX NUT

K10

J10

D10

15991

15991

15991

20

30

34

29 BATTERY BOX ASSY

30 BATTERY

31 NEG CABLE ASSY

42432−005 −−− 1

SEE OPTIONS REF

47311−133 −−− 1

32 POS CABLE ASSY 47311−113 −−− 1

33 BASE/FUEL TANK ASSY 41553−012 24150 1

34 CLOSE PIPE NIPPLE

35 RED PIPE BUSHING

T8

AP1208

15079

15079

1

1

36 STREET ELBOW

37 BALL VALVE

38 MALE HOSE END

AGS08 11999 1

26631−023 −−− 1

26525−020 −−− 1

39 HOSE BARB FITTING 26523−447 −−− 1

40 .38 I.D. X 67 IN. LG. HOSE 18513−054 −−− 1

41 HOSE CLAMP 26518−642 −−− 6

42 .50 I.D. X 35 IN. LG. HOSE 18513−056 −−− 1


44 .50 I.D. X 24 IN. LG. HOSE 18513−056 −−− 1

45 PIPE CAP

46 PIPE CAP

47 FUEL PICKUP

V08

V06

29332−146

15079

15079

−−−

2

1

2

48 .38 I.D. X 15 IN. LG. HOSE 18513−054 −−− 1

49 HOSE BARB 26523−333 −−− 2

50 HOSE BARB FITTING

51 HOSE CLAMP

26523−386

26518−641

−−−

−−−

2

2

52 .18 I.D. X 9 IN. LG. HOSE 18513−301 −−− 1

INDICATES PARTS RECOMMENDED FOR STOCK

CONSULT FACTORY FOR INDIVIDUAL PARTS


Pump Model PA4A60C−4024T−ESP

PARTS LIST

(From S/N 1362521 up)

PART

NUMBER

MAT’L

CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

MAT’L

CODE

QTY

53 FUEL GAUGE

54 HEX NUT

55 LOCK WASHER

56 HEX HD CAPSCREW

57 PIPE PLUG

58 HEX HD CAPSCREW

59 PIPE ASSEMBLY

29332−131

D06

B1010

−−−

15991

1

8

21171−511 −−− REF

22645−164 −−− REF

P04 15079 2

15991 6

46353−205 −−− 2

60 HEX HD CAPSCREW

61 WASHER

B1011 15991 14

21161−442 −−− 4

62 PUMP SUPPORT ASSY 41581−035 24150 1


64 GASKET 25113−034 −−− 2

65 SPOOL SUPPORT BRKT 34535−019 15080 1

66 LOCK WASHER

67 HEX HD CAPSCREW

J08

B0806

15991

15991

1

1

68 HEX NUT

69 LOCK WASHER

70 BRACKET

71 HEX HD CAPSCREW

72 ENCLOSURE ASSY

73 FOAM PACKAGE

D04

J04

33251−010

B0403

15991

15991

15120

15991

1

1

1

1

42146−017 −−− 1

46823−146 −−− REF

74 THREADED INSERT

75 HEX HD CAPSCREW

21769−159 −−− 12

B0503 15991 12

76 SOCKET CONNECTOR 27263−001 −−− 1

77 16/4 X 80 IN. LG. CABLE 18141−147 −−− 1

78 PLUG CONNECTOR

79 HEX HD CAPSCREW

27261−301 −−− 1

B0404 15991 2

K04 15991 2

33645−030 19460 1

80 FLAT WASHER

81 FLOOR MAT

NOT SHOWN:

SUCTION STICKER

CAUTION STICKER

INSTRUCTION TAG

6588AG

2613FJ

−−− 1

−−− 1

38817−085 −−− 1

DISCHARGE STICKER

START-UP TAG

6588BJ −−− 1

38816−269 −−− 1

WARNING DECAL 38816−345 −−− 2

LEVEL CONTROL LABEL 38816−332 −−− 1

OIIL DRAIN LABEL 38816−323 −−− 1

RADIATOR DRAIN LABEL 38816−322 −−− 1

PUMP DRAIN LABEL

WARNING DECAL

INSTRUCTION TAG

38816−320 −−− 1

38816−203 −−− 2

38818−144 −−− 1

PRIME AIRE DECAL

SILENT PUMP DECAL

FLOAT SWITCH KIT

CABLE TIE

38812−078

48154−810

48312−980

27111−218

−−−

−−−

−−−

−−−

2

1

1

2

CABLE TIE MTG BLOCK 27111−352 −−− 2

FOAM TAPE 18668−003 −−− 1

OPTIONAL:

DRY CHARGE BATTERY 29331−517 −−− 1

WET CHARGE BATTERY 29331−527 −−− 1

PAGE E − 3

OM−06027

SECTION DRAWING

PA SERIES

PAGE E − 4




ITEM

NO.

PART NAME

1 PUMP END ASSY

2 J.D. 4024T ENGINE

3 HEX HD CAPSCREW

4 FLAT WASHER

5 MOUNTING BRACKET

6 CONTROL PANEL

7 BRACKET


9 AIR INTAKE PIPE

10 T-BOLT CLAMP

11 AIR INTAKE ELBOW

12 EXHAUST BLANKET


14 MUFFFLER CLAMP

46133−695 −−− 1

29224−153 −−− 1

B0605

K06

15991

15991

10

10

34621−320 13000 1

29284−012 −−− 1

34184−007 15120 1

44715−038 24150 1

31417−065 15000 2

26518−164 −−− 3

29284−033 −−− 1

29334−297 −−− 1

46241−013 −−− 1

29334−261 −−− 3

15 MUFFLER MTG BRKT

16 MUFFLER

17 WEATHER CAP

18 EXHAUST PIPE

19 HEX HD CAPSCREW

20 HEX NUT

21 LOCK WASHER

29334−298 −−− 1

29334−106 −−− 1

S1710 −−− 1

31912−039 15000 1

B0504

D05

J05

15991

15991

15991

3

3

14

22 FLAT WASHER

23 LOCK WASHER

K06

J06

15991 14

15991 12



26 FLAT WASHER

27 LOCK WASHER

28 HEX NUT

K10

J10

D10

15991

15991

15991

20

30

34

29 BATTERY BOX ASSY

30 BATTERY

31 NEG CABLE ASSY

42432−005 −−− 1

SEE OPTIONS REF

47311−133 −−− 1

32 POS CABLE ASSY 47311−113 −−− 1



35 RED PIPE BUSHING

T8

AP1208

15079

15079

1

1

36 STREET ELBOW

37 BALL VALVE

38 MALE HOSE END

AGS08 11999 1

26631−023 −−− 1

26525−020 −−− 1


40 .38 I.D. X 67 IN. LG. HOSE 18513−054 −−− 1

41 HOSE CLAMP 26518−642 −−− 6

42 .50 I.D. X 35 IN. LG. HOSE 18513−056 −−− 1


44 .50 I.D. X 24 IN. LG. HOSE 18513−056 −−− 1

45 PIPE CAP

46 PIPE CAP

47 FUEL PICKUP

V08

V06

29332−146

15079

15079

−−−

2

1

2

48 .38 I.D. X 15 IN. LG. HOSE 18513−054 −−− 1

49 HOSE BARB 26523−333 −−− 2


51 HOSE CLAMP

26523−386

26518−641

−−−

−−−

2

2

52 .18 I.D. X 9 IN. LG. HOSE 18513−301 −−− 1





PARTS LIST

(From S/N 1362521 up)

PART

NUMBER

MAT’L

CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

MAT’L

CODE

QTY

53 FUEL GAUGE

54 HEX NUT

55 LOCK WASHER

56 HEX HD CAPSCREW

57 PIPE PLUG

58 HEX HD CAPSCREW

59 PIPE ASSEMBLY

29332−131

D06

B1010

−−−

15991

1

8

21171−511 −−− REF

22645−164 −−− REF

P04 15079 2

15991 6

46353−205 −−− 2

60 HEX HD CAPSCREW

61 WASHER

B1011 15991 14

21161−442 −−− 4



64 GASKET 25113−034 −−− 2


66 LOCK WASHER

67 HEX HD CAPSCREW

J08

B0806

15991

15991

1

1

68 HEX NUT

69 LOCK WASHER

70 BRACKET

71 HEX HD CAPSCREW

72 ENCLOSURE ASSY

73 FOAM PACKAGE

D04

J04

33251−010

B0403

15991

15991

15120

15991

1

1

1

1

42146−017 −−− 1

46823−146 −−− REF

74 THREADED INSERT

75 HEX HD CAPSCREW

21769−159 −−− 12

B0503 15991 12


77 16/4 X 80 IN. LG. CABLE 18141−147 −−− 1

78 PLUG CONNECTOR

79 HEX HD CAPSCREW

27261−301 −−− 1

B0404 15991 2

K04 15991 2

33645−030 19460 1

80 FLAT WASHER

81 FLOOR MAT

NOT SHOWN:

SUCTION STICKER

CAUTION STICKER

INSTRUCTION TAG

6588AG

2613FJ

−−− 1

−−− 1

38817−085 −−− 1

DISCHARGE STICKER

START-UP TAG

6588BJ −−− 1

38816−269 −−− 1





PUMP DRAIN LABEL

WARNING DECAL

INSTRUCTION TAG

38816−320 −−− 1

38816−203 −−− 2

38818−144 −−− 1

PRIME AIRE DECAL

SILENT PUMP DECAL

FLOAT SWITCH KIT

CABLE TIE

38812−078

48154−810

48312−980

27111−218

−−−

−−−

−−−

−−−

2

1

1

2


FOAM TAPE 18668−003 −−− 1

OPTIONAL:



PAGE E − 5

OM−06027

SECTION DRAWING

PA SERIES

PAGE E − 6




ITEM

NO.

PART NAME

1 PUMP END ASSY

2 J.D. 4024T ENGINE

3 HEX HD CAPSCREW

4 FLAT WASHER

5 MOUNTING BRACKET

6 CONTROL PANEL

7 BRACKET


9 AIR INTAKE PIPE

10 T-BOLT CLAMP

11 AIR INTAKE ELBOW

12 EXHAUST BLANKET


14 MUFFFLER CLAMP

46133−695 −−− 1

29224−153 −−− 1

B0605

K06

15991

15991

10

10

34621−320 13000 1

29284−012 −−− 1

34184−007 15120 1

44715−038 24150 1

31417−065 15000 2

26518−164 −−− 3

29284−033 −−− 1

29334−297 −−− 1

46241−013 −−− 1

29334−261 −−− 3

15 MUFFLER MTG BRKT

16 MUFFLER

17 WEATHER CAP

18 EXHAUST PIPE

19 HEX HD CAPSCREW

20 HEX NUT

21 LOCK WASHER

29334−298 −−− 1

29334−106 −−− 1

S1710 −−− 1

31912−039 15000 1

B0504

D05

J05

15991

15991

15991

3

3

14

22 FLAT WASHER

23 LOCK WASHER

K06

J06

15991 14

15991 12



26 FLAT WASHER

27 LOCK WASHER

28 HEX NUT

K10

J10

D10

15991

15991

15991

20

30

34

29 BATTERY BOX ASSY

30 BATTERY

31 NEG CABLE ASSY

42432−005 −−− 1

SEE OPTIONS REF

47311−133 −−− 1

32 POS CABLE ASSY 47311−113 −−− 1



35 RED PIPE BUSHING

T8

AP1208

15079

15079

1

1

36 STREET ELBOW

37 BALL VALVE

38 MALE HOSE END

AGS08 11999 1

26631−023 −−− 1

26525−020 −−− 1


40 .38 I.D. X 67 IN. LG. HOSE 18513−054 −−− 1

41 HOSE CLAMP 26518−642 −−− 6

42 .50 I.D. X 35 IN. LG. HOSE 18513−056 −−− 1


44 .50 I.D. X 24 IN. LG. HOSE 18513−056 −−− 1

45 PIPE CAP

46 PIPE CAP

47 FUEL PICKUP

V08

V06

29332−146

15079

15079

−−−

2

1

2

48 .38 I.D. X 15 IN. LG. HOSE 18513−054 −−− 1

49 HOSE BARB 26523−333 −−− 2


51 HOSE CLAMP

26523−386

26518−641

−−−

−−−

2

2

52 .18 I.D. X 9 IN. LG. HOSE 18513−301 −−− 1





PARTS LIST

(From S/N 1362521 up)

PART

NUMBER

MAT’L

CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

MAT’L

CODE

QTY

53 FUEL GAUGE

54 HEX NUT

55 LOCK WASHER

56 HEX HD CAPSCREW

57 PIPE PLUG

58 HEX HD CAPSCREW

59 PIPE ASSEMBLY

29332−131

D06

B1010

−−−

15991

1

8

21171−511 −−− REF

22645−164 −−− REF

P04 15079 2

15991 6

46353−205 −−− 2

60 HEX HD CAPSCREW

61 WASHER

B1011 15991 14

21161−442 −−− 4



64 GASKET 25113−034 −−− 2


66 LOCK WASHER

67 HEX HD CAPSCREW

J08

B0806

15991

15991

1

1

68 HEX NUT

69 LOCK WASHER

70 BRACKET

71 HEX HD CAPSCREW

72 ENCLOSURE ASSY

73 FOAM PACKAGE

D04

J04

33251−010

B0403

15991

15991

15120

15991

1

1

1

1

42146−017 −−− 1

46823−146 −−− REF

74 THREADED INSERT

75 HEX HD CAPSCREW

21769−159 −−− 12

B0503 15991 12


77 16/4 X 80 IN. LG. CABLE 18141−147 −−− 1

78 PLUG CONNECTOR

79 HEX HD CAPSCREW

27261−301 −−− 1

B0404 15991 2

K04 15991 2

33645−030 19460 1

80 FLAT WASHER

81 FLOOR MAT

NOT SHOWN:

SUCTION STICKER

CAUTION STICKER

INSTRUCTION TAG

6588AG

2613FJ

−−− 1

−−− 1

38817−085 −−− 1

DISCHARGE STICKER

START-UP TAG

6588BJ −−− 1

38816−269 −−− 1





PUMP DRAIN LABEL

WARNING DECAL

INSTRUCTION TAG

38816−320 −−− 1

38816−203 −−− 2

38818−144 −−− 1

PRIME AIRE DECAL

SILENT PUMP DECAL

FLOAT SWITCH KIT

CABLE TIE

38812−078

48154−810

48312−980

27111−218

−−−

−−−

−−−

−−−

2

1

1

2


FOAM TAPE 18668−003 −−− 1

OPTIONAL:



PAGE E − 7

OM−06027

SECTION DRAWING

PA SERIES

PAGE E − 8

Figure 4. PA4A60C−(SAE 4/10) Pump Assembly


PA SERIES

ITEM

NO.

20

21

22

23

24

14

15

16

17

18

19

10

11

12

13

8

9

6

7

4

5

25

26

1

2

3

30

31

32

33

27

28

29

34

35

36

NOT SHOWN:

PART NAME

PUMP END

PRIMING CHAMBER KIT

CONNECTOR

HOSE BARB FITTING

1/2" ID x 30" LG. HOSE

HOSE BARB FITTING

CHECK VALVE

AIR COMPRESSOR ASSY

SYNCHRONOUS BELT

BELT GUARD ASSY

HEX HD CAPSCREW

LOCK WASHER

FLAT WASHER

HOSE BARB FITTING

HOSE CLAMP

HOSE CLAMP

HEX HD CAPSCREW

LOCK WASHER

FLAT WASHER

SPACER

3/16" ID x 24 LG. HOSE

1/2" ID x 20" LG. HOSE

CLAMP

SPROCKET

BUSHING

4" CHECK VALVE KIT

−CHECK VALVE

−FLAPPER

−COVER O-RING

STUD

GASKET

PIPE PLUG

LOCK WASHER

HEX NUT

HOPPER SPOOL

COVER PLATE GASKET

COVER PLATE

LOCK WASHER

HEX HD CAPSCREW

PA4A60C−(SAE 4/10) Pump Assembly

PARTS LIST

PART

NUMBER

24131−496

48274−003

26642−124

26688−005

25152−366

C1011

1676G

P04

J10

D10

38644−802

38689−037

38224−021

J08

B0804

64C60C−(SAE 4/10)

48275−005

S1598

26523−047

18513−113

26523−446

26641−092

46181−907

24186−008

42351−326

B0402

J04

K04

26523−386

26518−641

26518−642

B0610

J06

K06

31141−034

18513−301

18513−113

27111−348

24271−112

STRAINER 2690C

G-R DECAL GR−06

MAT’L

CODE

−−−

−−−

−−−

−−−

−−−

−−−

15991

15991

15991

15000

−−−

−−−

−−−

−−−

−−−

−−−

−−−

−−−

−−−

−−−

24150

15991

15991

15991

−−−

−−−

−−−

−−−

−−−

15991

18000

15079

15991

15991

10000

18000

15080

15991

15991

24000

−−−


OM−06027

QTY

1

1

1

4

1

1

4

4

4

1

1

1

2

2

2

1

1

2

1

1

1

1

1

1

1

1

8

8

1

8

1

1

1

2

2

1

1

1

1

1

1


OM−06027

SECTION DRAWING

PA SERIES

PAGE E − 10

Figure 5. 64C60C−(SAE 4/10) Pump End Assembly


PA SERIES

ITEM

NO.

PART NAME

7

8

9

5

6

3

4

1

2

14

15

16

17

10

11

12

13

18

19

NOT SHOWN

PUMP CASING

HEX NUT

LOCK WASHER

SIGHT GAUGE

PIPE PLUG

PIPE PLUG

WEAR PLATE ASSY

REPAIR ROTATING ASSY

HEX HD CAPSCREW

LOCK WASHER

BEARING HOUSING O-RING

ROTATING ASSY SHIM SET

SEAL PLATE O-RING

NAME PLATE

DRIVE SCREW

PIPE CAP

PIPE NIPPLE

STREET ELBOW

PIPE PLUG

OIL LEVEL DECAL

SUCTION STICKER

ROTATION DECAL

WARNING DECAL

DISCHARGE STICKER

LUBE DECAL

DRIVE ASSEMBLY

PARTS LIST

64C60C−(SAE 4/10) Pump End Assembly

PART

NUMBER

38218−015

D06

J06

S1471

P08

P06

10532B

44163−450

B0806

J08

S1674

13130

25154−273

38818−127

BM#04−03

V08

T0822

RS08

P12

38816−123

6588AG

2613M

2613FE

6588BJ

11421A

44162−160


−−−

−−−

−−−

−−−

−−−

−−−

−−−

MAT’L

CODE

10000

15991

15991

−−−

15079

15079

15990

−−−

15991

15991

−−−

17040

−−−

13000

17000

15079

15079

11999

15079

OM−06027

QTY

1

1

4

1

1

2

1

1

2

1

1

1

4

1

1

4

1

4

1

1

1

1

1

1

1

1


OM−06027

SEAL AREA DETAIL

SECTION DRAWING

PA SERIES

PAGE E − 12

Figure 6. 44163−451 Repair Rotating Assembly


PA SERIES

ITEM

NO.

PART NAME

6A

6B

7

5

6

3

4

1

2

12

13

13A

14

15

15A

16

17

10

11

8

9

22

23

24

25

18

19

20

21

26

27

28

29

30

31

NOT SHOWN:

IMPELLER

IMPELLER ADJ SHIM SET

CARTRIDGE SEAL ASSEMBLY

SEAL PLATE

SEAL PLATE GASKET

OIL SEAL

OIL SEAL

OIL SEAL

LOCK WASHER

HEX HD CAPSCREW

BEARING HOUSING

VENTED PIPE PLUG

REDUCER PIPE BUSHING

AIR VENT

SIGHT GAUGE

SIGHT GAUGE

PIPE PLUG

PIPE PLUG

PIPE PLUG

HEX HD CAPSCREW

LOCK WASHER

MOUNTING FLANGE

GASKET

INTERMEDIATE GUARD

RETAINING RING

BALL BEARING

SHAFT KEY

IMPELLER SHAFT

BALL BEARING

SHAFT SLEEVE O-RING

SEAL PLATE O-RING

ROTATING ASSY ADJ SHIM SET

BEARING HOUSING O-RING

SHIPPING PLUG

AIR COMPRESSOR DRIVE KEY

INSTRUCTION TAG

PARTS LIST

44163−451 Repair Rotating Assembly

PART

NUMBER

10528

37J

46513−151

38272−234

10959G

S1352

S1352

S1352

J08

B0805−1/2

38251−423

4823A

AP0802

S1530

S1471

S1471

P12

P04

P04

21632−934

J06

38545−013

38683−275

42381−509

S442

S375

N0607

38514−822

S1088

25154−022

25152−273

13130

S1674

11495B

N0607

6588U


OM−06027

QTY

1

1

4

1

1

1

REF

1

1

1

1

1

1

1

1

8

8

1

1

4

1

1

1

1

1

2

1

1

1

REF

1

4

1

2

1

1

MAT’L

CODE

11010

17090

−−−

10010

20000

−−−

−−−

−−−

15991

15991

10000

15079

15079

−−−

−−−

−−−

15079

15079

15079

−−−

15991

11010

18000

24152

−−−

−−−

15990

1706H

−−−

−−−

−−−

17040

−−−

15079

15990

−−−


OM−06027

SECTION DRAWING

PA SERIES

PAGE E − 14

Figure 7. 46181−907 Air Compressor Assembly


PA SERIES

ITEM

NO.

PART NAME

7

8

9

5

6

3

4

1

2

14

15

16

17

10

11

12

13

18

NOT SHOWN:

FLAT WASHER

MACHINE SCREW

LOCK WASHER

HEX NUT

AIR COMPRESSOR COVER

AIR COMPRESSOR

90 ADAPTOR

PIPE NIPPLE

PIPE CAP

PULLEY ASSY

KNOB

PRESSURE RELIEF VALVE

PIPE ELBOW

SERVICE TEE

VENTURI

PIPE COUPLING

REDUCER PIPE BUSHING

PIPE PLUG

AIR COMPRESSOR DRIVE KEY

PARTS LIST

46181−907 Air Compressor Assembly

PART

NUMBER

K#10

X#10−02

J#10

D#10

38354−043

26813−112

25412−003

T0616

V06

44112−003

38429−501

26662−029

R04

US04

26817−003

AE08

AR0804

P08

24113−601


OM−06027

QTY

1

1

1

1

1

4

4

4

4

1

1

1

1

1

1

1

1

1

REF

MAT’L

CODE

15991

15991

15991

15991

15120

−−−

−−−

15079

15079

−−−

19220

−−−

11999

119991

−−−

15079

15079

15079

−−−


OM−06027

SECTION DRAWING

PA SERIES

Figure 8. 48275−005 Priming Chamber Kit

ITEM

NO.

PART NAME

7

8

9

5

6

3

4

1

2

PRIMING CHAMBER ASSY

PIPE BUSHING

STREET ELBOW

BALL VALVE

STUD

HEX NUT

LOCK WASHER

GASKET

BAFFLE


PAGE E − 16

PART

NUMBER

46112−709

AP1608

RS08

26631−052

C0809

D08

J08

38687−053

31113−011

MAT’L

CODE

−−−

11999

11999

−−−

15991

15991

15991

19060

17000


QTY

4

1

1

4

4

1

1

1

1

PA SERIES

SECTION DRAWING

OM−06027

4

5

6

2

3

ITEM

NO.

1

Figure 9. 46112−709 Priming Chamber Assembly

PARTS LIST

PART NAME

PRIMING VALVE

−ORIFICE BUTTON

HEX HD CAPSCREW

LOCKWASHER

PRIMING VALVE GASKET

PRIMING CHAMBER

STRAINER ASSY



PART

NUMBER

26664−007

26688−021

B0806

J08

38683−657

38343−020

46641−222

MAT’L

CODE

−−−

−−−

15991

15991

19060

10000

17000

PAGE E − 17

QTY

8

8

1

1

1

1

1

OM−06027

SECTION DRAWING

PA SERIES

Figure 10. 44162−160 Drive Assembly

ITEM

NO.

6

6

5

5

7

7

3

4

1

2

PAGE E − 18

PART NAME

COUPLING KIT

−BUSHING

−COUPLING ASSEMBLY

LOCK WASHER

SOCKET HEAD CAPSCREW

SOCKET HEAD CAPSCREW

HEX HD CAPSCREW

HEX HD CAPSCREW

HEX HD CAPSCREW

LOCK WASHER

USE FOR SAE APPLICATIONS

USE FOR METRIC APPLICATIONS

PART

NUMBER

48112−005

24131−496

24391−105

21171−536

BD0606−1/2

22644−220

B0605

22645−164

22645−164

21171−511

MAT’L

CODE

−−−

−−−

−−−

−−−

15991

−−−

15991

−−−

−−−

−−−


QTY

8

8

12

12

1

8

1

1

12

12


PUMP AND SEAL DISASSEMBLY

AND REASSEMBLY


Follow the instructions on all tags, label and decals attached to the pump.

This pump requires little service due to its rugged, minimum-maintenance design. However, if it becomes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the Sectional Views (see Figures 1 through 10) and the corresponding Parts Lists. Maintenance and repair instructions for the engine and air compressor are covered separately in the specific literature supplied by the manufacturers.

This manual will alert personnel to known procedures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel. However, this manual cannot possibly anticipate and provide detailed 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 maintenance procedures are used, and that any procedures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such practices.

Some pump service functions may be performed without separating the pump end assembly from the engine. However, the priming chamber (2, Figure 4) and discharge check valve assembly (28,

Figure 4) must be removed to service most pump components. The following instructions assume complete disassembly of the pump is required.

This manual will alert personnel to known procedures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel.

However, this manual cannot possibly anticipate 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 maintenance procedures are used, and that any procedures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such practices.



2. Shut down the engine and disconnect the positive battery cable to ensure that the pump will remain inoperative.


4. Check the temperature and make sure it is cool before opening any covers, plates, gauges, or plugs.



7. Drain the pump.

Before attempting to service the pump, shut down the engine and take precautions to ensure that it will remain inoperative. Close all valves in the suction and discharge lines and drain the pump casing by removing the casing drain plug (20, Figure

5). Clean and reinstall the drain plug.


This pump is designed to handle material which could cause illness through di-

PAGE E − 19

OM−06027 rect exposure or emitted fumes. Wear adequate protective clothing when working on the pump or piping.

This pump is equipped with an automatic starting system, and is subject to automatic restart. Keep hands and clothing away from the unit to prevent injury during automatic operation. Disconnect the positive battery cable before performing any maintenance. Failure to do so may result in serious personal injury.

Use only replacement parts provided or approved by Gorman-Rupp. Use of nonauthorized parts may result in damage to the equipment and/or injury to personnel and will invalidate the warranty.

Priming Chamber Removal And Disassembly

(Figure 8)

Disconnect both the suction piping and the air discharge tubing from the priming chamber assembly

(1). Support the priming chamber assembly using a sling and a suitable lifting device. Remove the hardware (6 and 7) and separate the priming chamber assembly, gasket (8) and baffle (9) from the pump assembly.

(Figure 9)

Remove the hardware (2 and 3) securing the priming valve (1) to the priming chamber (5). Carefully lift the valve components from the priming chamber. Remove the gasket (4) and clean the mating surfaces.

If the priming valve float is stuck or the strainer (6) is clogged, it can usually be cleaned without further disassembly.

The only serviceable part of the priming valve is the orifice button (not shown). If liquid continues to bypass through the priming chamber after adjusting

PAGE E − 20

PA SERIES the orifice button (see Priming Chamber Reassembly and Installation for adjustment), the button may require replacement. To replace the orifice button, remove one of the e-clips" from the pivot pin closest to the orifice button and remove the pivot pin. This will allow the linkage to be raised high enough to access the orifice button.

Remove the hex nut and lockwasher securing the orifice button to the linkage bar and unscrew the orifice button from the linkage bar.

Discharge Check Valve Removal and

Disassembly

(Figure 4)

Remove the hardware (not shown) securing the discharge check valve bracket to the base.

Support the discharge check valve assembly (26) using a sling and a suitable lifting device. Remove the hardware (not shown) and separate the discharge check valve assembly and gasket (not shown) from the pump assembly (1).

The flapper and cover O-ring are the only serviceable parts of the check valve. If the flapper requires replacement, remove the hardware securing the cover. Separate the cover and O-ring and remove the flapper.

Separating Pump and Drive Assembly From

Engine

(Figure 4)

The pump and drive assembly must be separated from the engine before further disassembly.

Disengage the hardware (11, 12 and 13) and remove the belt guard assembly (10). Remove the hardware (17, 18 and 19) securing the air compressor assembly (8) to the mounting flange (8,

Figure 5). Use a pry bar to raise the air compressor high enough to remove the spacers (20). Remove the belt (9) from the air compressor drive pulley

(not shown).

Disconnect all hoses and fittings from the air compressor and use a suitable hoist and sling to remove the air compressor assembly.

(Figure 9)

Support the pump end using a hoist and sling, and remove the hardware (not shown) securing the pump casing to the base.


PA SERIES

Remove the hardware (6 and 7) securing the mounting flange (18, Figure 6) to the engine bellhousing. Remove the intermediate guards (20,

Figure 6) and separate the assemblies by pulling the intermediate straight away from the engine.

As the assemblies separate, the flexible portion of the coupling assembly (3) will remain on the shaft.

To remove the coupling from the shaft, unscrew the two allen head setscrews from the bushing (2).

Screw one of the setscrews into the puller hole on the circumference of the bushing. As the coupling and bushing separate, remove the bushing, and slide the coupling off the shaft. Remove the shaft key (23, Figure 6).

It is not necessary to remove the outer ring of the coupling from the engine flywheel unless the coupling must be replaced. To remove the ring, disengage the hardware (4 and 5) securing it to the flywheel.

Remove any leveling shims used under the casing mounting feet. Tie and tag the shims for ease of reassembly.

Move the pump end to a clean, well equipped shop area for further disassembly.

(Figure 4)

Remove the belt (9). Remove the capscrews from the center of the bushing (25). Reinstall the capscrews in the tapped holes in the bushing and tighten them in an alternating pattern until the bushing is jacked" out of the sprocket (24). Slide the bushing and sprocket off the shaft. Remove the key (31,

Figure 6).

Draining Oil From Seal Cavity

(Figure 6)

If any further disassembly is to be performed on the pump, the seal oil cavity must be drained to prevent the oil in the seal cavity from escaping as the pump casing is removed.

Position a clean container under the seal cavity drain plug (15A). Remove the plug and drain the oil from the seal cavity into the container. For shorter drain time, remove the vented plug (10). Clean and reinstall the drain plug and vent plug. Inspect the

MAINTENANCE & REPAIR oil for water, dirt or a cloudy condition which could indicate seal failure.

Loosening Impeller

(Figure 6)

With the pump end separated from the engine, wedge a block of wood between the vanes of the impeller (1) and the pump casing (1, Figure 5) to prevent rotation.

Install the shaft key (23) in the shaft keyway. Install a lathe dog on the drive end of the shaft (24) with the V" notch positioned over the shaft key.

With the impeller rotation still blocked, see Figure

11 and use a long piece of heavy bar stock to pry against the arm of the lathe dog in a counterclockwise direction (when facing the drive end of the shaft). Use caution not to damage the shaft or keyway. When the impeller breaks loose, remove the lathe dog, key and wood block.

Turn

Counterclockwise

Lathe Dog Arm

OM−06027

Heavy

Bar Stock

V" Notch

Shaft Key

Impeller Shaft

Lathe Dog

Setscrew

Figure 11. Loosening Impeller

Pump Casing And Wear Plate Removal

(Figure 5)

Support the pump casing using a suitable hoist and sling.

Use lifting and moving equipment in

PAGE E − 21

OM−06027 good repair and with adequate capacity to prevent injuries to personnel or damage 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. Suction and discharge hoses and piping must be removed from the pump before lifting.

NOTE

Drain the oil from the seal cavity before removing the pump casing. See Draining Oil From Seal Cavity .

Remove the hardware (9 and 10) securing the pump casing (1) to the rotating assembly (8). Pull the pump casing straight away from the rotating assembly to prevent binding on the impeller. Remove the shims (12) and clean the contacting surfaces. Tie and tag the shims or measure and record their thickness for ease of reassembly.

Inspect the wear plate assembly (7) for excessive wear or scoring. If replacement is required, remove the hardware (2 and 3) and pull the wear plate out of the pump casing.

PA SERIES

Use a pair of stiff wires with hooked ends to remove the stationary element and seat from the seal plate

(4).

An alternate method of removing the stationary seal components is to remove the hardware (7 and

8) and separate the seal plate and gasket (5) from the bearing housing (9). Position the seal plate on a flat surface with the impeller side down. Use a wooden dowel or other suitable tool to press on the back side of the stationary seat until the seat, Orings, and stationary element can be removed.

Remove the shaft sleeve O-ring (26) and seal plate

O-ring (27).

If no further disassembly is required, refer to Seal

Installation .

Shaft and Bearing Removal and Disassembly

(Figure 6)

When the pump is properly operated and maintained, the bearing housing should not require disassembly. Disassemble the shaft and bearings only when there is evidence of wear or damage.

Impeller Removal

(Figure 6)

With the rotating assembly removed from the pump casing, unscrew the impeller (1) from the shaft (24). Use caution when unscrewing the impeller; tension on the shaft seal spring will be released as the impeller is removed. Inspect the impeller and replace if cracked or badly worn.

Remove the impeller adjusting shims (2); tie and tag the shims, or measure and record their thickness for ease of reassembly.

Seal Removal

(Figures 6 and 13)

Slide the integral shaft sleeve and rotating portion of the seal off the shaft as a unit.

PAGE E − 22

Shaft and bearing disassembly in the field is not recommended. These operations should be performed only in a properly equipped shop by qualified personnel.

Remove the bearing housing drain plug (15) and drain the lubricant. Clean and reinstall the drain plug.

Disengage the hardware (16 and 17) and remove the mounting flange (18), gasket (19) and oil seal

(6A). Press the oil seal from the mounting flange.

Place a block of wood against the impeller end of the shaft (24) and tap the shaft and assembled bearings (22 and 25) from the bearing housing.

Press the oil seals (6 and 6B) from the bearing housing.

After removing the shaft and bearings, clean and inspect the bearings in place as follows.



To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place . It is strongly recommended that the bearings be replaced any time the shaft and bearings are removed.

Clean the bearing housing, shaft and all component parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage and replace as necessary.

If bearing replacement is required, remove the snap ring (21) and use a bearing puller to remove the inboard and outboard bearings from the shaft.

Shaft and Bearing Reassembly and Installation

(Figure 6)

Inspect the shaft (24) for distortion, nicks or scratches, or for thread damage on the impeller end. Dress small nicks and burrs with a fine file or emery cloth. Replace the shaft if defective.

Clean and inspect the bearings as indicated in

Shaft And Bearing Removal And Disassembly .

Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent containers.

Clean the bearings thoroughly in fresh cleaning solvent. Dry the bearings with filtered compressed air and coat with light oil.

To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place . It is strongly recommended that the bearings be replaced any time the shaft and bearings are removed.

The bearings may be heated to ease installation.

An induction heater, hot oil bath, electric oven, or hot plate may be used to heat the bearings. Bearings should never be heated with a direct flame or directly on a hot plate.

NOTE

If a hot oil bath is used to heat the bearings, both the oil and the container must be absolutely clean. If the oil has been previously used, it must be thoroughly filtered.

Bearings must be kept free of all dirt and foreign material. Failure to do so will greatly shorten bearing life. Do not spin dry bearings. This may scratch the balls or races and cause premature bearing failure.

Rotate the bearings by hand to check for roughness or binding and inspect the bearing balls. If rotation is rough or the bearing balls are discolored, replace the bearings.

The bearing tolerances provide a tight press fit onto the shaft and a snug slip fit into the bearing housing. Replace the bearings, shaft, or bearing housing if the proper bearing fit is not achieved.


NOTE

Position the outboard bearing (22) on the shaft with the retaining ring on the bearing O.D. toward the drive end of the shaft .

Heat the bearings to a uniform temperature no higher than 250 F (120 C), and slide the bearings onto the shaft, one at a time, until they are fully seated against the shaft shoulders. This should be done quickly, in one continuous motion, to prevent the bearings from cooling and sticking on the shaft.

After the bearings have been installed and allowed to cool, check to ensure that they have not moved

PAGE E − 23

OM−06027 away from the shaft shoulders in shrinking. If movement has occurred, use a suitably sized sleeve and a press to reposition the bearings against the shaft shoulders.

If heating the bearings is not practical, use a suitably sized sleeve and an arbor (or hydraulic) press to install the bearings on the shaft.

When installing the bearings onto the shaft, never press or hit against the outer race, balls, or ball cage. Press only on the inner race.

Secure the outboard bearing to the shaft with the snap ring (21)

Apply a light coating of oil to the lip of the inboard oil seal (6B) and press it into the bearing housing bore with the lip positioned as shown in Figure 6. Press the oil seal into the housing until the face is just flush with the machined surface on the housing.

It is recommended that a sleeve be positioned against the inboard oil seal to prevent the lip of the oil seal from rolling as the shaft and bearings are installed in the bearing housing. The O.D. of the sleeve should be just smaller than the bearing housing bore, while the I.D. of the sleeve should be just larger than the O.D. of the lip seal area of the shaft.

With the lip seal sleeve in place, lubricate the lip seal area of the shaft, and slide the shaft and assembled bearings into the bearing housing until the retaining ring on the outboard bearing seats against the bearing housing. Remove the lip seal sleeve.

PA SERIES face of the oil seal should be just flush with the machined face of the bearing housing.

Apply a light coating of oil to the lip of the oil seal

(6A) and press it into the mounting flange (18) with the lip positioned as shown in Figure 6. The face of the oil seal should be flush with the chamfer on the mounting flange bore.

Install the mounting flange gasket (19) and secure the mounting flange to the bearing housing with the hardware (16 and 17). Be careful not to damage the lip of the oil seal on the shaft keyway.

Lubricate the bearings as indicated in LUBRICA-

TION at the end of this section.

Securing Bearing Housing And Drive Assembly

To Engine

(Figure 4)

Install the key (31, Figure 6) in the shaft keyway, making sure to leave room in the keyway for the drive key (23, Figure 6). Install the sprocket (24) and bushing (25) on the shaft to the dimension shown in Figure 12.

NOTE

When properly installed to the dimension shown in

Figure 12, the key (23, Figure 6) will not extend fully through the bushing. This is an acceptable fit for this application.

When installing the shaft and bearings into the bearing bore, push against the outer race. Never hit the balls or ball cage.

Apply a light coating of oil to the lip of the outboard oil seal (6) and press it into the bearing housing with the lip positioned as shown in Figure 6. The

PAGE E − 24

Figure 12. Drive Sprocket Positioning

Secure the bushing and sheave to the shaft by torqueing the bushing screws to 23.3 ft. lbs. (280 in. lbs. or 3,2 m. kg.). Install the belt (9) over the


PA SERIES OM−06027 sprocket and up through the slot in the mounting flange (18, Figure 6).

(Figure 10)

Install the shaft key (23, Figure 6) in the shaft keyway. Position the flexible portion of the coupling assembly (3) on the shaft as shown in Figure 6.

NOTE

The flexible portion of the coupling must be properly positioned on the shaft. The heads of the capscrews in the center of the coupling must be positioned away from the pump .

Make certain that the flexible portion of the coupling is just flush with the end of the shaft. This positioning is critical.

If the coupling is not properly positioned on the shaft, the coupling parts may not fully engage, or a pre-load condition can cause premature bearing failure.

The end of the shaft must be just flush with the face of the bushing. This will allow the two portions of the coupling to fully engage when the intermediate is secured to the engine bellhousing, without pre-loading the bearings.

With the flexible portion of the coupling and the bushing properly positioned on the shaft, tighten the two setscrews in an alternating sequence until the bushing and coupling are fully secured. Torque the setscrews to 23.3 ft. lbs. (280 in. lbs. or 3,2 m.

kg.).

If the complete coupling assembly is being replaced, apply ‘Loctite Retaining Compound No.

242’ or equivalent to the threads of the hardware (4 and 5), and secure the outer ring of the coupling to

MAINTENANCE & REPAIR the engine flywheel by torquing the hardware to 45 ft. lbs. (540 in. lbs. or 6,2 m. kg.).

Using a suitable lifting device, position the assembled drive and rotating assembly so the flexible portion of the coupling seats inside the outer ring attached to the engine flywheel.

NOTE

To ease installation, lightly lubricate the rubber portion of the coupling with a non-petroleum based lubricant such as vegetable oil or glycerin, or a silicon-based lubricant such as WD40" or equivalent.

Do not use petroleum-based lubricants, or any other substance which may soften or otherwise damage the rubber.

Align the keyway in the bushing (2) with the shaft key, and slide it onto the shaft until the face of the bushing is just flush with the end of the shaft. Rotate the flexible portion of the coupling until the tapped holes for the two setscrews align with those in the bushing, and install the setscrews.

Install the intermediate guards (20, Figure 6) and secure the mounting flange to the engine bellhousing with the previously removed hardware (6 and

7).

(Figure 3)

Use a suitable hoist and sling to position the air compressor assembly (8) on the mounting flange

(18, Figure 6). Slide the belt (9) over the air compressor sprocket. Use a pry bar to raise the compressor high enough to install the spacers (20) between the compressor and the mounting flange.

Secure the compressor to the mounting flange with the hardware (17, 18 and 19). Reinstall the guard (10) and secure it with the hardware (11, 12 and 13).

Seal Reassembly and Installation

(Figures 6, 13, 14 and 15)

Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent containers.

Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent. Inspect the stationary seat bore in the seal plate for dirt, nicks and burrs, and remove any that exist. The stationary seat bore

PAGE E − 25

OM−06027 must be completely clean before installing the seal.

A new seal assembly should be installed any time the old seal is removed from the

SPRING

RETAINER

PA SERIES pump. Wear patterns on the finished faces cannot be realigned during reassembly.

Reusing an old seal could result in premature failure.

To ease installation of the seal, lubricate the shaft sleeve O-ring and the external stationary seat Oring with a very small amount of light lubricating oil.

See Figure 13 for seal part identification.

SEAL PLATE

O-RINGS

IMPELLER

SLEEVE

O-RING

IMPELLER

SHIMS

IMPELLER

SHAFT

BELLOWS

ROTATING

ELEMENT

STATIONARY

ELEMENT

INTEGRAL

SHAFT

SLEEVE

SPRING

CENTERING

WASHER

SHEAR

RING

(SHEARED)

DRIVE BAND

STATIONARY

SEAT

Figure 13. 46513−151 Cartridge Seal Assembly

This seal is not designed for operation at temperatures above 160 F (71 C). Do not use at higher operating temperatures.

the tubing wall should be as thin as possible. The length should be long enough to cover the threads on the end of the shaft. Slide the tube over the shaft threads, then slide the O-ring off the tube and onto the shaft. Remove the tube, and continue to slide the O-ring down the shaft until it seats against the shaft shoulder.

If the seal plate was removed, install the seal plate gasket (5). Position the seal plate over the shaft and secure it to the bearing housing with the hardware (7 and 8).

When installing a new cartridge seal assembly , remove the seal from the container, and remove the mylar storage tabs from between the seal faces.

To prevent damaging the shaft sleeve O-ring (26) on the shaft threads, stretch the O-ring over a piece of tubing. The I.D. of the tubing must be slightly larger than the O.D. of the shaft. To ease installation

PAGE E − 26

New cartridge seal assemblies may be


PA SERIES equipped with mylar storage tabs between the seal faces. These storage tabs must be removed before installing the seal.

Lubricate the external stationary seat O-ring with light oil. Slide the seal assembly onto the shaft until the external stationary seat O-ring engages the bore in the seal plate.

OM−06027

STATIONARY SEAT

FULLY SEATED IN

SEAL PLATE BORE

Clean and inspect the impeller as described in Impeller Installation and Adjustment . Install half of the set of impeller shims (2) provided with the seal, and screw the impeller onto the shaft until it is seated against the seal (see Figure 14).

O-RING ENGAGED

WITH SEAL PLATE

BORE

SHEAR RING

(SHEARED)

Figure 15. Seal Fully Installed

Measure the impeller-to-seal plate clearance, and add or remove impeller adjusting shims to obtain the proper clearance as described in Impeller Installation and Adjustment .

If necessary to reuse an old seal in an emergency, carefully separate the rotating and stationary seal faces from the bellows retainer and stationary seat.

Figure 14. Seal Partially Installed

Continue to screw the impeller onto the shaft. This will press the stationary seat into the seal plate bore.

NOTE

SHEAR RING

(UNSHEARED)

A firm resistance will be felt as the impeller presses the stationary seat into the seal plate bore.

A new seal assembly should be installed any time the old seal is removed from the pump. Wear patterns on the finished faces cannot be realigned during reassembly.

Reusing an old seal could result in premature failure.

Handle the seal parts with extreme care to prevent damage. Be careful not to contaminate precision finished faces; even fingerprints on the faces can shorten seal life. If necessary, clean the faces with a non-oil based solvent and a clean, lint-free tissue.

Wipe lightly in a concentric pattern to avoid scratching the faces.

Carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.

As the stationary seat becomes fully seated, the seal spring compresses, and the shaft sleeve will break the nylon shear ring. This allows the sleeve to slide down the shaft until seated against the shaft shoulder. Continue to screw the impeller onto the shaft until the impeller, shims, and sleeve are fully seated against the shaft shoulder (see Figure

15).


Do not attempt to separate the rotating portion of the seal from the shaft sleeve when reusing an old seal. The rubber bel-

PAGE E − 27

OM−06027 lows will adhere to the sleeve during use, and attempting to separate them could damage the bellows.

Inspect the seal components for wear, scoring, grooves, and other damage that might cause leakage. Inspect the integral shaft sleeve for nicks or cuts on either end. If any components are worn, or the sleeve is damaged, replace the complete seal; never mix old and new seal parts .

Install the stationary seal element in the stationary seat. Press this stationary subassembly into the seal plate bore until it seats squarely against the bore shoulder. A push tube made from a piece of plastic pipe would aid this installation. The I.D. of the pipe should be slightly larger than the O.D. of the shaft sleeve.

Slide the rotating portion of the seal (consisting of the integral shaft sleeve, spring centering washer, spring, bellows and retainer, and rotating element) onto the shaft until the seal faces contact.

Proceed with Impeller Installation and Adjustment .

Impeller Installation And Adjustment

(Figure 5)

Inspect the impeller (1) and replace it if cracked or badly worn.

The shaft and impeller threads must be completely clean before reinstalling the impeller. Even the slightest amount of dirt on the threads can cause the impeller to seize to the shaft, making future removal difficult or impossible without damage to the impeller or shaft.

Apply a small amount of ‘Never-Seez’ or equivalent anti-lock compound on the shaft threads. Screw the impeller onto the shaft until tight.

NOTE

At the slightest sign of binding, immediately back the impeller off, and check the threads for dirt. Do not try to force the impeller onto the shaft .

PAGE E − 28

PA SERIES

A clearance of .025 to .040 inch (0,64 to 1,02 mm) between the impeller and the seal plate is necessary for maximum pump efficiency. Measure this clearance, and add or remove impeller adjusting shims as required.

Pump Casing And Wear Plate Installation

(Figure 5)

If the wear plate (7) was removed, position the replacement wear plate in the casing and secure it with the hardware (2 and 3).

Lubricate the O-rings (11 and 13) with light grease, and install them in the grooves in the bearing housing and seal plate. Ease the rotating assembly into the pump casing. Be careful not to damage the Orings.

Install the same thickness of adjusting shims (12) as previously removed, and secure the rotating assembly to the pump casing with the hardware (9 and 10). Do not fully tighten the capscrews until the impeller face clearance has been set.

A clearance of .010 to .020 inch (0,25 to 0,5 mm) between the impeller and the wear plate is also recommended for maximum pump efficiency. This clearance can be obtained by adding or removing an equal thickness of shims from each rotating assembly shim sets (12) until the impeller scrapes against the wear plate when the shaft is turned. After the impeller scrapes, add approximately .010

inch (0,25 mm) of shims to each shim set.

After the face clearance has been set, tighten the hardware securing the rotating assembly to the pump casing.

Reinstall any leveling shims used under the pump casing mounting feet and secure the casing (1) to the base with the previously removed hardware.

Discharge Check Valve Reassembly And

Installation

(Figure 4)

If the discharge check valve (26) was disassembled to replace the flapper or cover O-ring, position the flapper in the valve body and check to ensure free movement.

Install the valve cover O-ring and secure the cover to the body with the previously removed hardware.


PA SERIES

Apply a small amount of light grease to the discharge flange gasket to hold it in place and position it against the pump casing flange. Support the discharge check valve assembly using a sling and a suitable lifting device. Using the previously removed hardware, secure the discharge check valve assembly and flange gasket to the pump assembly (1).

Priming Chamber Assembly And Installation

(Figure 9)

Clean and inspect the components of the priming valve (1). Inspect the linkage and ensure the orifice button (not shown) squarely engages the valve seat. Replace the orifice button if required (see

Priming Chamber Removal and Disassembly for orifice button removal).

If the orifice button was removed, screw the new orifice button into the linkage bar until fully seated.

Align the hole in the linkage bar with the holes in the bracket and reinstall the pivot pin. Secure the pivot pin with the previously removed e-clip".

Adjust the orifice button seating as necessary by screwing the orifice button into or out of the linkage bar. Proper adjustment is achieved when the orifice button fully seats against the orifice before the linkage bar on the float bottoms against the threads on the orifice button. When adjustment is complete, install and tighten the lock washer and hex nut securing the orifice button.

Install the strainer (6) and priming valve gasket (4).

Lower the float into the priming chamber (5) and secure the priming valve with the previously removed hardware (2 and 3).

(Figure 8)

Install the baffle (9) and gasket (8) and use a sling and suitable lifting device to position the priming chamber assembly on the hopper spool (32, Figure 4). Secure the priming chamber assembly with the hardware (6 and 7).

Reconnect the suction piping to the hopper spool and the air discharge tubing to the priming chamber assembly.


LUBRICATION

OM−06027

Seal Assembly

(Figure 6)

Before starting the pump, remove the vented plug

(10) and fill the seal cavity with approximately 5 quarts (4,7 liters) of SAE No. 30 non-detergent oil or to the center of the sight gauge (4, Figure54).

Clean and reinstall the vented plug. Maintain the oil level at the middle of the sight gauge.

Bearings

(Figure 6)

The bearing housing was fully lubricated when shipped from the factory. Check the oil level regularly through the sight gauge (13) and maintain it at the midpoint of the gauge. When lubrication is required, remove the air vent (12) and add SAE No.

30 non-detergent oil through the opening. When lubricating a dry (overhauled) intermediate, fill the bearing cavity with approximately 28 ounces (0,8 liter). Clean and reinstall the air vent. Do not overlubricate. Over-lubrication can cause the bearings to over-heat, resulting in premature bearing failure.

NOTE

The white reflector in the sight gauge must be positioned horizontally to provide proper drainage.

Under normal conditions, drain the bearing housing once each year and refill with clean oil. Change the oil more frequently if the pump is operated continuously or installed in an environment with rapid temperature change.

Monitor the condition of the bearing lubricant regularly for evidence of rust or moisture condensation. This is especially important in areas where variable hot and cold temperatures are common.

For cold weather operation, consult the factory or a lubricant supplier for the recommended grade of oil.

Engine

Consult the literature supplied with the engine, or contact your local engine representative.

PAGE E − 29

For U.S. and International Warranty Information,

Please Visit www.grpumps.com/warranty or call:

U.S.: 419−755−1280

International: +1−419−755−1352

For Canadian Warranty Information,

Please Visit www.grcanada.com/warranty or call:

519−631−2870

THE GORMAN-RUPP COMPANY MANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA

Gorman-Rupp Pumps PA4A60C-4024T-ESP 1362521 and up User Manual 52 Pages

Gorman-Rupp Pumps PA4A60C-4024T-ESP 1362521 and up User Manual

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

PA SERIES PUMP

MODEL

PA4A60C−4024T−ESP

THE GORMAN-RUPP COMPANY MANSFIELD, OHIO

INTRODUCTION

SAFETY - SECTION A

INSTALLATION − SECTION B

OPERATION − SECTION C

TROUBLESHOOTING − SECTION D

Preventive Maintenance Schedule

PUMP MAINTENANCE AND REPAIR − SECTION E

For U.S. and International Warranty Information,

Please Visit www.grpumps.com/warranty or call:

U.S.: 419−755−1280

International: +1−419−755−1352

For Canadian Warranty Information,

Please Visit www.grcanada.com/warranty or call:

519−631−2870

THE GORMAN-RUPP COMPANY MANSFIELD, OHIO

Related manuals

Gorman-Rupp Pumps PA4A60C-4024T-ESP 1362521 and up User Manual 52 Pages

Gorman-Rupp Pumps PA4A60C-4024T-ESP 1362521 and up User Manual

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AND MAINTENANCE MANUAL

WITH PARTS LIST

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THE GORMAN-RUPP COMPANY MANSFIELD, OHIO

INTRODUCTION

SAFETY - SECTION A

INSTALLATION − SECTION B

OPERATION − SECTION C

TROUBLESHOOTING − SECTION D

Preventive Maintenance Schedule

PUMP MAINTENANCE AND REPAIR − SECTION E

For U.S. and International Warranty Information,

Please Visit www.grpumps.com/warranty or call:

U.S.: 419−755−1280

International: +1−419−755−1352

For Canadian Warranty Information,

Please Visit www.grcanada.com/warranty or call:

519−631−2870

THE GORMAN-RUPP COMPANY MANSFIELD, OHIO

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