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GORMAN-RUPP PUMPS PA Series Installation, Operation And Maintenance Manual

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OM-07620-01
SEPTEMBER 14, 2023
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
PA SERIES® PUMP
MODELS:
PA4A60-4045T S5-ESP
GORMAN-RUPP PUMPS | GRPUMPS.COM
© 2023 The Gorman-Rupp Company.

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Summary of Contents for GORMAN-RUPP PUMPS PA Series

  • Page 1 OM-07620-01 SEPTEMBER 14, 2023 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST PA SERIES® PUMP MODELS: PA4A60-4045T S5-ESP GORMAN-RUPP PUMPS | GRPUMPS.COM © 2023 The Gorman-Rupp Company.
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ....................PAGE I - 1 SAFETY - SECTION A ..................PAGE A - 1 INSTALLATION - SECTION B ................PAGE B - 1 Pump Dimensions ............................. PAGE B - 1 PREINSTALLATION INSPECTION ..........................PAGE B - 2 Battery Installation ............................
  • Page 4 TABLE OF CONTENTS (continued) PERIODIC CHECKS ..............................PAGE C - 4 Seal Cavity and Bearing Lubrication ......................PAGE C - 4 Bearing Temperature Check ........................... PAGE C - 4 Engine Fuel Filter ............................... PAGE C - 5 Engine Oil ................................PAGE C - 5 COLD WEATHER PRESERVATION .........................

  • Page 5: Introduction

    PA SERIES OM-07620 INTRODUCTION HAZARD AND INSTRUCTION Thank You for purchasing a Gorman-Rupp pump. Read this manual carefully to learn how to safely in- DEFINITIONS stall and operate your pump. Failure to do so could re- sult in personal injury or damage to the pump.

  • Page 6: Safety - Section A

    PA SERIES OM-07620 SAFETY - SECTION A This information applies to Prime Aire® Series pumps. Refer to the manual ac companying the en- gine or power source before attempting to begin oper ation. Do not attempt to disengage any part of Because pump installations are seldom identical, an overheated pump unit.
  • Page 7 PA SERIES OM-07620 After the pump has been positioned, Do not operate the pump without the make certain that the pump and all piping guards in place over the rotating parts. connections are tight, properly support- Exposed rotating parts can catch cloth- ed and secure before operation.
  • Page 8 PA SERIES OM-07620 Fuel used by internal combustion engines Never tamper with speed control presents extreme explosion settings to gain more power. These re hazard. Make certain that all settings establish safe operating limits fuel lines are securely connected and that should not be exceeded.

  • Page 9: Installation Section B

    PA SERIES OM-07620 INSTALLATION SECTION B Review all SAFETY information in Section A. tion. Since the pressure supplied to the pump is critical to performance and safety, be sure to limit the incom- Since pump installations are seldom identical, this sec-...

  • Page 10: Battery Installation

    PA SERIES OM-07620 POSITIONING PUMP Carefully read all tags, decals, and marking- son the pump assembly, and perform all duties indicated. Note that the pump shaft rotates in the required direction. Death or serious personal injury and damage to the pump or components can...

  • Page 11: Suction And Discharge Piping

    PA SERIES OM-07620 Guages The pump is drilled and tapped for installing discharge If the pump has been mounted on a pressure and vacuum suction gauges. It is recom- movable base, do not attempt to oper- mended that gauges be installed to monitor pump ate the pump unless the unit is level.

  • Page 12: Suction Lines In Sumps

    PA SERIES OM-07620 be sealed with pipe dope to ensure an air- tight seal. If two suction lines are installed in a single sump, the Follow the sealant manufacturer’s rec ommendations flow paths may interact, reducing the efficiency of one when selecting and applying the pipe dope.

  • Page 13: Discharge Lines

    PA SERIES OM-07620 Figure 2. Recommened 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 If the application involves a high discharge breaker is used in the line.

  • Page 14: Float Switch Installation

    PA SERIES OM-07620 Float Switch Installation away from the flow. If a stand pipe is available, attach the float switch cable to the standpipe in the sump at The Float Switch auto-start system employs either a the approximate desired liquid level.
  • Page 15 PA SERIES OM-07620 ing chamber never fully freezes. Next, install a drain line between the pump drain and the wet well or sump. This line must remain sub- The second method involves configuring the pumping merged in the liquid below the pump down lev el of system to drain both the priming chamber and pump the liquid level control device;...

  • Page 16: Operation - Section C

    PA SERIES OM-07620 OPERATION - SECTION C Review all SAFETY information in Section A. Maintenance and Repair, Section E for further details. STARTING Follow the instructions on all tags, labels and decals attached to the pump. Check the fuel level and oil levels in the engine, air compressor, pump bearings and seal housing.

  • Page 17: Operation In Extreame Heat

    PA SERIES OM-07620 tions or fittings. Keep all line connections and fittings tight to maintain maximum pump efficiency. Pump Vacuum Check Never tamper with speed control Read the vacuum gauge with the pump primed and settings to gain more power. These at operation speed.

  • Page 18: Stopping

    PA SERIES OM-07620 essary. The strainer should also be checked if pump flow rate begins to drop. If a vacuum suc- All safety shutdown features are preset at the factory tion gauge has been installed, monitor and record for optimum performance and safety; do not attempt the readings regularly to detect strainer blockage.

  • Page 19: Engine Fuel Filter

    PA SERIES OM-07620 COLD WEATHER PRESERVATION and/or excessive vibration. When pumps are first started, the bearings may seem If the pump will idle for an extened period of time in below freezing conditions, drain the pump and prim- to run at temperatures above normal. Continued per- ing hopper to prevent damage from freezing.

  • Page 20: Troubleshooting - Section D

    PA SERIES OM-07620 TROUBLESHOOTING - SECTION D Review all SAFETY information in Section A. This pump is equipped with an auto- Before attempting to open or service matic starting system, and is subject the pump: 1. Familiarize yourself with this manual.
  • Page 21 PA SERIES OM-07620 TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP STOPS OR FAILS TO DELIVER Discharge Check Valve Clogged Check and clean check valve RATED FLOW OR PRESSURE (cont.) Impeller or other wearing parts Replace worn or damaged parts worn or damaged...

  • Page 22: Preventive Maintenance

    PA SERIES OM-07620 TROUBLE POSSIBLE CAUSE PROBABLE REMEDY BEARINGS RUN TOO HOT Bearing temperature is high, but Check bearing temperature regu- within limits larly to monitor any increase Low or incorrect lubricant Check for proper type and level of lubricant...
  • Page 23 PA SERIES OM-07620 Preventive Maintenance Schedule Service Interval* Item Semi- Daily Weekly Monthly 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)

  • Page 24: Pump Maintenance And Repair - Section E

    PA SERIES OM-07620 PUMP MAINTENANCE AND REPAIR - SECTION E MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE. * STANDARD PERFORMANCE FOR PUMP MODEL PA4A60-4045T S5-ESP * Based on 70°F (21°C) clear water at sea level with Contact the Gorman-Rupp Company to verify per- minimum suction lift.
  • Page 25 PA SERIES OM-07620 ILLUSTRATION Figure 1. Pump Model PA4A60-4045T S5-ESP MAINTENANCE & REPAIR PAGE E-2...

  • Page 26: Parts Lists

    PA SERIES OM-07620 PARTS LIST PUMP MODEL PA4A60-4045T S5-ESP (From S/N 1841973 Up) If your pump serial number is followed by an “N”, your pump is NOT a standard production model. Contact the Gorman-Rupp Company to verify part numbers. Item Part Name Part No.
  • Page 27 PA SERIES OM-07620 ILLUSTRATION Figure 2. Pump Model PA4A60-4045T S5-ESP (cont’d) MAINTENANCE & REPAIR PAGE E-4...
  • Page 28 PA SERIES OM-07620 Pump Model PA4A60-4045T S5-ESP PARTS LIST Item Part Name Part No. PUMP END ASSEMBLY 46133-518 POWER UNIT J DEERE 4045T S5 46143-283 ENCLOSURE ASSEMBLY 42164-088 AIR INTAKE PIPE 31418-160 15210 90 DEG COBRA ELBOW, 4” 29284-080 T-BOLT CLAMP 4-1/2”...
  • Page 29 PA SERIES OM-07620 ILLUSTRATION Figure 3. Power Unit Kit MAINTENANCE & REPAIR PAGE E-6...

  • Page 30: Power Unit Kit

    PA SERIES OM-07620 PARTS LIST Power Unit Kit Item Part Name Part No. Item Part Name Part No. BASE/FUEL TANK ASSEMBLY 41553-055 24150 HOSE ASSEMBLY 46341-426 JD 4045T S5 ENGINE 29224-489 CONNECTOR 26351-065 CNTRL PNL INSTALL KIT 48122-610 PRESSURE RELIEF VALVE...
  • Page 31 PA SERIES OM-07620 ILLUSTRATION DETAIL A Figure 4. Power Unit Kit (Continued) MAINTENANCE & REPAIR PAGE E-8...
  • Page 32 PA SERIES OM-07620 PARTS LIST Power Unit Kit (Continued) Item Part Name Part No. Item Part Name Part No. BASE/FUEL TANK ASSEMBLY 41553-055 24150 HOSE ASSEMBLY 46341-426 JD 4045T S5 ENGINE 29224-489 CONNECTOR 26351-065 CNTRL PNL INSTALL KIT 48122-610 PRESSURE RELIEF VALVE...
  • Page 33 PA SERIES OM-07620 ILLUSTRATION Figure 5. Pump Assembly MAINTENANCE & REPAIR PAGE E-10...
  • Page 34 PA SERIES OM-07620 PARTS LIST Pump Assembly Item Part Name Part No. PUMP END ASSEMBLY 46133-517 GASKET 1676G 18000 » STUD C1011 15991 HEX NUT D10 15991 LOCK WASHER J10 15991 4” HOPPER SPOOL 38644-802 10000 CHECK VALVE KIT 4”...
  • Page 35 PA SERIES OM-07620 ILLUSTRATION Figure 6. Pump End Assembly MAINTENANCE & REPAIR PAGE E-12...

  • Page 36: Pump End Assembly

    PA SERIES OM-07620 PARTS LIST Pump End Assembly Item Part Name Part No. » REPAIR PUMP CASING SEE NOTE BELOW WEAR PLATE ASSY 10532B 15990 REPAIR ROTATING ASSEMBLY 44163-594 LOCK WASHER J06 15991 HEX NUT D06 15991 O-RING 25154-273 O-RING S1674 SHIM SET - .50 DIA SHAFT...
  • Page 37 PA SERIES OM-07620 ILLUSTRATION SEAL AREA DETAIL Figure 7. Repair Rotating Assembly MAINTENANCE & REPAIR PAGE E-14...

  • Page 38: Repair Rotating Assembly

    PA SERIES OM-07620 PARTS LIST Repair Rotating Assembly Item Part Name Part No. IMPELLER 10528 11010 ADJ. SHIM SET 37J 17090 1.50 SEAL ASSY 46513-151 SEAL PLATE 38272-234 10010 GASKET 10959G 20000 OIL SEAL S1352 LOCK WASHER J08 15991 HEX HEAD CAP SCREW...
  • Page 39 PA SERIES OM-07620 ILLUSTRATION Figure 8. Priming Chamber Kit PARTS LIST Item Part Name Part No. PRIMING CHAMBER ASSEMBLY 46112-709 REDUCER PIPE BUSHING AP1608 15070 STREET ELBOW RS08 11999 BALL VALVE 1/2” 26631-052 STUD C0809 15991 HEX NUT D08 15991...

  • Page 40: Priming Chamber Kit

    PA SERIES OM-07620 ILLUSTRATION Figure 9. Priming Chamber Assembly PARTS LIST Item Part Name Part No. PRIMING VALVE 26664-007 -ORIFICE BUTTON 26688-021 HEX HEAD CAP SCREW B0806 15991 LOCK WASHER J08 15991 PRIMING VALVE GASKET 38683-657 19060 PRIMING CHAMBER 38343-020 10000...
  • Page 41 PA SERIES OM-07620 ILLUSTRATION Figure 10. DRIVE ASSEMBLY PARTS LIST Item Part Name Part No. COUPLING KIT 48112-005 -BUSHING 24131-496 -COUPLING ASSEMBLY 24391-105 -LOCKWASHER 21171-536 -SOCKET HEAD CAPSCREW B0606-1/2 15991 - SOCKET HEAD CAPSCREW 22644-220 HEX HEAD CAPSCREW B0605 15991...

  • Page 42: Pump And Seal Disassembly And Reassembly

    PA SERIES OM-07620 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Review all SAFETY information in Section A. Follow the instructions on all tags, label and decals attached to the pump. This manual will alert personnel to known procedures which require special attention,...

  • Page 43: Priming Chamber Removal And Disassembly

    PA SERIES OM-07620 Priming Chamber Removal and Disassembly (Figure 8) Disconnect both the suction piping and the air dis- charge tubing from the priming chamber assembly (1). Death or serious personal injury and Support the priming chamber assembly using a sling damage to the pump or components can and a suitable lifting device.

  • Page 44: Separating Pump And Drive Assembly From Engine

    PA SERIES OM-07620 parts of the check valve. If the flapper requires replace- plug (15). Remove the plug and drain the oil from the ment, remove the hardware securing the cover. Sepa- seal cavity into the container. For shorter drain time, rate the cover and gasket and remove the flapper.

  • Page 45: Impeller Removal

    PA SERIES OM-07620 NOTE Remove the shaft sleeve O‐ring (26) and seal plate O‐ Drain the oil from the seal cavity before removing the ring (28). pump casing. See Draining Oil From Seal Cavity. If no further disassembly is required, refer to Seal In- stallation.

  • Page 46: Shaft And Bearing Reassembly And Installation

    PA SERIES OM-07620 Clean the bearing housing, shaft and all component the shaft if defective. parts (except the bearings) with a soft cloth soaked in cleaning solvent. Inspect the parts for wear or damage Clean and inspect the bearings as indicated in Shaft and Bearing Removal and Disassembly.
  • Page 47 PA SERIES OM-07620 the shaft shoulders. Install the drive flange gasket (19) and secure the drive If heating the bearings is not practical, use a suitably flange to the bearing housing with the hard ware (16 sized sleeve, and an arbor (or hydraulic) press to install and 17).

  • Page 48: Seal Reassembly And Installation

    PA SERIES OM-07620 With the flexible portion of the coupling and the bush- ing 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 Most cleaning solvents are toxic and am- 23.3 ft.
  • Page 49 PA SERIES OM-07620 RETAINER SEAL PLATE SPRING O‐RINGS IMPELLER SLEEVE O‐RING IMPELLER SHIMS IMPELLER SHAFT INTEGRAL SHAFT ROTATING STATIONARY SLEEVE BELLOWS ELEMENT ELEMENT SHEAR SPRING RING CENTERING (SHEARED) WASHER STATIONARY DRIVE BAND SEAT Figure 12. Cartridge Seal Assembly O‐RING ENGAGED...

  • Page 50: Impeller Installation And Adjustment

    PA SERIES OM-07620 shaft shoulder (see Figure 14). STATIONARY SEAT FULLY SEATED IN SEAL PLATE BORE Do not attempt to separate the rotating portion of the seal from the shaft sleeve when reusing an old seal. The rubber bellows will adhere to the sleeve during use, and attempting to separate them could damage the bellows.

  • Page 51: Discharge Check Valve Reassembly And Installation

    PA SERIES OM-07620 Apply a small amount of `Never‐Seez’ or equivalent ing mounting feet and secure the casing (1) to the base anti‐lock compound on the shaft threads. Screw the with the previously removed hardware impeller onto the shaft until tight.

  • Page 52: Lubrication

    PA SERIES OM-07620 Lower the float into the priming chamber (5) and se- Bearings cure the priming valve with the previously re moved hardware (2 and 3). (Figure 7) (Figure 8) The bearing housing was fully lubricated when shipped from the factory. Check the oil level regu larly...
  • Page 53 For Warranty Information, Please Visit www.grpumps.com/warranty or call: U.S.: 419-755-1280 Canada: 519-631-2870 International: +1-419-755-1352 GORMAN‐RUPP PUMPS...

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Pa4a60-4045t s5-esp

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