Gorman-Rupp Pumps PA4A60-4024T-ESP User Manual

ACDEU

OM−06301−01

January 8, 2010

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

PA SERIES PUMP

MODEL

PA4A60−4024T−ESP

THE GORMAN-RUPP COMPANY  MANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED  ST. THOMAS, ONTARIO, CANADA Printed in U.S.A

www.grpumps.com.

2010 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 PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREINSTALLATION INSPECTION PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Installation PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POSITIONING PUMP PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION AND DISCHARGE PIPING PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Configuration PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections to Pump PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gauges PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION LINES PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fittings PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainers PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealing PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Lines In Sumps PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Line Positioning PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISCHARGE LINES PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Siphoning PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALIGNMENT PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTO-START PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Float Switch Installation PAGE B − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

PRIMING PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Starting PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Starting PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Routine Operation PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation In Extreme Heat PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATIONAL CHECKS PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leakage PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Vacuum Check PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature And Overheating PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainer Check PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STOPPING PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Stopping PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Stopping PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Shutdown System PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

TABLE OF CONTENTS

(continued)

PERIODIC CHECKS PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Cavity and Bearing Lubrication PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearing Temperature Check PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Compressor PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Checks PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COLD WEATHER PRESERVATION PAGE C − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

STANDARD PERFORMANCE CURVE PAGE E − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS LISTS:

Pump Model PAGE E − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Unit Kit PAGE E − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Assembly PAGE E − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump End Assembly PAGE E − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Rotating Assembly PAGE E − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Kit PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Assembly PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Assembly PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E − 15. . . . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Removal And Disassembly PAGE E − 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Discharge Check Valve Removal and Disassembly PAGE E − 16. . . . . . . . . . . . . . . . . . . . . . . . .

Separating Pump And Drive Assembly From Engine PAGE E − 16. . . . . . . . . . . . . . . . . . . . . . . .

Draining Oil From Seal Cavity PAGE E − 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loosening Impeller PAGE E − 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Casing And Wear Plate Removal PAGE E − 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Removal PAGE E − 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Removal PAGE E − 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft and Bearing Removal and Disassembly PAGE E − 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft and Bearing Reassembly and Installation PAGE E − 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing Bearing Housing And Drive Assembly To Engine PAGE E − 20. . . . . . . . . . . . . . . . . .

Seal Reassembly and Installation PAGE E − 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Installation And Adjustment PAGE E − 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Casing And Wear Plate Installation PAGE E − 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Discharge Check Valve Reassembly And Installation PAGE E − 24. . . . . . . . . . . . . . . . . . . . . . .

Priming Chamber Assembly And Installation PAGE E − 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE E − 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Assembly PAGE E − 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearings PAGE E − 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine PAGE E − 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

INTRODUCTION

OM−06301PA SERIES

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 non­volatile, non-flammable liquids containing speci­fied entrained solids. 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.

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.

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 Gorman­Rupp Company:

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

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

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.

PAGE I − 1INTRODUCTION

PA SERIES

SAFETY - SECTION A

This information applies to Prime Aire
Series pumps. Refer to the manual ac­companying the engine before attempt­ing to begin operation.

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.

r

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

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.

OM−06301

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.

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-

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.

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.

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

PAGE A − 1SAFETY

PA SERIESOM−06301

hose connections are tight, properly
supported and secure before operation.

Do not operate the pump against a
closed discharge valve. If operated
against a closed discharge valve, pump
components will deteriorate, and the
liquid could come to a boil, build 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.

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.

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.

fingers or tools, causing severe injury to
personnel.

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 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.

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.

Never tamper with the governor to gain
more power. The governor establishes

safe operating limits that should not be
Do not operate the pump without guards
in place over the rotating parts. Ex­posed rotating parts can catch clothing,

PAGE A − 2 SAFETY

exceeded. The maximum continuous

operating speed for this pump is 1950

RPM.

PA SERIES OM−06301

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.

Most of the information pertains to a standard
static lift application where the pump is positioned
above the free level of liquid to be pumped.

If installed in a flooded suction application where
the liquid is supplied to the pump under pressure,
some of the information such as mounting, line

OUTLINE DRAWING

configuration, and priming must be tailored to the

specific application. Since the pressure supplied

to the pump is critical to performance and safety,

be sure to limit the incoming pressure to 50% of the

maximum permissible operating pressure as

shown on the pump performance curve.

For further assistance, contact your Gorman-Rupp

distributor or the Gorman-Rupp Company.

Pump Dimensions

See Figure 1 for the approximate physical dimen-

sions of this pump.

Figure 1. Pump Model PA4A60C−4024T−ESP

PREINSTALLATION INSPECTION

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:

a. Inspect the pump for cracks, dents, damaged

threads, and other obvious damage.

b. Check for and tighten loose attaching hard-

ware. Since gaskets tend to shrink after dry­ing, check for loose hardware at mating sur­faces.

PAGE B − 1INSTALLATION

OM−06301 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.

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. Re-

fer 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 re-
placed to ensure maximum pump service.

If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Gorman-Rupp distributor or the factory to deter­mine the repair or updating policy. Do not put the
pump into service until appropriate action has
been taken.

POSITIONING PUMP

Use lifting and moving equipment in

good repair and with adequate capacity

to prevent injuries to personnel or dam-

age to equipment. Attach lifting equip-

ment to the lifting device fitted to the

pump. If chains or cable are wrapped

around the pump to lift it, make certain

that they are positioned so as not to

damage the pump, and so that the load

will be balanced. The bail is intended for

use in lifting the pump assembly only.

Suction and discharge hoses and pip-

ing must

be removed from the pump be-

fore lifting.

Lifting

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 INSTALLATION

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 mount-

ing 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 posi-

tioned as level as possible to ensure sufficient lubri-

cation and fuel supply to the engine.

If the pump has been mounted on a moveable

base, make certain the base is stationary by setting

PA SERIES OM−06301

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

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 dis-

charge 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 prim-

ing, 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 in-

stalled with the flat part of the reducers uppermost

to avoid creating air pockets. Valves are not nor-

mally used in suction lines, but if a valve is used,

install it with the stem horizontal to avoid air pock-

ets.

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 − 3INSTALLATION

OM−06301 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 dis-

tance 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

PA SERIES OM−06301

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

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.

If the application involves a high discharge

head, gradually close the discharge

throttling valve before stopping the pump.

ALIGNMENT

The alignment of the pump and engine is critical for

trouble-free mechanical operation. See Section E,

Securing Intermediate And Drive Assembly To

Engine in MAINTENANCE AND REPAIR, for de-

tails.

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 installa-

tion details for the liquid level sensing system pro-

vided with your pump.

PAGE B − 5INSTALLATION

OM−06301 PA SERIES

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-

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 teth-

ered 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, posi-

tion 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

CABLE

TETHER

POINT

1.25" Pipe
(Not Furnished)

ON

(Emptying)

OFF

(Filling)

OPERATING

RANGE

(See Table Below)

OFF

(Emptying)

ON

(Filling)

Figure 3. Float Switch Data

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)

APPROXIMATE FREE CORD LENGTH IN FT. (M)

2.0

(0.6)

3.0

(0.9)

4.0

(1.2)

PAGE B − 6 INSTALLATION

PA SERIES

OM−06301

OPERATION − SECTION C

Review all SAFETY information in Section A.

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

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.

OPERATION

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 educ-

tor 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.

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 IN­STALLATION. Make sure that the piping connec-

tions are tight, and that the pump is securely
mounted. Check that the pump is properly lubri-

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.

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. Dis-

connect the positive battery cable be-

fore performing any maintenance. Fail-

ure to do so may result in serious per-

sonal injury.

Consult the engine operations manual before at-

tempting 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-

OPERATION PAGE C − 1

OM−06301 PA SERIES

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.

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.

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 appli-

cable).

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 Maintenance and Repair, Sec-

tion E for the maximum continuous op-

erating speed for this pump.

Operation In Extreme Heat

The safety shutdown system will automatically

stop the unit if engine operating temperature ex-

ceeds design limits. If engine over-temperature

shutdown occurs, allow the unit to cool before re-

starting.

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.

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

nance and Repair manual for further details.

Routine Operation

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 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. Dis-

connect the battery before performing

any maintenance. Failure to do so may

result in serious personal injury.

OPERATIONAL CHECKS

Leakage

Once the pump is fully primed, no leakage should

be visible at pump mating surfaces, or at pump

OPERATIONPAGE C − 2

PA SERIES

OM−06301

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.

Strainer Check

Check the strainer regularly, and clean it as neces-

sary. 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 neces-

sary, 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 en-

gine 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’.

If the application involves a high discharge

head, gradually close the discharge

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 tempera-

throttling valve before stopping the pump.

After stopping the pump, switch off the engine igni-

tion and remove the key to ensure that the pump

will remain inoperative.

tures, and vapor pressure within the
pump can cause parts being disen-

Automatic Stopping

gaged 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
plug to prevent injury to personnel from
hot liquid.

OPERATION PAGE C − 3

In the automatic mode, the pump will stop when

the liquid in the wet well or sump lowers and acti-

vates the Off" float switch(s). The pump will restart

automatically when the liquid rises and activates

the On" float switch(s).

OM−06301 PA SERIES

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.

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, Main-
tenance and Repair). Bearing overheating can
also be caused by shaft misalignment and/or ex­cessive vibration.

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.

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.

Additional Checks

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

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

OPERATIONPAGE C − 4