Page 1
ACU
OM‐06099‐01
March 14, 2008
Rev. A 05‐15‐12
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
SUBMERSIBLE PUMPS
MODELS
S4B1-E50 460/3
and
S4B1-E50 575/3
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
2008 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.
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:
Page 3
TABLE OF CONTENTS
INTRODUCTION PAGE I - 1.................................................
SAFETY ‐ SECTION A PAGE A - 1............................................
INSTALLATION - SECTION B PAGE B - 1....................................
GENERAL INFORMATION PAGE B - 1..................................................
PUMP SEAL PAGE B - 1..............................................................
LUBRICATION PAGE B - 1.............................................................
PUMP INSTALLATION PAGE B - 1......................................................
Pump Motor Specifications PAGE B - 2..............................................
Pump Dimensions PAGE B - 2.....................................................
Lifting PAGE B - 2.................................................................
Positioning the Pump PAGE B - 3...................................................
Piping PAGE B - 3................................................................
ELECTRICAL CONNECTIONS PAGE B - 4...............................................
Field Wiring Connections (Incoming Power) PAGE B - 4...............................
Grounding Methods PAGE B - 5....................................................
Pump Power Cable Connections PAGE B - 6.........................................
Control Box Specifications PAGE B - 7..............................................
Motor Cable Grounding Test PAGE B - 7.............................................
Control Box Connections PAGE B - 7...............................................
Liquid Level Devices PAGE B - 7....................................................
WIRING DIAGRAMS PAGE B - 8.......................................................
OPERATION - SECTION C PAGE C - 1......................................
GENERAL INFORMATION PAGE C - 1..................................................
Pump Performance PAGE C - 1.....................................................
Control Box PAGE C - 1...........................................................
PUMP OPERATION PAGE C - 1........................................................
Liquid Temperature And Overheating PAGE C - 1.....................................
Impeller Rotation PAGE C - 2.......................................................
STARTING, STOPPING AND OPERATIONAL CHECKS PAGE C - 3.........................
Starting PAGE C - 3...............................................................
Stopping PAGE C - 3..............................................................
Operational Checks PAGE C - 3....................................................
COLD WEATHER PRESERVATION PAGE C - 4...........................................
LUBRICATION PAGE C - 4.............................................................
Draining Oil PAGE C - 5...........................................................
Condition of Oil Oil PAGE C - 5.....................................................
Adding Oil 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........................................
i
Page 4
TABLE OF CONTENTS
(continued)
PARTS LISTS:
Pump Assemblies PAGE E - 3......................................................
Terminal Housing and Cable Assemblies PAGE E - 5..................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 6.........................
PUMP END DISASSEMBLY PAGE E - 7.................................................
Strainer Removal PAGE E - 7.......................................................
Draining Oil From Seal Cavity PAGE E - 7............................................
Draining Oil From Motor Cavity PAGE E - 7..........................................
Positioning Pump For Disassembly PAGE E - 7.......................................
Strainer Plate and Suction Head Removal PAGE E - 7.................................
Impeller Removal PAGE E - 7......................................................
Lower Seal Removal PAGE E - 8....................................................
Upper Seal Removal PAGE E - 8...................................................
PUMP END REASSEMBLY PAGE E - 8..................................................
Cleaning and Inspection of Pump Parts PAGE E - 8...................................
Upper Seal Installation PAGE E - 9..................................................
Lower Seal Installation PAGE E - 10..................................................
Impeller Installation PAGE E - 11.....................................................
Suction Head and Strainer Plate Installation PAGE E - 11...............................
Strainer Screen and Base Plate Installation PAGE E - 12................................
MOTOR DISASSEMBLY PAGE E - 12....................................................
Terminal Housing and Power Cable Removal and Disassembly PAGE E - 12..............
Intermediate and Motor Housing Disassembly PAGE E - 13.............................
Rotor and Bearing Removal PAGE E - 13.............................................
Stator Removal PAGE E - 14........................................................
Relief Valve PAGE E - 14............................................................
Hoisting Bail PAGE E - 15...........................................................
MOTOR REASSEMBLY PAGE E - 15.....................................................
Stator Installation PAGE E - 15......................................................
Bearing Installation PAGE E - 16.....................................................
Rotor and Intermediate Reassembly PAGE E - 17......................................
Terminal Housing and Power Cable Reassembly and Installation PAGE E - 18.............
Sealing Terminal Housing Connections With Silicone Adhesive PAGE E - 18..............
Sealing Terminal Housing Connections With Potting Compound PAGE E - 20.............
Terminal Housing Installation PAGE E - 21............................................
FINAL ASSEMBLY PAGE E - 21.........................................................
VACUUM TESTING PAGE E - 21........................................................
LUBRICATION PAGE E - 22.............................................................
Seal Cavity PAGE E - 22............................................................
Motor Housing Cavity PAGE E - 23...................................................
ii
Page 5
INTRODUCTION
OM-06099S SERIES PUMPS
Thank You for purchasing a Gorman‐Rupp S Se
ries Pump. Read this manual carefully to learn
how to safely install and operate your pump. Fail
ure to do so could result in personal injury or dam
age to the pump.
Because pump installations are seldom identical,
this manual cannot possibly provide detailed in
structions and precautions for every aspect of
each specific application. Therefore, it is the re
sponsibility of the owner/installer of the pump to
ensure that applications not addressed in this
manual are performed only after establishing that
neither operator safety nor pump integrity are com
promised by the installation. Pumps and related
equipment must be installed and operated ac
cording to all national, local and industry stan
dards.
The pump motor must be operated through the
control box furnished with the pump as standard
equipment. For control box information, consult
the separate control box manual accompanying
the unit.
Pump construction is aluminum, with ductile iron
wearing parts. The pump may be operated fully or
partially submerged. Neither the pump nor the
control box are explosion‐proof, and should not be
operated in a hazardous atmosphere.
RECORDING MODEL AND
SERIAL NUMBER
Please record the pump model and serial number
in the spaces provided on the inside front cover of
this manual. Your Gorman‐Rupp distributor needs
this information when you require parts or service.
WARRANTY INFORMATION
The warranty provided with your pump is part of
Gorman‐Rupp's support program for customers
who operate and maintain their equipment as de
scribed in this and the other accompanying litera
ture. Please note that should the equipment be
abused or modified to change its performance be
yond the original factory specifications, the war
ranty will become void and any claim will be de
nied.
The following are used to alert personnel to proce
dures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel:
If there are any questions regarding the pump
which are not covered in this manual or in other lit
erature accompanying the unit, please contact
your Gorman‐Rupp distributor or the Gorman‐
Rupp Company:
The Gorman‐Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: (419) 755-1011
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-2870
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure re
quired and the injury which will result
from failure to follow the procedure.
Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.
PAGE I - 1INTRODUCTION
Page 6
OM-06098
S SERIES PUMPS
damage which could result from failure to
follow the procedure.
Hazards or unsafe practices which COULD
result in minor personal injury or product or
property damage. These instructions de
scribe the requirements and the possible
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
PAGE I - 2 INTRODUCTION
Page 7
OM-06099 S SERIES PUMPS
SAFETY - SECTION A
This information applies to the S Series
submersible motor driven pumps indi
cated on the front cover of this manual.
Before connecting any cable to the con
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and pre
cautions for each specific application.
Therefore, it is the owner/installer's re
sponsibility to ensure that applications
not addressed in this manual are per
formed only after establishing that nei
ther operator safety nor pump integrity
are compromised by the installation.
trol box, be sure to ground the control
box. Refer to the Control Box Manual for
the suggested grounding methods.
The pump motor is designed to be oper
ated through the control box furnished
with the pump. The control box provides
overload protection and power control.
Do not connect the pump motor directly
to the incoming power lines.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Lock out incoming power to the
control box to ensure that the
pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Close the discharge valve (if
used).
This pump is not designed to pump vol
atile, explosive, or flammable materials.
Do not attempt to pump any liquids for
which you pump is not approved, or
which may damage the pump or endan
ger personnel as a result of pump fail
ure. Consult the factory for specific ap
plication data.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Obtain the services of a
qualified electrician to make all electri
cal connections. Make certain that the
pump and enclosure are properly
grounded; never use gas pipe as an
electrical ground. Be sure that the in
coming power matches the voltage and
phase of the pump and control before
connecting the power source. Do not
run the pump if the voltage is not within
the limits. If the overload unit is tripped
during pump operation, correct the
problem before restarting the pump.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Make certain that the control
handle on the control box is in the OFF
PAGE A - 1SAFETY
Page 8
S SERIES PUMPS OM-06099
position and locked out, or that the pow
er supply to the control box has been
otherwise cut off and locked out, before
attempting to open or service the pump
assembly. Tag electrical circuits to pre
vent accidental start‐up.
Never attempt to alter the length or re
pair any power cable with a splice. The
pump motor and cable must be com
pletely waterproof. Injury or death may
result from alterations.
All electrical connections must be in ac
cordance with The National Electric
Code and all local codes. If there is a
conflict between the instructions pro
vided and N.E.C. Specifications, N.E.C.
Specifications shall take precedence.
All electrical equipment supplied with
this pump was in conformance with
N.E.C. requirements in effect on the
date of manufacture. Failure to follow
applicable specifications, or substitu
tion of electrical parts not supplied or
approved by the manufacturer, can re
sult in severe injury or death and void
warranty.
After the pump has been installed, make
certain that the pump and all piping or
hose connections are secure before op
eration.
trician to troubleshoot, test and/or ser
vice the electrical components of this
pump.
Approach the pump cautiously after it
has been running. Although the motor is
cooled by the liquid being pumped, nor
mal operating temperatures can be high
enough to cause burns. The tempera
ture will be especially high if operated
against a closed discharge valve. Never
operate against a closed discharge
valve for long periods of time.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over
heated pump. Vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Al
low the pump to completely cool before
servicing.
Do not attempt to lift the pump by the
motor power cable or the piping. Attach
proper 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 posi
tioned so as not to damage the pump,
and so that the load will be balanced.
Pumps and related equipment must be
installed and operated according to all na
Obtain the services of a qualified elec
PAGE A-2 SAFETY
tional, local and industry standards.
Page 9
S SERIES PUMPS
OM-06099
INSTALLATION - SECTION B
GENERAL INFORMATION
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this
section is intended only to summarize general rec
ommendations and practices required to inspect,
position, and arrange the pump and piping. If there
are any questions concerning your specific instal
lation, contact your Gorman‐Rupp distributor or
the Gorman‐Rupp Company.
Liquid level devices are available from Gorman‐
Rupp as optional equipment. For information on
installing and operating these items, refer to the lit
erature accompanying them.
Pump Model Designation
Following is a description of the model numbering
system for S Series pumps. These submersible
pumps are available in a range of sizes. Refer to the
following chart to identify the size of your specific
pump model.
ratings on the control box and incoming pow
er.
e. Carefully read all tags, decals, and markings
on the pump, and perform all duties indicated.
f. Check for oil leaks. If there is any indication of
an oil leak, see LUBRICATION at the end of
this manual.
PUMP SEAL
There are two shaft seals in the pump. The lower
seal prevents liquid from entering the intermediate
cavity at the impeller end. The upper seal prevents
oil leakage from the motor housing cavity and acts
as back‐up protection in the event of lower seal fail
ure.
LUBRICATION
These pumps utilize two lubrication cavities. The
motor housing cavity provides lubrication to the
motor assembly and bearings, while the intermedi
ate cavity provides lubrication to the pump seal.
Pump Model
S
Series
3 C 1 E 230/3- 6.2
Pump Construction
Discharge Size
Pump Hydraulics
Voltage/Phase
H.P.
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be
fore shipment from the factory. Before installation,
check for damage which may have occurred dur
ing shipment. Check as follows:
a. Inspect the pump assembly for cracks, dents,
damaged threads, and other obvious dam
age.
b. Check for loose attaching hardware. Since
gaskets tend to shrink after drying, check for
loose hardware at the mating surfaces.
c. Inspect the power cable for cuts or any other
obvious damage.
d. Check that amperes, phase, voltage and
hertz indicated on the name plate match the
The pumps are fully lubricated when shipped from
the factory. However, lubrication levels must be
checked before installing the pump (see LU
BRICATION in MAINTENANCE AND REPAIR SECTION E). An additional quart (0,9 liter) of oil is
provided to “top off” the oil level in the pump motor
cavity. If the oil level is abnormally low, determine
the cause before putting the pump into service.
Due to differences in pump design, the quantity of
oil and manner in which oil is to be added to the
seal cavity varies between pump models. Refer to
Table B‐2 for oil capacities and positions for filling
the seal cavity in each pump. Motor cavities requir
ing lubrication should always be positioned verti
cally for filling. Refer to LUBRICATION, Section C
for lubrication specifications and intervals.
PUMP INSTALLATION
When installing or servicing the pump
or controls, follow all requirements for
the installation of wiring or electrical
PAGE B - 1INSTALLATION
Page 10
OM-06099 S SERIES PUMPS
equipment as outlined in the National
Electric Code. Follow all safety require
ments. Failure to observe these require
ments could result in injury or death to
personnel.
Do not allow the free end of the power
cable to enter the liquid being pumped.
The free end of the cable must be kept dry
Table B‐1. Pump Specifications
Model Voltage/
Phase
460/3
S4B
575/3
Dual
Voltage
NO 4 INCH50 HP 1750
Pump
HP/
KW
Motor
Speed
(RPM)
to prevent liquid from wicking through the
cable and into the motor.
NOTE
Refer to the performance curve in Maintenance
and Repair - Section E when determining the
most efficient piping installation. The recom
mended maximum submergence depth is 65
feet.
Pump Motor Specifications
See Table B‐1 for pump specifications.
Full
Load
Amperes
71
57
No
Load
Amperes
14
11
Locked
Rotor
Amperes
246
197
Discharge
Size
(NPT)
Table B‐2. Additional Specifications
Approximate
Weight - Lbs. (kg)
Pump
Model
S4B
Pump Dimensions
For the approximate physical dimensions of your
pump, refer to the pump specification data sheet
or contact your Gorman‐Rupp distributor or the
Gorman‐Rupp Company.
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.
Voltage/
Phase
460/3
575/3
Pump
741 (336) 43 (20) 160 (4,7) 256 (7,6) V
50 Ft. Cable
Oil Capacity
Ounces (Liters)
Seal
Cavity
Refer to Table B-2 for the approximate maximum
weight for your pump.
Motor
Cavity
Seal Cavity
Filling
Position
(H)orizontal
(V)ertical
Do not attempt to lift the pump by the
motor power cable or the piping. Attach
proper 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 posi
tioned so as not to damage the pump,
and so that the load will be balanced.
PAGE B - 2 INSTALLATION
Page 11
S SERIES PUMPS
OM-06099
Positioning the Pump
NOTE
Before installing and operating the pump, check
the direction of impeller rotation to ensure that the
pump is properly wired at the control box. See IM
PELLER ROTATION, Section C.
The pump is designed to operate fully or partially
submerged. The rotating parts are oil lubricated,
and the motor is cooled by a constant flow of liquid
or air discharged through internal passages.
As a safeguard against rupture or explosion due to
heat, models equipped with oil‐lubricated motors
are fitted with a pressure relief valve which will open
if vapor pressure within the pump motor reaches a
critical point.
The pump will operate if positioned on its side, but
this is not recommended because the motor
torque could cause the pump to roll during opera
tion.
The pump should be independently secured and
supported by the lifting device fitted on the pump.
If the application involves a lot of debris, protect the
pump from excessive wear and clogging by sus
pending it in a perforated barrel or culvert pipe. If
the bottom is heavily sludge‐covered, rest the
pump on support blocks or suspend it from a raft
or similar device near the surface of the liquid. See
Figure B-1 for typical pump installations.
All liquid entering the pump must pass through a
strainer screen. Any spherical solids which pass
through the screen will pass through the pump.
BY BAIL IN PERFORATED CULVERT PIPE ON SUPPORTS
Figure B-1 Typical Pump Installations
Piping
No suction piping is required in a standard installa
tion.
These pumps are provided with a suction strainer
to prevent large solids from clogging the impeller.
If required, the strainer can be removed and the
pump suction “staged” to the discharge of another
pump, allowing one pump to feed the other on high
discharge head applications.
To determine the size of the discharge connection,
see Table B-1, Pump Specifications. Either
hose or rigid pipe may be used. To facilitate mobil
ity and maintenance, it is recommended that the
discharge line be fitted with a quick disconnect fit
PAGE B - 3INSTALLATION
Page 12
OM-06099 S SERIES PUMPS
ting near the pump. The discharge line must be in
dependently supported to avoid strain and vibra
tion on the pump.
Either hose or rigid pipe may be used to make dis
charge connections. For maximum pumping ca
pacity, keep the line as short and straight as pos
sible. Elbows and fittings used in discharge lines
increase friction loss, minimize their use.
It is recommended that a check valve or throttling
valve be installed in the discharge line to control si
phoning or back flow when the pump is shut off.
ELECTRICAL CONNECTIONS
Install and operate this pump in accor
dance with the National Electrical Code
and all local codes. Have a qualified
electrician perform all checks and con
nections in this section.
Never attempt to alter the length of the
pump motor cable or to repair it with a
splice. The power cable and pump mo
tor must be kept completely waterproof.
Serious damage to the pump and injury
or death to personnel can result from
any alteration to the cable.
Control Box Installation
sible to the operator, and located close enough to
the pump to avoid excessive voltage drop due to
cable length (see Pump Power Cable Connec
tion). After the box is installed, make certain the
front cover latches properly.
Failure to mount the control box vertically
on a level surface may affect operation of
the pump controls.
Field Wiring Connections (Incoming Power)
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Obtain the services of a
qualified electrician to make all electri
cal connections. Make certain that the
pump and enclosure are properly
grounded; never use gas pipe as an
electrical ground. Be sure that the in
coming power matches the voltage and
phase of the pump and control before
connecting the power source. Do not
run the pump if the voltage is not within
the limits.
Do not connect the pump motor directly
The pump is designed to be operated
through the control box furnished with
the pump. The control box provides
overload protection and power control.
Do not connect the pump motor directly
to the incoming power lines.
The control box is a rainproof enclosure with a pad
lockable front cover. The enclosure is not de
signed to be watertight, and should not be sub
merged. Refer to the control box manual for enclo
sure dimensions and parts.
Secure the control vertically on a level surface,
above flood level. The box should be easily acces
PAGE B - 4 INSTALLATION
to the incoming power lines. The pump
motor is designed to operate through a
Gorman‐Rupp approved control box
which provides overload protection and
power control; otherwise, the pump
warranty will be voided. Make certain
that the pump and control box are prop
erly grounded. Install and operate the
control box in accordance with the Na
tional Electric Code and all local codes.
Failure to follow these could result in in
jury or death to personnel.
Field wiring is not provided with the pump, and
must be supplied by the user. The field wiring must
Page 13
S SERIES PUMPS
OM-06099
be of the proper size and type to ensure an ade
quate voltage supply to the pump. Voltage avail
able at the motor must be within the range indi
cated in Table B‐3.
To calculate the voltage available at the motor, pro
ceed as follows:
a. Measure the voltage across the incoming
lines (1 & 2 for single phase, 1 & 2, 2 & 3, and 1
& 3 for three phase) while the pump is oper
ating at full capacity. Refer to the literature
supplied with the control box for power supply
connections.
b. Next, subtract the motor cable voltage drop
(see Table 4, Pump Power Cable Specifica
tions).
c. Do not continue to operate the pump if this
voltage is not within the recommended limits.
Obtain the services of a qualified electrician to
determine the correct field wiring size and oth
er details to ensure an adequate voltage sup
ply to the pump.
Table B‐3. Pump Voltage Requirements
NOMINAL
VOLTAGE
575 3 520 630
Make certain all connections are tight and that
cable entry points are rainproof. Support the cable
weight, if required, to prevent excessive strain on
cable clamps and cable.
Grounding Methods
Electrically ground the installation before connect
ing the field wiring to the control box. Install a
grounding terminal to the enclosure and connect
it to a properly embedded electrode.
The material used for the electrode must be an ex
cellent conductor of electricity, such as copper. If
iron or steel is used, it must be galvanized or other
wise metal plated to resist corrosion. Do not coat
the electrode with any material of poor conductiv
ity, such as paint or plastic.
The electrode must conform to the recommenda
tions of N.E.C. ARTICLE 250. Follow all installation
requirements of the N.E.C., and all applicable
codes. See Figure B-3 for some suggested
grounding methods.
PHASE
3460 420 500
MINIMUM
VOLTAGE
MAXIMUM
VOLTAGE
a) PLATE ELECTRODE b) DRIVEN ELECTRODE c) BURIED ELECTRODE
SOIL
1/4 INCH (6,4 MM)
STEEL PLATE 2 SQ.
FEET (1858,1 SQ. CM)
SURFACE AREA
(MINIMUM)
Figure B-3. Suggested Grounding Methods
a. Plate Electrode: An iron or steel plate, 1/4
inch (6,4 mm) thick, completely impeded in
the ground. The plate must present a surface
area of at least 2 square feet (1858,1 sq. cm.).
SOIL
3/4 INCH (19,1
MM) NOMINAL
DIAMETER
(MINIMUM)
8 FEET
(2,4 M)
b. Driven Electrode: A rod or pipe, 3/4 inch
(19,1 mm) in diameter minimum, 8 feet (2,4 m)
long, completely driven into the ground.
SOIL
3/4 INCH (19,1 MM)
NOMINAL DIAMETER
(MINIMUM) 8 FEET
(2,4 M) LONG
ROCK
PAGE B - 5INSTALLATION
Page 14
OM-06099 S SERIES PUMPS
c. Buried electrode: If rock or stone prevents
embedding the full 8 foot (2,4 m) length of the
ground rod, bury it horizontally in a trench.
Space the ground rod or plates at least 6 feet
(1,8) from any other electrode or ground rod,
such as those used for signal circuits, radio
grounds, lightning rods, etc.
The earth surrounding the ground rod or plate
must contain enough moisture to make a
good electrical connection. In dry or sandy
areas, pour water around the rod, or consult
qualified personnel to devise a method of im
proving the connections.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Make certain that the control
box is properly grounded after installa
tion.
Refer to the literature accompanying the control
box for field wiring connections.
Pump Power Cable Connections
this pump is high enough to cause inju
ry or death. Obtain the services of a
qualified electrician to make all electri
cal connections. Make certain that in
coming power to the control box is in the
OFF position and locked out, or that the
power supply to the control box has
been otherwise cut off and locked out,
before connecting power or accessory
cables.
The pump is provided with a 50 ft. (15,2 m) power
cable (see Table B-4 for standard power cable
specifications). If a longer cable is required, an op
tional cable assembly must be ordered from the
factory. Splicing of the power cable is not recom
mended by the Gorman‐Rupp Company due to
safety and warranty considerations.
Never attempt to alter the length or re
pair any power cable with a splice. The
pump motor and cable must be com
pletely waterproof. Injury or death may
result from alternations.
The electrical power used to operate
Table B‐4. Pump Power Cable Specifications
DC
Amp
Cable
A.W.G
Pump
Model
S4B
NOTE: * Amp Rating at 30C (86F) Canada Use Type SOW Cable
When necessary to change or connect the pump
power cable to the control box, make certain the in
coming power is OFF and LOCKED OUT, Make
certain the control box is PROPERLY GROUNDED
PAGE B - 6 INSTALLATION
Voltage/
Phase
460/3
575/3
** Amp Rating at 40C (104F)
Cable
Size
6 1.01 (26) 0.21 (5) 79** GGC 0.45
O.D.
Inches
(mm)
Conductor
Dia.
Inches
(mm)
Rating
(See
Note
Below)
and that the electrical data on the control matches
the motor name plate data.
Cable
Type
Resistance
(ohms) at
25C (77F)
per 1000 ft.
(305 m)
Voltage
Drop
per 100 ft.
(30,5m) at
Max. Load
6.39
5.13
Page 15
S SERIES PUMPS
OM-06099
Connect the pump power cable to the control box
as shown in the wiring diagrams in the control box
manual. Use conduit or cable clamps to secure the
power cable to the control box. Make certain that
all connections are tight and that cable entry points
are rainproof.
NOTE
The power cable furnished with the pump includes
three electrical conductors (white, red, and black),
two grounding conductors (green) and one ground
check conductor (yellow). The yellow ground
check lead is used in conjunction with customer‐
supplied ground monitoring equipment. If this
equipment is not used, the yellow lead should be
used as a ground conductor.
Control Box Specifications
Any control box used to operate the
pump must be approved by the Gor
man‐Rupp Company for the application.
Motor Cable Grounding Test
NOTE
For reference, internal motor wiring connections
are shown in Maintenance and Repair - Section
E.
Liquid Level Devices
The standard pump is not furnished with a means
to automatically regulate liquid level. However, the
pump may be controlled to perform filling or dewa
tering functions by using either of the following op
tional sensing devices (see Figure B-4):
Diaphragm Type: two fixed‐position sen
sors (upper and lower) each contain a dia
phragm which flexes with changes in liquid
level, thus activating an enclosed miniature
switch.
Bulb (Float) Type: a bulb raises or lowers
(floats) with the liquid level, thus activating
an enclosed miniature switch.
The liquid level circuitry may be prewired as a fac
tory option, or easily added to the standard control
box in the field by qualified personnel. The unit is
complete except for the remote float switches. For
installation and operation, see the detailed instruc
tions included with the optional package.
Do not connect the pump control cable
to the control box or incoming voltage
before verifying the pump ground;
otherwise, personnel will be exposed to
serious injury or death.
Using a volt‐ohm meter, connect one lead to the
motor cable green/yellow ground lead. Connect
the other lead to an uninsulated point on the pump
body. The test circuit should close.
If the test circuit does not close, there is a defect in
the cable or motor which must be corrected.
Control Box Connections
This pump is shipped completely wired for the volt
age shown on the name plate, and is ready for op
eration through an approved control box.
Ground and wire the control box in accordance
with the instructions accompanying it.
Liquid level devices must be positioned far
enough apart to allow 10 minutes between
starts. If the pump motor cycles more than
6 starts per hour, it will over‐heat, resulting
in damage to the motor windings or control
box components.
Other types of liquid level devices may also be
used. Consult the factory for the liquid level device
best suited for your application.
If the pump requires liquid level devices,
install the liquid level devices and connect
them to the control box in accordance with
the instructions accompanying the de
vices.
PAGE B - 7INSTALLATION
Page 16
OM-06099 S SERIES PUMPS
PUMP
CONTROL BOX
TO LEVEL CONTROL CIRCUIT
IN MAIN CONTROL BOX
LIQUID LEVEL
RANGE
OFF
DEWATERING
ON (FILLING)
BULB (FLOAT TYPE)
Figure B-4. Liquid Level Devices
PUMP
CONTROL BOX
TO LEVEL CONTROL CIRCUIT
IN MAIN CONTROL BOX
LIQUID LEVEL
RANGE
OFF
DEWATERING
ON (FILLING)
DIAPHRAGM TYPE
cluded with the option before making wir
ing connections.
WIRING DIAGRAMS
The internal wiring of the sensing devices
are different for filling and dewatering func
tions. Be sure to follow the instructions in
Refer to the appropriate wiring diagram in the liter
ature accompanying the control box when making
electrical connections.
PAGE B - 8 INSTALLATION
Page 17
S SERIES PUMPS OM-06099
OPERATION - SECTION C
GENERAL INFORMATION
Review all SAFETY information in Section A.
The pump motor and control box are not
designed to be explosion‐proof. Do not
operate in an explosive atmosphere.
Any control box used to operate the
This pump is designed to handle most
non‐volatile, non‐flammable liquids. Do
not attempt to pump any liquids for
which your pump is not approved, or
which may damage the pump or endan
ger personnel as a result of pump fail
ure. Consult the factory for specific ap
plication data.
Follow the instructions on all tags, labels and de
cals attached to the pump.
Pump Performance
pump must be approved by the Gor
man‐Rupp Company for the application.
Improper location of a non‐explosion
proof control box could result in de
struction of equipment, injury or death
to personnel.
See the operating instructions furnished with the
control box, and with other optional accessories
and controls, before attempting to start the pump.
PUMP OPERATION
Liquid Temperature and Overheating.
Since operation of the pump motor is de
pendent upon the quality and performance
of the electrical controls, the pump warran
ty is valid only when controls have been
specified or provided by The Gorman‐
Rupp Company.
Refer to the performance curve in Maintenance
and Repair - Section E for the specific perfor
mance for your pump.
Control Box
A control box is provided to facilitate operation of
the pump. It contains controls for starting and stop
ping the pump, and provides overload protection
for the pump motor. The pump control may be
equipped with an optional automatic liquid level
sensing device, in which case those circuits are
also contained within the control box.
Overheated pumps can cause severe
burns and injury. If the pump becomes
overheated:
1. Stop the pump immediately.
2. Lock out the power to the control
panel to ensure that the pump will
remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Close the discharge valve (if
used).
5. Refer to instructions in this manual
before restarting the pump.
Overheating can occur if the pump is misapplied;
if it is started more than 6 times within one hour; if
the temperature of the liquid being pumped ex
ceeds the temperature for which the pump was de
signed, if the control box fails to provide overload
PAGE C - 1OPERATION
Page 18
OM-06099 S SERIES PUMPS
or thermal protection, or if the pump is operated
against a closed discharge valve for an extended
period of time.
Do not start the pump more than 6 times
per hour. If the motor does not cool be
tween starts it will overheat, resulting in
damage to the motor windings.
As a safeguard against rupture or explosion due to
heat, models equipped with oil‐lubricated motors
are fitted with a pressure relief valve which will open
if vapor pressure within the pump motor reaches a
critical point. Always terminate power to the pump
and control before investigating pump or control
box problems.
4. Check the temperature before ser
vicing.
5. Vent the pump slowly and cau
tiously
6. Refer to instructions in this manual
before restarting the pump.
It is recommended that the pressure relief valve as
sembly be replaced at each overhaul, or any time
the pump motor overheats and activates the valve.
Never replace this valve with a substitute which
has not been specified or provided by the Gorman‐
Rupp Company.
Impeller Rotation
Check impeller rotation as follows before operation
to ensure that the impeller is rotating in the correct
direction.
Approach the pump cautiously after it
has been running. Although the motor is
cooled by the liquid being pumped, nor
mal operating temperatures can be high
enough to cause burns. The tempera
ture will be especially high if operated
against a closed discharge valve. Never
operate against a closed discharge
valve for long periods of time.
If overheating does occur, stop the pump immedi
ately and allow it to cool before servicing it. Ap
proach any overheated pump cautiously.
Overheated pumps can cause severe
burns and injuries. If overheating of the
pump occurs:
While checking impeller rotation, secure
the pump to prevent the power cable from
coiling.
Suspend the pump from the lifting device fitted on
the pump. Apply power briefly and note the direc
tion of pump kickback. As viewed from the top, the
pump should kick in a counterclockwise direc
tion; this will indicate that impeller rotation is cor
rect.
If the pump kicks in a clockwise direction, impeller
rotation is incorrect. If the pump is powered by a
three‐phase motor, have a qualified electrician in
terchange the control box connections of any two
pump motor power leads. Re‐check pump kick
back; it should now be in a counterclockwise direc
tion.
If rotation is incorrect on a single‐phase motor, con
tact the factory before installing the pump.
1. Stop the pump immediately.
2. Ventilate the area.
3. Allow the pump to completely cool.
PAGE C - 2 OPERATION
The electrical power used to operate
Page 19
S SERIES PUMPS OM-06099
this pump is high enough to cause inju
ry or death. Make certain that incoming
power is off and locked out before inter
changing motor leads.
Never start the pump more than 6 times per
hour. If the pump motor does not cool be
tween starts, it will over‐heat, resulting in
damage to the motor windings.
Stopping
DIRECTION OF
KICKBACK
AT STARTUP
Figure C-1. Checking Pump Rotation
STARTING, STOPPING, AND
OPERATIONAL CHECKS
Starting
Follow the instructions accompanying the control
box for stopping the pump.
On pumps equipped with a motor ther
mal protector, the integral thermal over
load device will shut off the motor if the
temperature rises above design limits.
When the pump cools and the tempera
ture falls below these limits, the motor
will restart automatically. To avoid the
hazards of an unexpected motor start‐
up, do not attempt to handle or service
the pump unless all power to the motor
has been shut off and locked out at the
control box; otherwise, serious person
al injury could result.
During motor shutoff by the thermal
overload device, control box circuits re
main live. Do not attempt to service any
control box components unless incom
ing power has been shut off.
Do not attempt to operate the pump until
impeller rotation has been checked; im
proper rotation will affect pump perform
ance and may damage the pump.
Follow the instructions accompanying the control
box, start the pump, and run any recommended
checks.
To stop the pump, turn the control handle OFF,
thereby opening the circuit breakers. This does
not terminate incoming power through the field
wiring connected to the control box.
After stopping the pump, be sure to perform all re
quired maintenance and preservation procedures.
Operational Checks
To detect minor problems, check the pump for
proper operation when it is first started, and at peri
odic intervals during operation.
PAGE C - 3OPERATION
Page 20
OM-06099 S SERIES PUMPS
COLD WEATHER PRESERVATION
To avoid serious damage to the pump,
check for unusual noises or excessive vi
bration while the pump is running. If noise
or vibration is excessive, stop operation
and refer to the troubleshooting chart in the
maintenance and repair manual.
Do not attempt to thaw the pump by us
ing a torch or other source of flame. This
could damage gaskets, O‐rings or heat
the oil in the seal housing above critical
temperatures, causing the pump to rup
The suction inlet or impeller may become clogged
with debris. In some cases, stopping the pump
momentarily may backflush this blockage. If back
flushing does not clear the debris, remove the
pump from the sump or wet well and clear manu
ally.
Never introduce air or steam pressure
into the pump casing to remove a block
age. This could result in personal injury
or damage to the equipment. If back
flushing is absolutely necessary, limit
ture or explode.
The pump will not freeze as long as the casing is
submerged in liquid. If the casing is not sub
merged, or if the liquid begins to freeze, remove the
pump from the sump or wet well and dry it thor
oughly. Run the pump for two or three minutes to
dry the inner walls.
If the pump does freeze while it is out of the liquid,
submerge it until thawed; if the liquid is near freez
ing, the pump must be submerged for an extended
period of time. Check thawing by starting the pump
and checking that the shaft rotates freely. If the
pump remains frozen, allow additional thawing
time before attempting to restart.
liquid pressure input to 50% of the maxi
mum permissible operating pressure
shown in the pump performance curve
If submerging does not thaw the pump, move it
into a warm area until completely thawed.
(refer to the accompanying Parts List
Manual).
LUBRICATION
Check the pump for overheating. Overheating can
occur if the pump is misapplied, required to start
repeatedly, if the control box fails to provide over
load or thermal protection, or if the pump is oper
ated against a closed discharge valve for an ex
tended period of time.
Do not remove plates, covers, gauges,
pipe plugs or fittings from an over
heated pump. Vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Al
low the pump to completely cool before
Do not start the pump more than 6 times
servicing.
per hour. If the motor does not cool be
tween starts it will overheat, resulting in
damage to the motor windings.
Check the oil level(s) as indicated in the following
LUBRICATION section.
PAGE C - 4 OPERATION
On a new pump, check the oil level in both seal and
motor cavities before initial startup, and drain and
replace the oil after the first 200 hours of operation.
Following this, check the oil level in the seal cavity
after the first two weeks of operation, and every
Page 21
S SERIES PUMPS OM-06099
month thereafter. Check the motor lubrication level
any time the pressure relief valve is activated, and
replace the oil annually.
Before installing or removing the lubrication
plug(s), always clean the area around the plug(s)
to prevent contamination.
Draining Oil
Refer to the Parts List in Maintenance and Repair
- Section E for drain plug location.
Remove the drain plug slowly to release any pres
sure. Install a short pipe nipple in the hole. Place a
clean container under the plug and, using a hoist,
tilt the pump at an angle of approximately 60.
Repeat the procedure for the motor housing oil.
Condition Of Oil
Adding Oil
Refer to Table B-2 in INSTALLATION for oil ca
pacities and positions for filling the seal cavity in
your pump. Motor cavities requiring lubrication
should always be positioned vertically for filling.
The grade of lubricant used is critical to the opera
tion of this pump. Use premium quality submers
ible pump oil as specified in the following table. Oil
must be stored in a clean, tightly closed container
in a reasonably dry environment.
When lubricating the seal cavity, remove the lu
brication plug as indicated in Draining Oil, and
position the pump as indicated in Table B-2. Add
premium quality submersible pump oil through
this plug hole. If the pump is to be positioned verti
cally or at an angle, fill the cavity to the bottom of
the plug hole. If the pump is to be positioned hori
zontally, completely fill the cavity.
Install and tighten the lubrication plug.
Check the condition of the oil drained from the
pump. Clear oil indicates that the pump seal(s) are
functioning properly. If the oil is milky or contains
a small amount of water, it must be changed.
If the oil contains a large amount of water, it must
be changed, and the seal(s) must be checked be
fore the pump is put back in operation (refer to the
Maintenance and Repair Manual).
When lubricating the motor cavity, add oil through
the hole for the pressure relief valve. If the pump is
equipped with a motor lubricant level plug, remove
this plug and fill the cavity until oil escapes through
the hole. If the pump is not equipped with a motor
lubricant level plug, fill the cavity to the top of the
hole.
Reinstall the pressure relief valve.
PAGE C - 5OPERATION
Page 22
OM-06099 S SERIES PUMPS
Table C-1. Pump Oil Specifications
Specifications:
Type Premium high viscosity index, anti‐wear hydraulic oil..............................
Viscosity @ 100F (38C) 110 to 155...............................................
Viscosity @ 210F (99C) 40 to 50..................................................
Dielectric 26,000 (volts‐min)........................................................
Recommended supplier:
Gulf Oil Company Gulf Harmony HVI AW 26..........................................
Acceptable alternate suppliers:
Gulf Oil Company Gulf Harmony 32 AW..............................................
Texas Oil Company Rando HD 32 or HD AZ 32........................................
Sun Oil Company Sunvis 816 or 916.................................................
BP (Also Boron) Energol‐HLP 32.....................................................
Shell Oil Company Tellus 32, Tellus T‐23 or T32.......................................
ARCO Duro 32...................................................................
Exxon (Also Esso) Nuto H 32........................................................
Petro‐Canada Harmony HVI 22......................................................
PAGE C - 6 OPERATION
Page 23
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.
NOTE
Many of the probable remedies listed in the TROU
BLESHOOTING CHART require use of electrical
test instruments; for specific procedures, see
ELECTRICAL TESTING at the end of the chart.
TROUBLESHOOTING CHART
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
S SERIES PUMPSOM-06099
PUMP FAILS TO
START, OVER
LOAD UNIT NOT
TRIPPED (MANU
AL MODE).
PUMP FAILS TO
START, OVER
LOAD UNIT NOT
TRIPPED (AUTO
MATIC MODE).
Power source incompatible with con
trol box.
No voltage at line side of circuit
breaker.
Open circuit in motor windings or
power cable.
Defective motor power cable. Replace cable.
Defective motor. Check for and replace defective mo
Liquid level device or control circuits
improperly connected to main con
trol box.
Level sensing device(s) improperly
positioned.
Level sensing device(s) fouled with
mud or foreign material.
Float type sensing device(s) tangled
or obstructed.
Defective liquid level sensing de
vice(s) or control panel.
Correct power source.
Check power source for blown fuse,
open circuit breaker, broken lead or
loose connections.
Check continuity.
tor components.
Check wiring diagrams: cor
rect or tighten connections.
Position device(s) at proper
level.
Clean sensing device(s).
Check installation for free
movement of float.
Repair or replace defective unit(s).
OVERLOAD UNIT
TRIPS
TROUBLESHOOTING
Low or high voltage, or excessive
voltage drop between pump and
control box.
Defective insulation in motor wind
ings or power cable; defective wind
ings.
Impeller jammed due to debris or in
sufficient clearance.
Bearing(s) frozen. Disassemble pump and check bear
Measure voltage at control box.
Check that wiring is correct type,
size, and length (see Field Wiring
Connection, Section B).
Check insulation resistance; check
continuity.
Disassemble pump and check im
peller.
ing(s).
PAGE D - 1
Page 24
TROUBLESHOOTING CHART (cont'd)
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
OM-06099S SERIES PUMPS
MOTOR RUNS,
BUT PUMP FAILS
TO DELIVER
RATED DIS
CHARGE.
Discharge head too high. Reduce discharge head or install
staging adaptor and additional
pump.
Low or incorrect voltage. Measure control box voltage, both
when pump is running and when
shut off.
Discharge throttling valve partially
closed; check valve installed improp
erly.
Discharge line clogged or restricted;
hose kinked.
Liquid being pumped too thick. Dilute liquid if possible.
Strainer screen or impeller clogged. Clear clog(s). Stop pump; back flow
Insufficient liquid in sump or tank. Stop pump until liquid level rises.
Worn impeller vanes; excessive im
peller clearance.
Pump running backwards. Check direction of rotation. If incor
Open discharge valve fully; check
piping installation.
Check discharge lines; straighten
hose.
may flush away debris.
Check impeller and clearance (see
PUMP END REASSEMBLY in
Maintenance and Repair, Section
E).
rect, interchange any two motor
leads at the control box (see Pump
Rotation, Section C).
PUMP RUNS
WITH EXCES
SIVE NOISE OR
VIBRATION
Pumping entrained air. Check liquid level in sump; check
position of pump and liquid level
sensing device(s).
Damaged or unbalanced impeller. Replace impeller.
Discharge piping not properly sup
ported.
Impeller jammed or loose. Check impeller.
Motor shaft or bearings defective. Disassemble pump and check mo
Pump is cavitating. Reduce discharge head or restrict
Check piping installation.
tor and bearings.
flow on low head applications.
PAGE D - 2
TROUBLESHOOTING
Page 25
S SERIES PUMPSOM-06099
ELECTRICAL TESTING
Make the electrical checks which follow to deter
mine if pump malfunctions are being caused by
problems in the motor or in the motor cable.
Test Equipment
A volt/amp/ohmmeter and megohmmeter of ade
quate range and quality are required to conduct
the electrical tests which follow.
Equipment Use
Ammeter To check AC Voltage
and current (amperage)
Ohmeter To measure resistance
(ohms) to ground
3. The pump submerged and running under
full load.
The voltage measured under each condition
must be the same.
b. If voltage is balanced when the pump is off but
is imbalanced when the pump is running,
thoroughly check the power source, all inter
connecting cables, and the pump motor to
isolate the defect.
c. Use an Amprobe or equivalent instrument to
measure the current draw (amperage) of
each phase while the pump is running under
full load, and with no load. In each condition,
the amperage readings for all three phases
must match as closely as can be measured.
Normal amperage values are listed in Table 1,
Section B; these values apply only when the
voltage at the site is the normal voltage listed.
Motor and Power Cable Continuity
Refer to the wiring diagram(s) accompany
ing the motor and control box before re
connecting any electrical leads which have
been disconnected. Connections to the
wrong terminals may damage the motor
and/or control devices.
Voltage Imbalance
Use a voltmeter to read each phase of the incom
ing 3 phase power. Each phase must balance with
the other two as closely as can be measured with a
commercial instrument. If the phases are out of
balance, contact your power company. If the
phases are balanced, check out the motor as de
scribed in the following steps:
a. Use a voltmeter, Amprobe, or equivalent in
strument to read the voltage of incoming
power lines 1 and 2, 2 and 3, and 1 and 3 at the
control box. Voltage must match as closely as
can be measured. If possible, measure the
voltage at the control box with:
1. The pump shut off.
2. The pump running in air.
Set the megohmmeter at R x 1 scale and zero‐ba
lance it. Test as follows:
a. Shut off incoming power to the control box,
and disconnect the motor power cable leads.
Connect the megohmmeter test leads to any
two power cable leads, and note the
megohmmeter reading. A high resistance
reading indicates an open or broken circuit in
the power cable or motor windings, or a bad
connection between the motor and cable.
b. Repeat Step a. with each set of leads. The
three readings shall be as close as can be
measured.
c. If readings indicate that continuity problems
exist in the motor or motor cable, the motor
must be returned to the factory or to a U/L‐ap
proved facility.
Insulation Resistance
Set the megohmmeter at R x 100, and zero‐ba
lance it. Test as follows:
a. Shut off incoming power to the control box,
and disconnect the motor power cable leads.
Connect one megohmmeter test lead to the
motor cable green/yellow ground lead. Touch
TROUBLESHOOTING
PAGE D - 3
Page 26
OM-06099S SERIES PUMPS
the other test lead to each of the motor cable
leads in turn. Note the readings.
b. Readings will indicate resistance values in
both the power cable and motor windings.If
resistance reads infinity (1), insulation is
good. If resistance reads between infinity (1),
and 1 megohm, insulation is acceptable but
should be rechecked regularly. If resistance
reads less than 1 megohm, insulation should
be checked more closely and frequently.
c. If readings indicate that a ground exists, test
the stator and motor power cable separately.
Replace as required.
PAGE D - 4
TROUBLESHOOTING
Page 27
OM-06099 S SERIES PUMPS
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 MODELS S4B1-E50 460/3 AND S4B1-E50 575/3
Based on 70F (21C) clear water at sea level
with minimum suction lift. Since pump installations
are seldom identical, your performance may be dif
ferent due to such factors as viscosity, specific
gravity, elevation, temperature, and impeller trim.
Contact the Gorman‐Rupp Company to verify per
formance or part numbers.
Pump speed and operating condition
If your pump serial number is followed by an “N”,
your pump is NOT a standard production model.
points must be within the continuous per
formance range shown on the curve.
PAGE E - 1MAINTENANCE AND REPAIR
Page 28
S SERIES PUMPS OM-06099
SECTION DRAWING
PARTS PAGE
Figure E-1. S4B1-E50 460/3 And S4B1-E50 575/3 Pump Assemblies
MAINTENANCE AND REPAIRPAGE E - 2
Page 29
OM-06099 S SERIES PUMPS
S4B1-E50 460/3 And S4B1-E50 575/3 Pump Assemblies
Parts List
(From S/N 1396095 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.
1 DIFFUSER 10092A 11030 1
2 IMPELLER 10091 11030 1
3 LOWER SEAL ASSY 12430 --- 1
4 UPPER SEAL ASSY S1934 --- 1
5 HEX HD CAPSCREW B1011 15991 6
6 HEX NUT D10 15991 6
7 LOCKWASHER J10 15991 6
8 DIFFUSER GSKT 10092G 20000 1
9 ADJ SHIM SET 37J 17090 REF
10 UPPER IMP WASHER 10047A 17000 1
11 SEAL DRAIN PLUG P06 17000 1
12 SEAL FILL PLUG P06 17000 1
13 MOTOR DRAIN PLUG P06 17000 1
14 RETAINING RING S245 --- 1
15 BEARING CAP GSKT 10085G 20000 1
16 MOTOR HOUSING GSKT 10106G 20000 1
17 MOTOR HOUSING GSKT 10110G 20000 1
18 MOTOR HOUSING GSKT 10112G 20000 1
19 MOTOR HOUSING ASSY 42822-023 24130 1
20 MOTOR OIL LEVEL PLUG P06 17000 1
21 HEX HD CAPSCREW B1006 15991 2
22 LOCKWASHER J10 15991 2
23 WASHER 21161-442 --- 2
24 HOISTING BAIL 10094 2400V 1
25 BAIL BUSHING 10095 15071 2
26 DISCH FLANGE GSKT 1676G 18000 1
27 DISCHARGE FLANGE 1756 10010 1
28 DISCH FLANGE STUD C1010 15991 8
29 HEX NUT D10 15991 8
30 PIPE CAP V16 11999 1
31 STREET TEE ASSY 14138 --- 1
32 PRESS RELIEF VALVE 14139 --- 1
33 FILL TUBE ASSY 10040 24040 1
34 HEAVY PIPE NIPPLE THA1612 15079 1
35 STUD C0607 15991 6
36 DEFORM LOCKNUT DD06 15991 6
37 TERM HSG/CABLE ASSY 47367-059 --- 1
38 UPPER BALL BEARING S1080 --- 1
39 ROTOR/SHAFT ASSY 47112-081 --- 1
40 STATOR ASSY
-460V 47113-083 --- 1
-575V 47113-084 --- 1
41 NAME PLATE 2613CY 17020 1
42 DRIVE SCREW BM#04-03 17000 6
43 LOWER BALL BEARING 23431-461 --- 1
NUMBER
MAT'L
CODE
QTY ITEM
NO.
44 BEARING CAP 10087 10010 1
45 STUD C0810 17000 6
46 HEX NUT D08 17000 6
47 LOCKWASHER J08 17000 6
48 HEX HD CAPSCREW B0608 15991 4
49 LOCKWASHER J06 15991 4
50 INTERMEDIATE 10093 13040 1
51 STRAINER PLATE GSKT 10056G 20000 1
52 STRAINER PLATE 10054 13040 1
53 SUCT HEAD O‐RING 25151-463 --- 1
54 STRAINER SCREEN 10090 1599V 1
55 BASE PLATE 10036 13080 1
56 HEX HD CAPSCREW B1042 15991 6
57 HEX NUT D10 15991 6
58 LOCKWASHER J10 15991 6
59 DIFFUSER STUD 10782A 17000 5
60 NYLON LOCKNUT BC08 17000 5
61 SUCT HEAD ASSY 42111-426 -----1
62 IMPELLER WASHER 10773 17000 1
63 IMPELLER JAM NUT AT14S 17000 1
64 IMPELLER KEY N0406 17000 1
NOT SHOWN:
OPTIONAL:
LIQUID LEVEL DEVICES:
PART NAME PART
NUMBER
CONTROL BOX
-460V 27515-505 --- 1
-575V 27515-515 --- 1
HEATER PACK
-460V 27521-211 --- 1
-575V 27521-210 --- 1
1 QT SUB MOTOR OIL 9568 --- 1
MOTOR VOLTAGE TAG
-460V 6588BL --- 1
-575V 6588BM --- 1
IMPELLER PULLER 5894 --- 1
REPAIR GASKET SET 11000J --- 1
HEAT‐SHRINK TERM KIT 48315-005 --- 1
ANODE PLATE ASSY 42116-002 --- 1
STAGING ADAPTOR KIT 48272-005 --- 1
DIAPHRAGM TYPE GRP48-03 --- 1
GRP48-06 --- 1
FLOAT TYPE 27471-155 --- 1
120V LIQUID LEVEL 27521-321 --- 1
CONTROL RELAY
MAT'L
CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
PAGE E - 3MAINTENANCE AND REPAIR
Page 30
S SERIES PUMPS OM-06099
SECTION DRAWING
Figure E-2. Terminal Housing And Cable Assembly
MAINTENANCE AND REPAIRPAGE E - 4
Page 31
OM-06099 S SERIES PUMPS
Terminal Housing And Cable Assembly
Parts List
ITEM
NO.
1 TERMINAL GLAND 11367 13040 1
2 POWER CABLE 10325S --- 1
3 CABLE GRIP 11227L --- 1
4 STUD C0808 17000 2
5 HEX NUT D08 17000 2
6 GLAND BUSHING 10758K 19100 1
7 TERMINAL WASHER 10659 15991 1
8 TERMINAL HOUSING 11366 13040 1
9 TERMINAL S1949 --- 1
10 HEAT‐SHRINK TUBE 31413-014 19530 3
11 AL HD SETSCREW GA0501 1/2 14990 3
12 TERMINAL COLLAR 10144 14100 3
13 TERMINAL PLT ASSY 11163 24010 1
14 TERMINAL POST 38724-009 14100 3
15 AL HD SETSCREW GA0501 1/2 14990 3
16 DYNA SEAL WASHER S1586 --- 3
17 TERMINAL S1550 --- 1
18 RD HD MACH SCREW X0603 14990 2
19 T‐TYPE LOCKWASHER AK06 15991 2
20 DRIVE SCREW BM#04-03 17000 4
21 INFORMATION PLATE 38816-047 17990 1
PART NAME
PART
NUMBER
MAT'L
CODE
QTY
NOT SHOWN:
RTV SEALANT 18771-106 --- 1
INDICATES PARTS RECOMMENDED FOR STOCK
PAGE E - 5MAINTENANCE AND REPAIR
Page 32
S SERIES PUMPS OM-06099
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY
Review all SAFETY information in Section A.
Do not attempt to service the pump as
sembly unless all power to the motor
has been shut off at the control box;
otherwise, injury or death could result.
Use a lifting device with sufficient ca
pacity. If slings or chains are used to
move the pump or components, make
sure that the load is balanced; other
wise serious personal injury or death
could result.
The maintenance and repair instructions in this
manual are keyed to the sectional views, Figures
E-1 and E-2, and the corresponding parts lists.
Select a suitable location, preferably indoors, to
perform required maintenance. All work must be
performed by qualified personnel.
All repairs to the pump motor must be per
formed by a Gorman‐Rupp authorized
Submersible repair facility or the factory.
Any repairs to the motor assembly per
formed by the customer or an unautho
rized repair facility negates the warranty.
This section provides maintenance instructions re
quired to properly service the pump components.
Pump motor maintenance may be performed only
by a Gorman‐Rupp authorized Submersible repair
facility, or the factory. Otherwise, the pump warran
ty will be negated, and damage to the pump, and
injury or death to personnel can result. Contact the
factory for the authorized repair facility closest to
you.
Use the hoisting bail to remove the pump from the
wet well or sump, and move it to a location where
the discharge line can be removed. It is not neces
sary to disconnect a flexible discharge hose before
removing the pump. If rigid discharge piping is
used, disconnect the piping before attempting to
move the pump.
Do not attempt to lift the pump by the
motor power cable or the piping. Attach
proper 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 posi
tioned so as not to damage the pump,
and so that the load will be balanced.
Check the chart in TROUBLESHOOTING, Section
D of this manual, to determine the nature of the
pump problem. If the problem is mechanical in na
ture, such as worn pump parts, seal replacement,
lubrication, etc., refer to PUMP END DISASSEM
BLY for instructions.
If the problem is electrical, complete disassembly
may not be required. Refer to Electrical Testing in
TROUBLESHOOTING, Section D, and have a
qualified electrician check the control box, cable
and terminal housing. If the problem is determined
to be in the motor, proceed with PUMP END DIS
ASSEMBLY, followed by MOTOR DISASSEMBLY.
Otherwise, see Terminal Housing And Power Ca
ble Disassembly.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Make certain that the control
handle on the control box is in the off po
sition and locked out, or that the power
supply to the control box has been
otherwise cut off and locked out, before
attempting to open or service the pump
assembly. Tag electrical circuits to pre
vent accidental start‐up.
Carefully inspect any O‐rings or gaskets before re
moval and cleaning to determine if a proper seal
and compression existed prior to disassembly. If
sealing was faulty or questionable, the cause must
be determined and corrected before reassembly.
All gaskets and most O‐rings must be replaced if
MAINTENANCE AND REPAIRPAGE E - 6
Page 33
OM-06099 S SERIES PUMPS
disturbed. Repair gaskets and O‐rings are listed in
the Parts List.
PUMP END DISASSEMBLY
Strainer Removal
(Figure E-1)
To remove the strainer screen and base plate (54
and 55), raise the pump slightly, or lay it on its side
and disengage the hardware (56, 57 and 58) se
curing the strainer and base plate to the diffuser
(1). If the impeller (2) is clogged, the debris can
usually be removed without further disassembly.
Draining Oil From Seal Cavity
(Figure E-1)
If any further disassembly is to be performed on the
pump, the seal oil cavity must be drained.
Let the pump cool before removing the
seal cavity drain plug. Pressure built up
within a hot pump could cause the oil to
spray out when the plug is removed. Re
move the plug slowly and permit pressure
to vent to atmosphere.
could indicate a breakdown in the waterproof in
tegrity of the motor cavity, probably due to poor
gaskets or seals.
Positioning Pump For Disassembly
(Figure E-1)
It is recommended that the pump be positioned
upside‐down during disassembly. To hold the
pump in the inverted position, rest the pump se
curely on blocks. Be careful not to damage the
pressure relief valve (32) and the terminal housing
and cable assembly (37) while in this position. Use
adequate equipment and personnel to safely han
dle the pump until it is secured. If inverting the
pump is not practical, lay the pump on its side and
secure it to prevent rolling.
Strainer Plate And Suction Head Removal
(Figure E-1)
Remove the hardware (5, 6 and 7) securing the
strainer plate (52) to the intermediate (50). Remove
the strainer plate. Discard the strainer plate gasket
(51) and the suction head O‐ring (53). Remove the
nylon locknuts (60) securing the suction head (61)
to the diffuser (1). Pull the suction head off the dif
fuser studs (59).
Impeller Removal
(Figure E-1)
Lay the pump on its side with the pipe plugs (12
and 13) facing up. Clean any dirt from around the
plugs. Remove the seal cavity drain plug (12), and
install a short 3/8‐inch NPT nipple in the hole. Tip
the pump and drain the seal oil into a clean con
tainer. Inspect the oil for water, dirt, or cloudy condi
tion which could indicate lower seal failure or poor
gasket seal.
Draining Oil From Motor Cavity
(Figure E-1)
If motor problems are suspected, remove the mo
tor cavity drain plug (13), and install a short nipple
in the hole. Tip the pump and drain the motor oil
into a clean container. Inspect the oil for dark color
which could indicate motor overheating, water or
dirt contamination. The presence of dirt or water
Wedge a block of wood between the vanes of the
impeller (2) and the suction head studs (59) to pre
vent impeller rotation. Remove the impeller nut (63)
and washer (62). Remove the wood block from be
tween the vanes of the impeller.
Install the impeller puller (supplied with the pump)
and pull the impeller from the rotor shaft. Use cau
tion when removing the impeller; tension on the
seal spring will be released. Retain the impeller key
(64). Inspect the impeller for wear or damage and
replace as required.
Remove the impeller adjusting shims (9) and the
upper impeller washer (10). Tie and tag the shims
for ease of reassembly.
If no further disassembly is required, proceed to
the appropriate areas in PUMP END REASSEMB
LY.
PAGE E - 7MAINTENANCE AND REPAIR
Page 34
S SERIES PUMPS OM-06099
Lower Seal Removal
(Figures E-1 and E-3)
Carefully remove the seal spring. Lubricate the ro
tor shaft (39) and work oil under the bellows as
sembly. Use the hooked ends of two stiff wires to
hook the retainer and pull the rotating portion of the
seal off the shaft.
To remove the stationary portion of the seal, use a
pair of screwdrivers to pry the diffuser (1) out of the
intermediate (50). Slide the diffuser off the shaft.
Remove and discard the diffuser gasket (8). Place
a clean cloth on a flat surface and place the diffuser
on the cloth with the impeller side down. Use a drift
pin or screwdriver to press on alternate sides of the
stationary seat until the stationary seat and O‐rings
are removed.
If no further disassembly is required, proceed to
the appropriate areas in PUMP END REASSEMB
LY.
If no further disassembly is required, proceed to
the appropriate areas in PUMP END REASSEMB
LY.
NOTE
Do not disassemble the motor unless it is neces
sary and a clean, well‐equipped shop is available. If
the motor housing components are to be serviced,
see MOTOR DISASSEMBLY in this section. Do not
reassemble the end components at this time.
PUMP END REASSEMBLY
NOTE
Reuse of old O‐rings, gaskets, or shaft seal parts
will result in premature leakage or reduced pump
performance. It is strongly recommended that new
gaskets and shaft seal assemblies be used during
reassembly (see the parts list for numbers).
Cleaning And Inspection Of Pump Parts
Upper Seal Removal
(Figures E-1 and E-3)
Unless cracked or otherwise worn, it is not neces
sary to remove the intermediate (50) for access to
the upper seal assembly (4).
NOTE
Do not attempt to loosen the hardware (48and 49)
securing the bearing cap (44) to the intermediate
(50) at this time (see MOTOR DISASSEMBLY). The
rotor shaft and bearings could be damaged.
Remove the seal retaining ring (14) using snap ring
pliers. Use caution when removing the retaining
ring; tension on the seal spring will be released.
Remove the spring retainer and seal spring.
Lubricate the rotor shaft (39) and work oil up under
the bellows. Use the hooked ends of two stiff wires
to hook the retainer and pull the rotating portion of
the seal off the shaft.
Slide the hooked ends of two wires along the shaft
and under the stationary seal seat. Hook the back
side of the seat and pull it from the intermediate
bore.
(Figure E-1)
With the pump inverted, stuff a clean tissue into the
stationary seal seat bore of the intermediate (50) or
wrap a small rag around the shaft to prevent for
eign material from entering the motor cavity.
Carefully inspect any O‐rings or gaskets before re
moval and cleaning to determine if a proper seal
and compression existed prior to disassembly. If
sealing was faulty or questionable, the cause must
be determined and corrected before reassembly.
Replace any parts as required.
Thoroughly clean all reuseable parts with a soft
cloth soaked in cleaning solvent. Remove all O‐
rings and gaskets, and clean the sealing surfaces
of dirt or gasket material. Be careful not to scratch
gasket surfaces.
Most cleaning solvents are toxic and
flammable. Use them only in a well ven
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
MAINTENANCE AND REPAIRPAGE E - 8
Page 35
OM-06099 S SERIES PUMPS
Inspect the rotor shaft (39) for damaged threads,
scoring, or nicks. Remove nicks and burrs with a
fine file or hand honing stone to restore original
contours. If the shaft is bent or severely damaged,
the rotor and shaft must be replaced as an assem
bly (see MOTOR DISASSEMBLY).
Neither of the shaft seal assemblies (3 or 4) should
be reused because wear patterns on the finished
faces cannot be realigned during reassembly. This
could result in premature failure. If necessary to re
use an old seal in an emergency, carefully wash
all metallic parts in fresh cleaning solvent and allow
to dry thoroughly.
ROTOR
SHAFT
ROTATING
ELEMENT
SPRING
Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate the preci
sion 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 circular pattern to avoid
scratching the faces.
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leak
age. If any components are worn, replace the com
plete seal; never mix old and new seal parts.
Install the shaft seals as illustrated in Figure E-3.
STATIONARY
SEAL SEAT
STATIONARY
ELEMENT
SPRING
RETAINER
STATIONARY
SEAL SEAT
O‐RING
DIFFUSER
BELLOWS AND
RETAINING ASSY
IMPELLER
WASHER
SHIM SET
BELLOWS AND
RETAINING ASSY
SEAL
RETAINING RING
O‐RING
STATIONARY
ELEMENT
ROTATING
ELEMENT
SPRING
IMPELLER
Figure E-3. Upper And Lower Seal Assemblies
Upper Seal Installation
This seal is not designed for operation at
temperatures above 122 F (50 C). Do not
use at higher operating temperatures.
(Figures E-1 and E-3)
Do not unwrap a new seal assembly until time of
installation. Cleanliness of seal components is criti
cal, especially the seal faces.
PAGE E - 9MAINTENANCE AND REPAIR
Page 36
S SERIES PUMPS OM-06099
Clean the rotor shaft (39) and seal cavity area of the
intermediate (50). Be sure the area is dry and free
of lint and dirt. Check the seal bore for burrs or
nicks that might prevent a good seal. Remove
them with a fine file or emery cloth to restore origi
nal contours. If the shaft is bent or damaged, the
complete rotor and shaft must be replaced as an
assembly. Apply a light coating of oil to the bore of
the intermediate.
Carefully remove the material stuffed into the seat
bore (or unwrap the shaft). Be sure no debris
stopped by the material falls into the seal cavity.
NOTE
When pressing seal components onto the shaft,
use hand pressure only. A push tube cut from a
length of plastic pipe will aid in installing seal com
ponents. The I.D. of the push tube should be ap
proximately the same as the I.D. of the seal spring.
Subassemble the stationary element in the station
ary seat. Position this subassembly in the interme
diate bore with the sealing face up and cover the
seal face with a clean tissue. Use your thumbs to
press the assembly into the bore. Apply equal
pressure on opposite sides until the seat contacts
the bore shoulder. Remove the tissue and inspect
the seal face to ensure that it is clean and dry. If
cleaning is necessary, use clean tissue to wipe
lightly in a circular pattern.
Unpack the rotating portion of the seal. Be certain
the seal face of the rotating element is free of grit or
surface damage. Because the rotating element
may not stay in the bellows retainer when turned
upside down, place a small amount of grease at
equal spaces on the back of the element and posi
tion it in the bellows retainer. The grease should
hold the element in position until the seal is in
stalled. Assemble the drive grooves of the rotating
element into the drive lugs of the bellows retainer.
Apply a light coating of oil to the seal seating sur
face on the shaft, the groove for the retaining ring
(14), and I.D. of the bellows. Position the seal rotat
ing portion on the shaft with the seal face down.
Apply firm, steady pressure on the bellows retainer
until it slides down the shaft and the seal faces con
tact. This step should be done in one continuous
motion to prevent the bellows from sticking or roll
ing as it passes over the retaining ring groove.
Slide the seal spring over the shaft and bellows re
tainer, and install the spring retainer. Install the seal
retaining ring (14). See Figure E-3 for the proper
order of seal assembly.
Lower Seal Installation
(Figures E-1 and E-3)
Thoroughly clean the gasket surfaces and seal
bore of the diffuser (1). The seal bore must be free
of burrs and nicks which could damage the seal.
Inspect the diffuser for cracks, distortion, or ero
sion and replace it if defective.
Position the diffuser on a clean flat surface with the
impeller side up.
Unpack the stationary seat and element. Subas
semble the stationary element in the stationary
seat. Apply a light coating of oil to the diffuser bore
and the O.D. of the seal seat and O‐ring. Keep the
sealing face dry.
Position the subassembly in the diffuser bore, and
cover it with a clean tissue. Use your thumbs to
press the seat into the bore. Apply equal pressure
on opposite sides of the seat until it is fully seated in
the bore. Remove the tissue and inspect the seal
face to ensure that it is clean and dry. If cleaning is
necessary, use clean tissue to wipe lightly in a cir
cular pattern.
NOTE
When pressing seal components onto the rotor
shaft, use hand pressure only. A push tube cut from
a length of plastic pipe will aid in installing seal
components. The I.D. of the push tube should be
approximately the same as the I.D. of the seal
spring.
Secure the diffuser gasket (8) to the diffuser using
a light coating of `3M Gasket Adhesive No. 847' or
equivalent compound.
Carefully position the diffuser and stationary seal
components on the rotor shaft, over the studs (59)
and against the intermediate (50). Be careful not
to damage the stationary element already in
stalled.
Unpack the rotating portion of the seal. Be certain
the seal face of the rotating element is free of grit or
MAINTENANCE AND REPAIRPAGE E - 10
Page 37
OM-06099 S SERIES PUMPS
surface damage. Because the rotating element
may not stay in the bellows retainer when turned
upside down, place a small amount of grease at
equal spaces on the back of the element and posi
tion it in the bellows retainer. The grease should
hold the element in position until the seal is in
stalled. Assemble the drive grooves of the rotating
element into the drive lugs of the bellows retainer.
Apply a light coating of oil on the shaft and the I.D.
of the bellows.
Slide the seal rotating portion onto the lubricated
shaft with the seal face down. Apply firm, steady
pressure on the bellows retainer until it slides down
the shaft and the seal faces contact.
Slide the seal spring over the shaft and bellows re
tainer. See Figure E-3 for proper order of seal as
sembly.
Impeller Installation
(Figure E-1)
moval. If this occurs, the lower bearing must be
pressed back into place (see MOTOR DISASSEM
BLY and MOTOR REASSEMBLY).
Suction Head And Strainer Plate Installation
(Figure E-1)
Inspect and thoroughly clean the suction head (61)
and its O‐ring groove. It must be clean and free of
any flaws which could cut the O‐ring or prevent a
good seal. Lightly oil the O‐ring (53) and install it in
the suction head.
Position the suction head on the diffuser studs
(59). Using a soft faced mallet, “walk” the suction
head into the diffuser until fully seated. Be careful
not to damage the O‐ring (53). Apply `Never‐Seez'
or equivalent compound to the threads of the studs
(59) and secure the suction head using the nylon
locknuts (60). Torque the locknuts evenly in a cross
sequence to 60 ft. lbs. (720 in. lbs. or 8,3 m. kg.).
Inspect the impeller (2) for cracks, broken vanes,
or wear from erosion, and replace it if damaged.
Clean the threads on the rotor shaft to remove any
old thread locking material. Be sure the impeller
bore and the shaft are free of oily film and com
pletely dry.
Install the upper impeller washer (10) with the in
side chamfer toward the shaft shoulder. Install the
adjusting shims (9) and the impeller key (64). Align
the keyway of the impeller (2) and push the impel
ler onto the shaft until seated firmly against the up
per impeller washer and shim set.
After the impeller is installed, coat the threads of
the rotor shaft with `Loctite Threadlocker No. 242'
or equivalent compound. Install the impeller wash
er (62) and the impeller nut (63). Wedge a block of
wood between the vanes of the impeller and torque
the nut to 175 ft. lbs. (2100 in. lbs. or 24,2 m. kg.).
Remove the block of wood and turn the impeller to
check for free rotation.
NOTE
If the impeller (2) is not fully seated and binds
against the diffuser, the shaft and lower bearing
have been driven out of position during impeller re
For maximum pump efficiency, there should be a
clearance of .010 to .015 inch (0,25 to 0,38 mm) be
tween the suction head and the face of the impeller.
Use a feeler gauge to measure this clearance. If the
clearance is not within the specific limits, remove
the suction head and impeller. Add or remove ad
justing shims (9) as required. Install the impeller
and suction head and recheck impeller clearance.
NOTE
If the intermediate and rotor assembly (50 and 39)
were not removed from the motor housing during
pump end disassembly, allowance must be made
for bearing play when checking impeller clearance.
Final impeller clearance must be determined with
the pump in a normal upright operating position.
Clean the gasket surface between the intermedi
ate (50) and the strainer plate (52) to ensure that
the old gasket and gasket cement is removed. In
spect the surface for major scratches. Secure the
strainer plate gasket (51) to the intermediate with a
light coating of `3M Gasket Adhesive No. 847' or
equivalent compound.
Position the strainer plate (52) over the diffuser,
aligning the bolt holes. Use a soft‐faced mallet to
tap the strainer plate into position.
PAGE E - 11MAINTENANCE AND REPAIR
Page 38
S SERIES PUMPS OM-06099
Apply `Never‐Seez' or equivalent compound to the
threads of the capscrews (5). Install the hardware
(5, 6 and 7) and torque evenly in a cross sequence
to 120 ft. lbs. (1440 in. lbs. or 16,6 m. kg.).
Strainer Screen And Base Plate Installation
(Figure E-1)
Inspect the strainer screen (54) and base plate (55)
for cracks, distortion or erosion, and replace it if de
fective.
Carefully position the strainer screen on the strain
er plate (52) so that it seats against the strainer
plate shoulder. Install the base plate over the
screen, aligning the bolt holes. Secure the com
plete strainer assembly using the hardware (56, 57
and 58). Make certain that the strainer seats prop
erly against the shoulder of the strainer plate.
See FINAL ASSEMBLY and VACUUM TESTING
followed by LUBRICATION before putting the
pump back into service.
MOTOR DISASSEMBLY
Disassembly of the motor is rarely required except
to replace the motor rotor, stator or bearings. Do
not disassemble the motor unless it is necessary
and a clean, well‐equipped shop is available.
assembly. Tag electrical circuits to pre
vent accidental start‐up.
Carefully inspect any O‐rings or gaskets before re
moval and cleaning to determine if a proper seal
and compression existed prior to disassembly. If
sealing was faulty or questionable, the cause must
be determined and corrected before reassembly.
Replace any parts as required.
Terminal Housing And Power Cable
Removal And Disassembly
(Figure E-1)
Total disassembly of the terminal housing and
power cable (37) is not always required. Disassem
ble and replace only the parts proven defective by
inspection or testing (see Electrical Testing in
TROUBLESHOOTING).
The terminal housing and power cable assembly
may be serviced without disassembling the motor
housing or pump end or without draining the oil
from the motor cavity. However, the oil must be
drained before attempting to disassemble the mo
tor housing and components.
Secure the pump in an upright position. Remove
the deform locknuts (36) securing the terminal
housing assembly (37) to the motor housing as
sembly (19).
(Figure E-2)
NOTE
It is recommended that a pump with a defective mo
tor be returned to Gorman‐Rupp, or to one of the
Gorman‐Rupp authorized Submersible Repair
Centers.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Make certain that the control
handle on the control box is in the off po
sition and locked out, or that the power
supply to the control box has been
otherwise cut off and locked out, before
attempting to open or service the pump
Carefully raise the terminal housing (8) from the
motor housing until the terminals (14) are accessi
ble. Loosen the allen head setscrews (15), and dis
connect the motor leads from the terminal posts.
Separate the terminal housing and power cable
assembly (2) from the motor housing.
No further disassembly is required to test the stator
or power cable.
To disconnect the power cable (2), remove the nuts
(5) securing the terminal gland (1) to the terminal
housing (8). Slide the gland back along the power
cable. Oil the bushing (6) and terminal housing
bore and pull firmly on the cable. (Allow the oil to
leak in around the bushing by agitating the cable in
the bore.) After the bushing has been loosened,
the cable should pull out far enough to expose the
bushing. Apply oil on the cable jacket and slide the
bushing and washer (7) back along the cable.
MAINTENANCE AND REPAIRPAGE E - 12
Page 39
OM-06099 S SERIES PUMPS
Quite often, pressure exerted on the bushing will
deform the cable jacket. If such happens, addition
al oil and effort will be required to remove the bush
ing.
NOTE
If the rubber bushing cannot be removed from the
terminal housing as indicated, it may be necessary
to cut the bushing into small pieces or cut the cable.
Push approximately 6 inches (152 mm) of the pow
er cable into the terminal housing so that the termi
nal plate comes free of the terminal housing. This
should permit access to the power cable connec
tions in the terminal plate.
NOTE
Do not remove the heat shrink tubing from the pow
er cable leads unless the power cable or terminals
require replacement. If replacement is required,
the connections between the power cable leads
and the terminals must be sealed with heat shrink
tubing before applying the silicone adhesive (see
Terminal Housing And Power Cable Reassemb
ly).
Remove the hardware (18 and 19) securing the
green and yellow ground leads to the terminal
housing. Reinstall the hardware.
See Terminal Housing/Power Cable Reassemb
ly if no further disassembly is required.
Intermediate And Motor Housing Disassembly
(Figure E-1)
See PUMP END DISASSEMBLY, and remove all
pump end and seal components.
With the pump end disassembled and the motor
cavity drained of oil, secure the pump in an in
verted position. Remove the hardware (46 and 47)
securing the intermediate (50) to the motor hous
ing (19). Do not remove the hardware (48 and 49)
around the rotor shaft (39) at this time.
Hook a three‐leg‐sling in the intermediate flange
holes and hoist the intermediate, rotor and shaft
(39), bearing cap (44) and both ball bearings (38
and 43) from the motor housing as an assembly. If
necessary, tap around the parting surfaces with a
soft faced mallet to loosen the seal between the in
termediate and motor housing. Remove the motor
housing gaskets (16, 17 and 18).
To disconnect the power cable (2) from the termi
nal housing, pull the terminal plate (13) away from
the terminal housing. When shipped from the fac
tory, the connections between the power cable
leads and the terminal collars (12) were encapsu
lated in heat‐shrink tubing (10) and bonded to the
terminal plate with silicone adhesive (not shown).
(In service, the adhesive may have been replaced
by potting compound during previous repair.) If
damage is extensive and the terminal plate and ter
minals are to be replaced, simply cut the power
cable leads above the terminal collars and heat‐
shrink tubing, and discard the terminal plate and
terminals.
If damage is not extensive and it is necessary to re
place the terminal plate (13) or terminal compo
nents, carefully cut away the tubing and adhesive.
Disconnect the power cable leads from the termi
nal posts, and separate the terminal plate (13) from
the terminal housing (8). Unscrew the terminal
posts (14), and remove the terminal collars (12),
posts and dyna seal washers (16) from the terminal
plate.
Cover the motor housing with a clean, lint free cloth
to avoid contamination by dirt or other foreign ma
terial.
Rotor And Bearing Removal
(Figure E-1)
Set the intermediate and rotor assembly on a clean
work area. Leave the lifting slings attached and re
duce the tension slightly. Remove the hardware
(48 and 49) securing the bearing cap to the inter
mediate. Steady the rotor and separate the inter
mediate. If necessary, tap the impeller end of the
rotor shaft with a soft faced mallet to loosen the
seal between the lower ball bearing (43) and the in
termediate bore.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
PAGE E - 13MAINTENANCE AND REPAIR
Page 40
S SERIES PUMPS OM-06099
strongly recommended that the bearings
be replaced any time the shaft and rotor
assembly is removed.
Before removing the bearings from the rotor shaft,
clean and inspect the bearings in place as follows.
Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.
Most cleaning solvents are toxic and
flammable. Use them only in a well ven
tilated area; free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
Rotate the bearings by hand to check for rough
ness or binding and inspect the bearing balls. If ro
tation is rough or the bearing balls discolored, re
place the bearings.
The bearing tolerances provide a tight press fit
onto the shaft and a snug slip fit into the motor
housing and bearing bore. Replace the shaft and
rotor (as an assembly), the motor housing or inter
mediate if the proper bearing fit is not achieved.
Position an expandable tool, such as a split disc,
approximately 2 inches (51 mm) inside the stator,
and expand it tightly and squarely on the I.D. At
tach a lifting device to the lifting eye of the tool, and
raise the assembly approximately 1 inch (25 mm)
off the work surface.
The motor housing (19) must be heated with a
torch to expand it enough for the stator to be re
moved. Apply heat evenly to the outside of the mo
tor housing; excessive heat is not required. Use a
soft‐faced mallet to rap alternate edges of the mo
tor housing, and “walk” the stator out. Continue
this process until the stator clears the motor hous
ing.
Take care not to damage the stator end
turns during removal from the motor hous
ing.
After the stator has been removed, wrap it in clean,
dry rags or other suitable material until reassembly.
The stator must be kept clean and dry. When han
dling the stator, do not set it on the end windings;
lay it on its side.
If replacement is required, use a bearing puller to
remove the upper and lower ball bearings from the
rotor shaft. Remove the bearing cap (44) and gas
ket (15) from the rotor shaft.
NOTE
It may be necessary to use the bearing cap (44) and
capscrews (48) in conjunction with a bearing puller
to remove the lower bearing.
Stator Removal
(Figure E-1)
Do not remove the stator (40) unless it is defective
(open windings, insulation resistance low, or stator
core damaged). If the stator must be removed, re
move the terminal housing as indicated in Termi
nal Housing And Power Cable Disassembly.
Do not attempt to rewind the stator. Wind
ing tolerances and materials are closely
controlled by the manufacturer, and any
deviation can cause damage or operating
problems. Replace the stator, or return it to
one of The Gorman‐Rupp Authorized Sub
mersible Repair Centers or The Gorman‐
Rupp factory, if defective.
Relief Valve
(Figure E-1)
It is recommended that the pressure relief valve
(32) be replaced at each overhaul, or at any time
the pump motor overheats and activates the valve.
Never replace this valve with a substitute which has
not been specified or provided by the Gorman‐
Rupp Company.
It is not necessary to remove the heavy pipe nipple
(34) to remove the pressure relief valve. If the nip
MAINTENANCE AND REPAIRPAGE E - 14
Page 41
OM-06099 S SERIES PUMPS
ple is removed, apply `Loctite Retaining Com
pound No. 680 or No. 620' or equivalent com
pound on both ends of the nipple only.
When installing the relief valve, use `Loctite Pipe
Sealant With Teflon No. 592' or equivalent com
pound on the threads. Position the valve out of the
way, next to the terminal housing (8, Figure E-2)
so there is enough room for the terminal housing to
clear.
Hoisting Bail
(Figure E-1)
If the hoisting bail (24) requires replacement, re
move the hardware (21, 22 and 23) securing the
bail to the motor housing. Make sure the bushings
(25) are in place when installing the hoisting bail.
MOTOR REASSEMBLY
Do not attempt to rewind the stator. Wind
ing tolerances and materials are closely
controlled by the manufacturer, and any
deviation can cause damage or operating
problems. Replace the stator, or return it to
one of The Gorman‐Rupp Authorized Sub
mersible Repair Centers or The Gorman‐
Rupp factory, if defective.
NOTE
Reuse of old O‐rings, gaskets, shaft seal parts will
result in premature leakage or reduce pump per
formance. It is strongly recommended that new
gaskets and shaft seal assemblies be used during
reassembly (see the parts list for numbers).
Stator Installation
(Figure E-1)
NOTE
Stator installation involves heating the motor hous
ing. This process must be done quickly. Therefore it
is recommended that these steps be performed by
two people to promote efficient installation of the
stator.
Clean all gasket and O‐ring surfaces of the motor
housing (19), completely removing any old gasket
and cement material. Inspect the sealing surfaces
for burrs, nicks and pits which could cause a poor
seal, and replace defective parts as required.
Thoroughly clean the inside of the motor housing
with fresh solvent. The interior must be dry and free
of dirt or lint.
Most cleaning solvents are toxic and
flammable. Use them only in a well ven
tilated area; free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
After the motor housing is thoroughly cleaned, po
sition it on a flat surface with the discharge end
down. Do not unwrap the stator (40) until the motor
housing has been prepared for stator installation.
The stator must be kept clean and dry. When han
dling the stator, do not set it on the end windings;
lay it on its side and block it from rolling.
Test the new stator as indicated in Electrical Test
ing in TROUBLESHOOTING, Section D, to ensure
that no damage has occurred during transit or han
dling.
NOTE
Remove any drops of varnish from the ends of the
stator before installation to ensure proper stack‐up
height when assembled.
Position an expandable tool, such as a split disc,
approximately 2 inches (51 mm) down inside the
stator (opposite the lead wire end), and expand it
tightly and squarely on the I.D. Attach a lifting de
vice to the lifting eye of the tool, and carefully lift the
assembly. Take care not to damage the stator end
turns. Slip a sleeve over the stator leads, or tape
them together to protect them during installation.
NOTE
Stator installation involves heating the motor hous
ing. This process must be done quickly to allow the
stator to slide into the motor housing before the
housing cools.
PAGE E - 15MAINTENANCE AND REPAIR
Page 42
S SERIES PUMPS OM-06099
Heat the motor housing (19) with a torch to expand
it enough for the stator (40) to be installed; when
heating the motor housing, make sure that the sta
tor is clear to avoid a fire hazard, or damage to the
windings. Apply heat evenly to the outside of the
housing; excessive heat is not required.
When the motor housing is sufficiently heated, po
sition the stator so that the leads are in line with the
terminal opening. Carefully lower the stator into the
motor housing until fully seated against the hous
ing shoulder. Be careful not to damage the stator
leads insulation during reassembly. If the stator
“cocks” in the motor housing, remove it and try
again.
After the stator is fully and squarely seated on the
motor housing shoulder, remove the expandable
disc tool. Untape or remove the protective sleeve
from the stator leads.
Cover the motor housing with a clean, lint‐free
cloth while the rotor is being assembled.
ings 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 thor
oughly filtered.
Heat the upper bearing (38) to a uniform tempera
ture no higher than 250F (120C). Slide the bear
ing onto the shaft until it is fully seated against the
shaft shoulder. This should be done quickly, in one
continuous motion, to prevent the bearing from
cooling and sticking on the shaft.
Use caution when handling hot bear
ings to prevent burns.
Bearing Installation
(Figure E-1)
Inspect the rotor shaft (39) for damaged threads,
scoring in the seal area, and a nicked or damaged
keyway. If the bearings were removed, inspect the
bearing areas for scoring or galling. Remove nicks
and burrs with a fine file or emery cloth. Inspect the
rotor area for separated laminations. If the shaft is
bent or damaged, or if the laminations are sepa
rated, replace the shaft and rotor (a single assem
bly).
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 rotor
assembly is 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. Bear
If heating the bearing is not practical, use a suitably
sized sleeve, and an arbor (or hydraulic) press to
install the bearing on the shaft.
When installing the bearing onto the shaft,
never press or hit against the outer race,
balls, or ball cage. Press only on the inner
race.
Clean the bearing cap (44) and position it over the
lower bearing (43) before heating.
NOTE
Position the cap on the bearing so that when in
stalled on the shaft, the bearing will be positioned
as indicated in Figure E-4.
Heat the lower bearing and cap to a uniform tem
perature no higher than 250F (120C). Slide the
assembled cap and bearing onto the shaft until the
bearing is fully seated against the shaft shoulder.
Do this quickly, in one continuous motion, to pre
vent the bearing from cooling and sticking on the
shaft.
MAINTENANCE AND REPAIRPAGE E - 16
Page 43
OM-06099 S SERIES PUMPS
INSTALLATION OF SKF 5200 AND 5300 SERIES BEARINGS
PART NUMBER MARKINGS ARE
LOCATED EITHER ON BEARING
O.D. (OFFSET FROM CENTER) OR
ON SIDE FACE OF BEARING. FOR
EITHER TYPE, POSITION BEAR
DIRECTION OF
THRUST
NOTE:
THIS BEARING IS MANUFACTURED WITH TWO SEALS OR SHIELDS. WHEN INSTALLED ON THE SHAFT, THE MAN
UFACTURER'S PART NUMBER DESCRIPTION (LOCATED ON SIDE FACE OF BEARING OR BEARING O.D.) MUST BE
LOCATED WITH THE TEXT AWAY FROM THE IMPELLER.
ING WITH TEXT AWAY FROM IM
PELLER.
Figure E-4. Bearing Installation
If heating the bearing is not practical, use a suitably
sized sleeve and an arbor (or hydraulic) press to in
stall the cap and bearing on the shaft.
When installing the bearing onto the shaft,
never press or hit against the outer race,
balls, or ball cage. Press only on the inner
race.
After the bearings have been installed and allowed
to cool, check to ensure that they have not moved
out of position in shrinking. If movement has oc
curred, use a suitably sized sleeve and a press to
reposition the bearings. Make certain that they are
seated squarely against the shaft shoulders.
Secure the gasket (15) to the cap with a light coat
ing of gasket adhesive.
Rotor And Intermediate Reassembly
Most cleaning solvents are toxic and
flammable. Use them only in a well ven
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
Position the rotor (39), assembled bearings (38
and 43) and bearing cap (44) on a work surface
with the impeller end up, and use blocks to secure
it in this position.
To ease alignment of the bearing cap and inter
mediate, install two long studs, finger‐tight only,
180 apart in the bearing cap mounting holes.
Using a three‐leg sling and lifting eyes in the inter
mediate flange holes, carefully lower the intermedi
ate over the shaft and lower bearing, guiding the
studs in the bearing cap through the holes in the
intermediate as it is lowered into place.
(Figure E-1)
Use fresh solvent to clean all gasket and O‐ring
surfaces of the motor housing (19) and intermedi
ate (50), completely removing any old gasket and
cement material. Inspect the sealing surfaces for
burrs, nicks and pits which could cause a poor
seal. Repair or replace as require.
Apply `Never‐Seez' or equivalent compound to the
threads of the capscrews (48). Use two of the caps
crews and lockwashers (49) to draw the intermedi
ate and bearing cap together. Remove the studs
temporarily installed in the bearing cap and install
the remaining two capscrews and lockwashers;
torque the capscrews evenly in a cross‐sequence
to 20 ft. lbs. (240 in. lbs. or 2,8 m. kg.).
PAGE E - 17MAINTENANCE AND REPAIR
Page 44
S SERIES PUMPS OM-06099
Refer to PUMP END REASSEMBLY, and reas
semble the pump end components.
Terminal Housing And Power Cable
Reassembly And Installation
(Figure E-2)
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Make certain that the control
handle on the control box is in the OFF
position and locked out, or that the pow
er supply to the control box has been
otherwise cut off and locked out, before
attempting to open or service the pump
assembly. Tag electrical circuits to pre
vent accidental startup. Obtain the ser
vices of a qualified electrician, and refer
to the wiring diagram(s) in INSTALLA
TION, Section B, to make electrical con
nections.
Clean the exterior of the power cable with warm
water and mild detergent. Check for obvious physi
cal damage. Check the cable for continuity and in
sulation resistance (see Electrical Testing in
TROUBLESHOOTING). Do not attempt repairs
except to cut off either end of the cable; splicing is
not recommended. Reinstall any wire tags or ter
minals which may have been removed.
Never attempt to alter the length or re
pair any power cable with a splice. The
pump motor and cable must be com
pletely waterproof. Injury or death may
result from alterations.
Use oil to lightly lubricate the outside of the pump
power cable (2), and the bores of the terminal
housing (8), terminal gland (1) and gland bushing
(6) for ease of assembly. Slide the terminal gland,
cable grip (3), gland bushing (6), terminal washer
(7) and terminal housing (8) on the cable, allowing
approximately 3 ft. (1 m) of cable to extend beyond
the terminal housing. Temporarily tape the green
and yellow ground wires to the cable.
Sealing Terminal Housing Connections
With Silicone Adhesive
(Figure E-2)
Do not attempt to operate this pump un
less the power cable leads are properly
sealed in the terminal housing. Mois
ture entering the terminal housing
could cause a short circuit, resulting in
pump damage and possible serious in
jury or death to personnel.
When shipped from the factory, the cable leads
and terminal collars (12) were encapsulated in
heat‐shrink tubing (10), and bonded to the terminal
plate (13) with silicone adhesive to provide a water‐
tight seal. If this insulating material has been dam
aged or removed during maintenance, it must be
replaced using materials and equipment approved
by Gorman‐Rupp (see the parts list for repair kits).
NOTE
Heat‐shrink tubing must be used to seal the power
and control cable leads to the terminals before
bonding the leads to the terminal plate. If silicone
adhesive is not available in the field, a commercially
available potting kit may be used to bond the con
nections to the terminal plate. If this alternate seal
ing method is used, refer to the instructions in Seal
ing Terminal Plate Connections With Potting
Compound. Use only materials and heating equip
ment approved by Gorman‐Rupp for field repairs.
Before resealing the power and control cables, re
move all the old adhesive material (or potting com
pound) from the leads, terminal collars, and termi
nal plate. Inspect all parts for damage, and replace
as required. If the rubber bonding material on the
terminal plate (13) is severely worn or cracked, the
terminal plate must be replaced. If the bonding ma
terial has been noticeably compressed, it should
be supplemented with two gaskets contained in
the overhaul gasket kit (see Options listed in the
Parts List manual).
MAINTENANCE AND REPAIRPAGE E - 18
Page 45
OM-06099 S SERIES PUMPS
NOTE
Clean the cable leads and terminal plate in the ar
eas to be sealed with cleaning solvent. Incomplete
sealing will occur if the surfaces are dirt, oil or
grease coated.
Assemble the terminal posts (14), dyna seal wash
ers (16 ), and terminal collars (12) to the terminal
plate as shown in Figure E-2.
NOTE
Both the power cable and motor conductor leads
should be tinned prior to reassembly.
Slide a length of heat‐shrink tubing (10) up over
each of the power cable leads. Insert the leads in
the terminal collars and secure them using the al
len head setscrews (11). Slide the tubing down
each lead until the terminals are covered, and the
tubing contacts the terminal plate. The tubing
must extend up the leads far enough to ensure a
good seal.
NOTE
Do not use a mold or reservoir with the silicone
adhesive.
See Figure E-6 and check terminal locations. Ap
ply a 1/4 to 3/8 in. (6,4 to 9,7 mm) thick layer (maxi
mum) of silicone adhesive around each of the ter
minal posts as shown in Figure E-5. Remove any
adhesive from gasketed surfaces.
Silicone Sealant
Figure E-5. Silicone Adhesive Sealing
Carefully heat each tube with a commercially avail
able hot air gun capable of producing 750F
(399C), and shrink the tubes around the cable
leads and terminal collars.
Use only Dow‐Corning 737 Silicone Adhe
sive (see the Parts List Manual for the part
number) or potting compound for sealing
terminal housing connections. Use of un
approved sealing products will void the
pump warranty.
All air pockets, voids or gaps in the sili
cone sealant must be removed to en
sure a water‐tight seal in the terminal
housing. Otherwise, moisture entering
the terminal housing could cause a
short circuit, resulting in pump damage
and possible serious injury or death to
personnel.
Allow the adhesive to cure for at least one hour be
fore securing the terminal housing to the motor
housing.
PAGE E - 19MAINTENANCE AND REPAIR
Page 46
S SERIES PUMPS OM-06099
1 YELLOW - CONNECT TERMINAL TO GROUND
WHITE
(T1)
RED
(T3)
Figure E-6. Terminal Housing Wiring Connections
Sealing Terminal Housing Connections
With Potting Compound
(Figure E-2)
Potting compound and silicone adhesive have the
same electrical properties when correctly applied.
Silicone adhesive is used at the factory to facilitate
production. A commercially available potting kit
(Products Research Corp., part number
PR‐1201‐Q Class 1 potting compound, Chemseal
potting compound, part number GS3100, or equiv
alent) may also be used to seal the connections.
Clean and assemble all terminal components as
indicated in Sealing Terminal Plate With Silicone
Adhesive. Use medium grit sandpaper to prepare
the surface of the terminal plate in the area where
the potting mold will be installed.
NOTE
Clean the cable lead and terminal plate in the areas
to be potted with cleaning solvent before potting.
Potting compound will not adhere properly to oil or
grease coated surfaces.
Trim the potting mold so it is just long enough to
cover the terminal collars. Slide the potting mold
up over the leads of the power cable and control
cable.
Secure each cable lead as described in the pre
vious section. Slide the potting mold down over the
INSIDE TERMINAL HOUSING
2 GREEN -TOGETHER IN ONE TERMINAL.
CONNECT TERMINAL TO
GROUND INSIDE TERMINAL
HOUSING
BLACK
(T2)
terminal collars and onto the terminal plate. Hang
the cable in a vertical position with the terminal
plate horizontal. The cable leads and terminals
should be centered in the potting mold. Use quick‐
setting cement, such as `3‐M Weather Seal' to se
cure the potting mold to the terminal plate.
Most potting base compounds contain
toluene; use adequate ventilation and
avoid prolonged breathing of vapors.
Most potting accelerators contain lead;
avoid ingestion or prolonged contact
with the skin. Read and follow all warn
ings and recommendations accompa
nying the potting kit.
See the instructions with the potting kit regarding
application life and setting and curing time. Mix the
base compound and accelerator and fill the mold
until the electrical connections are completely in
sulated. Tamp the potting material to eliminate air
bubbles and ensure the material has completely
covered the area around the terminal posts.
NOTE
The potting compound must completely cover the
terminal collar and lead connections.
MAINTENANCE AND REPAIRPAGE E - 20
Page 47
OM-06099 S SERIES PUMPS
When potting has been completed, leave the ter
minal plate assembly undisturbed until the potting
material has cured. Complete curing usually takes
about 24 hours. Curing time can be shortened by
using a heat lamp, but be careful not to melt the
potting or potting mold, or burn the cable. When
the potting material is no longer “tacky” to the
touch, it has cured.
Terminal Housing Installation
(Figure E-2)
After the terminal plate has been sealed, slide the
terminal housing down the cable. Untape the
ground lead(s) and secure them to the terminal
housing with the hardware (18 and 19). Be sure
the lead(s) make good contact with the housing.
Pull gently on the cable to remove any excess
length from within the terminal housing. The termi
nal plate should fit loosely against the terminal
housing.
NOTE
A .09 to .15 in. (3,05 mm) gap is required between
the terminal gland flange and the terminal housing
when the nuts (5, Figure E-2) are fully tightened.
See FINAL ASSEMBLY and VACUUM TESTING
followed by LUBRICATION.
FINAL ASSEMBLY
(Figure E-1)
If the discharge flange (27) was removed from the
motor housing, replace the discharge flange gas
ket (26). Apply `Never‐Seez' or equivalent com
pound on the flange studs (28), and secure the
flange with the nuts (29).
If the hoisting bail (24) was removed, install the bail
bushings (25) and secure the bail to the motor
housing with the hardware (21, 22 and 23).
VACUUM TESTING
Lubricate the upper bore of the terminal housing,
and slide the gland washer (7), bushing (6) and
cable grip (3) into place. Slide the terminal gland
(1) into place and install the nuts (5). Do not fully
tighten the nuts at this time.
Attach the appropriate motor lead (T1, T2, T3) to
each terminal post (14) using the allen head set
screws (15).
Position the terminal housing and terminal plate
against the upper motor housing. If required, ro
tate the terminal housing and twist the motor leads
to remove excess slack.
(Figure E-1)
Coat the threads of the motor housing studs (35)
with `Never‐Seez' or equivalent compound, and
secure the terminal housing assembly to the motor
housing with the hardware (36); torque the nuts
evenly in a cross sequence to 20 ft. lbs. (240 in. lbs.
or 2,8 m. kg.). Tighten the nuts (5, Figure E-2)
drawing the terminal gland (1) down into the termi
nal bore to the dimenstion shown in Figure E-2.
Do not overtighten and damage the terminal gland
or hardware.
To ensure the water‐tight integrity of the pump, it is
recommended that the motor and seal cavities be
vacuum tested any time the seal(s) and/or motor
are serviced.
Drain all of the oil from both the seal and motor
cavities before performing the test. Oil within the
cavities will be drawn into the system, resulting in
damage to the vacuum pump or manometer.
Use a manometer with a range of 30 to 0 to 30 inch
es of mercury to perform the test. Do not use a vac
uum gauge. Vacuum gauges are not sensitive
enough to detect minor leaks.
It is recommended that a vacuum pump be used to
draw the vacuum on the cavities. If a vacuum pump
is not available, a compressor/venturi system may
be used. If the compressor/venturi cannot draw
the higher vacuum level shown in Table E-1, draw
the motor cavity vacuum down as far as the system
will allow, then draw the seal cavity down so the dif
ferential between the two cavities is the same as
the differential between the vacuum readings
shown in the table.
Install full‐closing ball‐type shutoff valves with
quick‐disconnect fittings in the pipe plug holes in
PAGE E - 21MAINTENANCE AND REPAIR
Page 48
S SERIES PUMPS OM-06099
both the motor and seal cavities. Test the motor
cavity for its full duration first, then use the shutoff
valve to maintain the motor cavity vacuum while
testing the seal cavity. The motor cavity vacuum
must be higher than the vacuum in the seal cavity
to prevent separation of the seal faces or unseating
Vacuum Pump
Venturi
Air Compressor
Manometer
Tee
Quick Disconnect
Fitting
Figure E-7. Vacuum Test System
Table E-1 shows the vacuum to be drawn on each
cavity, and the duration to maintain each vacuum
reading. Any change in vacuum reading during
the stationary seal seat between the seal and mo
tor cavities.
Figure E-7 shows a simple schematic for setting
up either a vacuum pump or a venturi/compressor
test system.
Quick Disconnect
Fitting
Full-Closing
Ball-Type
Shutoff Valve
the test indicates a leak which must be identified
and corrected before putting the pump back into
service.
Submersible
Pump
Table E-1. Vacuum Test Data
Pump
Model
S4B 30 6 20 2
Motor Cavity
Vacuum
(In. Hg.)
(Minutes)
LUBRICATION
Seal Cavity
Check the oil level in the seal cavity before initial
startup, after the first two weeks of operation, and
every month thereafter.
Check the oil level only when the pump
is cool. If the oil level plug is removed
when the pump is hot, pressure in the
seal cavity can cause hot oil to be
ejected as the plug is removed.
Duration
oil into a transparent cup. If the oil level is abnor
mally low, or the color milky or dark, refer to Drain
ing Oil From Seal Cavity in this section for instruc
tions and troubleshooting tips. If the oil is clear, ap
ply `Loctite Pipe Sealant With Teflon No. 592.' or
equivalent to the threads of the pipe plug, before
reinstalling the plug.
To fill the seal cavity, remove the pipe plug (10) and
add the recommended grade of submersible
pump oil. Apply `Loctite Pipe Sealant With Teflon
No. 592.' or equivalent to the threads of the pipe
plug, before reinstalling the plug.
See Table E‐2 for quantity of lubricant when lubri
cating a dry (overhauled) pump. See Table E‐3 for
lubricant specifications.
Seal Cavity
Vacuum
(In. Hg.)
Duration
(Minutes)
To check the seal cavity oil, lay the pump on its side
and remove the seal cavity plug (8) in the interme
diate. Tip the pump and drain off a small amount of
The grade of lubricant used is critical to the opera
tion of this pump. Use premium quality hydraulic oil
as specified in the following table. Oil must be
MAINTENANCE AND REPAIRPAGE E - 22
Page 49
OM-06099 S SERIES PUMPS
stored in a clean, tightly closed container in a rea
sonably dry environment.
Table E-2. Oil Quantity
Pump Model Seal Cavity Motor Cavity
S4B 256 ounces (10,4 liters)160 ounces (2,8 liters)
Table E‐3. Pump Oil Specifications
Specifications:
Type Premium high viscosity index, anti‐wear hydraulic oil..............................
Viscosity (SSU @ 104F [40C]) 110 to 155.........................................
Viscosity (SSU @ 210F [100C]) 40 to 50...........................................
Dielectric 26,000 (volts‐min)........................................................
Recommended supplier:
Gulf Oil Company Gulf Harmony AW Hydraulic Fluid MG 32............................
Acceptable alternate suppliers:
Gulf Oil Company Gulf Harmony 32 AW..............................................
Texas Oil Company Rando HD 32 or HD AZ 32........................................
Sun Oil Company Sunvis 816 or 916.................................................
BP (Also Boron) Energol‐HLP 32.....................................................
Shell Oil Company Tellus 32, Tellus T‐23 or T32.......................................
ARCO Duro 32...................................................................
Exxon (Also Esso) Nuto H 32........................................................
Petro‐Canada Harmony HVI 22......................................................
Motor Housing Cavity
With the pump in an upright position, remove the
pipe cap (30) on the top of the pump. See Table E‐2
and add the recommended grade of lubricant
(Table E‐3) to the motor cavity. Maintain the oil at
this level. Apply `Loctite Pipe Sealant With Teflon
No. 592' or equivalent sealant to the threads of the
street tee assembly (29). Reinstall and tighten the
cap.
Never attempt to fill the motor cavity
through the drain plug (11) opening or the
oil level plug (17). A volume of air must be
trapped above the motor to permit thermal
expansion of the motor oil.
PAGE E - 23MAINTENANCE AND REPAIR
Page 50
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
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