Gorman-Rupp Pumps S8B1-E100 User Manual

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Page 1

ACU

OM‐06259‐01

March 31, 2009

Rev. A 05‐15‐12

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

SUBMERSIBLE PUMPS

MODELS

S8B1-E100 460/3

and

S8B1-E100 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.

2009 The Gorman‐Rupp Company

Page 2

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

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 - 17.............

Sealing Terminal Housing Connections With Silicone Adhesive PAGE E - 18..............

Sealing Terminal Housing Connections With Potting Compound PAGE E - 19.............

Terminal Housing Installation PAGE E - 20............................................

FINAL ASSEMBLY PAGE E - 20.........................................................

VACUUM TESTING PAGE E - 21........................................................

LUBRICATION PAGE E - 22.............................................................

Seal Cavity PAGE E - 22............................................................

Motor Housing Cavity PAGE E - 22...................................................

Page 5

INTRODUCTION

OM-06259S 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

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OM-06259

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

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OM-06259 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

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S SERIES PUMPS OM-06259

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.

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S SERIES PUMPS

OM-06259

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

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

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OM-06259 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

S8B

575/3

Dual

Voltage

NO 8 INCH100 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

135

108

Load

Amperes

40.3

30.9

Locked

Rotor

Amperes

715

556

Discharge

Size

(NPT)

Table B‐2. Additional Specifications

Approximate

Weight - Lbs. (kg)

Pump

Model

S8B

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

870 (395) 105 (48) 224 (6,6) 768 (22,7) 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

PAGE B - 2 INSTALLATION

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S SERIES PUMPS

OM-06259

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.

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-06259 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)

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-06259

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-06259 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

Amp

Cable

A.W.G

Pump

Model

S8B

NOTE: * Amp Rating at 30C (86F)  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 40C (104F)

Cable

Size

1 1.51 (38) 0.38 (9,6) 161** GGC 0.13

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

25C (77F)

per 1000 ft.

(305 m)

Voltage

Drop per 100 ft. (30,5m) at Max. Load

3.51

2.81

Page 15

S SERIES PUMPS

OM-06259

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-06259 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-06258

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-06258 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.

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-06258

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-06258 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-06258

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 Maintenance and Repair, Section E).

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-06258 S SERIES PUMPS

Table C-1. Pump Oil Specifications

Specifications:

Type Premium high viscosity index, anti‐wear hydraulic oil..............................

Viscosity @ 100F (38C) 110 to 155...............................................

Viscosity @ 210F (99C) 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-06259

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-06259S 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-06259

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-06259S 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-06259 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 S8B1-E100 460/3 AND S8B1-E100 575/3

Based on 70F (21C) 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-06259

SECTION DRAWING

PARTS PAGE

Figure E-1. S8B1-E100 460/3 And S8B1-E100 575/3 Pump Assemblies

MAINTENANCE AND REPAIRPAGE E - 2

Page 29

OM-06259 S SERIES PUMPS

S8B1-E100 460/3 And S8B1-E100 575/3 Pump Assemblies

Parts List

(From S/N 1432260 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 38632-023 11030 1 2 IMPELLER 38623-526 11030 1 3 LOWER SEAL ASSY 12430A --- 1 4 UPPER SEAL ASSY S1934 --- 1 5 STRAINER SCREEN 10090 1599V 1 6 SUCTION HEAD GSKT 38683-817 20000 1 7 DIFFUSER GSKT 38682-812 20000 1 8 SEAL PLATE O‐RING S2207 --- 1

9 SEAL DRAIN PLUG P06 17000 1 10 MOTOR DRAIN PLUG P06 17000 1 11 SEAL FILL PLUG P06 17000 1 12 HEX HD CAPSCREW B0608 15991 4 13 LOCKWASHER J06 15991 4

14 BEARING CAP GSKT 10085G 20000 1 15 MOTOR HOUSING GSKT 38684-703 20000 1 16 MOTOR HOUSING GSKT 10038G 20000 1 17 BEARING CAP 10085 10010 1

18 MOTOR HOUSING ASSY 42822-014 24130 1 19 MOTOR CAVITY OIL P06 17000 1

LEVEL PLUG 20 BAIL BUSHING 10045 15071 2 21 HOISTING BAIL 10039 2400V 1 22 HEX HD CAPSCREW B1210 15991 2 23 LOCKWASHER J12 15991 2 24 FLAT WASHER K12 15991 2

25 DISCH FLANGE GSKT 1759G 18000 1 26 DISCHARGE FLANGE 1759 10010 1 27 PIPE CAP V16 11999 1 28 STREET TEE ASSY 14138 --- 1

29 PRESS RELIEF VALVE 14139 --- 1 30 CLOSE PIPE NIPPLE THA1614 15079 1 31 UPPER BALL BEARING S1077 --- 1 32 DISCH FLANGE STUD C1211 15991 8 33 HEX NUT D12 15991 8 34 FILL TUBE ASSY 10040 24040 1 35 RETAINING RING S245 --- 1 36 TERMINAL HOUSING 47367-028 --- 1

AND CABLE ASSY 37 STUD C0607 15991 6 38 DEFORM LOCKNUT DD06 15991 6

39 ROTOR/SHAFT ASSY 47112-083 --- 1 40 STATOR ASSY

-460V 47113-087 --- 1

-575V 47113-088 --- 1 41 NAME PLATE 2613CY 17020 1 42 DRIVE SCREW BM#04-03 17000 6 43 MOTOR HOUSING GSKT 10062G 20000 1

NUMBER

MAT'L CODE

QTY ITEM

NO.

44 STUD 10443 17000 12 45 HEX NUT D10 17000 12 46 LOCKWASHER J10 17000 12

47 LOWER BALL BEARING 23425-611 --- 1 48 INTERMEDIATE 38261-020 13040 1 49 SEAL PLATE 38272-708 10010 1

50 DIFFUSER GSKT 38682-813 20000 1 51 SOC HD CAPSCREW BD0503 17000 6 52 HEX HD CAPSCREW B1216 15991 20 53 HEX NUT D12 15991 20 54 LOCKWASHER J12 15991 20 55 SPACER 31413-026 15079 6 56 BASE PLATE 10036 13080 1 57 HEX HD CAPSCREW B1024 15991 6 58 STUD C1211 17000 8 59 HEX NUT D12 17000 8 60 LOCKWASHER J12 17000 8 61 SUCTION HEAD 38246-033 10010 1 62 IMPELLER WASHER 11199 17000 1 63 IMPELLER NUT AT20S 17000 1

64 WEAR RING 38691-309 14000 1 65 WEAR RING 38691-309 14000 1

NOT SHOWN:

OPTIONAL:

LIQUID LEVEL DEVICES:

PART NAME PART

NUMBER

CONTROL BOX

-460/3 27515-506 --- 1

-575/3 27515-516 --- 1 1 QT SUB MOTOR OIL 9568 --- 1 MOTOR VOLTAGE TAG

-460/3 6588BL --- 1

-575/3 6588BM --- 1 IMP KNOCKER 2177C 14070 1 HEATER PACK

-460/3 27521-213 --- 1

-575/3 27521-212 --- 1

REPAIR GASKET SET 11000V --- 1 HEAT‐SHRINK TUBE & 48315-004 --- 1 ADHESIVE KIT TERM POTTING KIT 12442A --- 1 ANODE PLATE ASSY 42116-002 --- 1

DIAPHRAGM TYPE GRP48-03 --- 1

GRP48-06 --- 1 FLOAT TYPE 27471-155 --- 1 LIQ LEV CONTRL RELAY 27521-321 --- 1

MAT'L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

PAGE E - 3MAINTENANCE AND REPAIR

Page 30

S SERIES PUMPS OM-06259

SECTION DRAWING

Figure E-2. Terminal Housing And Cable Assembly

MAINTENANCE AND REPAIRPAGE E - 4

Page 31

OM-06259 S SERIES PUMPS

Terminal Housing And Cable Assembly

Parts List

ITEM NO.

1 TERMINAL POST 38724-009 14100 3 2 TERMINAL COLLAR 10052A 14100 3 3 HEAT‐SHRINK TUBE 31417-030 19530 3 4 T‐TYPE LOCKWASHER AK06 15991 2 5 RD HD MACH SCREW X0603 14990 2 6 TERMINAL 27214-062 --- 1 7 TERMINAL WASHER 31133-110 15991 1 8 GLAND BUSHING 31144-001 19100 1

9 INFORMATION PLATE 38816-047 17990 1 10 DRIVE SCREW BM#04-03 17000 4 11 CABLE GRIP 11227H --- 1 12 TERMINAL GLAND 10658 13040 1 13 POWER CABLE 10325L --- 1 14 HEX NUT D08 15991 2 15 STUD C0808 15991 2 16 TERMINAL HOUSING 10088B 13040 1 17 TERMINAL S1550 --- 1 18 AL HD SETSCREW GA0602 14990 3 19 TERMINAL PLT ASSY 11163 24010 1 20 DYNA SEAL WASHER S1586 --- 3 21 AL HD SETSCREW GA0501 1/2 14990 3

PART NAME

PART NUMBER

MAT'L CODE

QTY

NOT SHOWN:

RTV SEALANT 18771-106 --- 2

INDICATES PARTS RECOMMENDED FOR STOCK

PAGE E - 5MAINTENANCE AND REPAIR

Page 32

S SERIES PUMPS OM-06259

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.

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-06259 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 assembly (5), raise the pump slightly, or lay it on its side and disengage the hardware (55 and 57) securing the strainer and base plate (56) 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.

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 ter minal housing and cable assembly (36) while in this position. Use adequate equipment and per sonnel to safely handle 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.

Suction Head And Diffuser Removal

(Figure E-1)

Remove the hardware (59 and 60) securing the suction head (61) to the diffuser (1). Pull the suction head from the diffuser and remove the suction head gasket (6). Remove the hardware (52, 53 and

54) securing the diffuser (1) to the intermediate (48). Tap around the parting surfaces with a soft‐ faced mallet and separate the assemblies. Re move and discard the diffuser gaskets (7 and 50).

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.

Lay the pump on its side with the pipe plugs (9 and

10) facing up. Clean any dirt from around the plugs. Remove the seal cavity drain plug (9), 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 (10), 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 could indicate a breakdown in the waterproof in tegrity of the motor cavity, probably due to poor gaskets or seals.

Inspect the wear ring (64) for excessive wear or scoring and replace as required. The wear ring is a press fit into the suction head. To remove the wear ring, drill two small holes horizontally through the ring 180 apart. Use a small chisel or mechanical cutting device to complete the cuts through the wear ring.

Use caution not to damage the suction head when removing the wear ring.

Impeller Removal

(Figure E-1)

NOTE

The impeller hub is drilled and tapped with two 3/8

- 16 UNC screw holes for use with an impeller pull er (not furnished) if desired.

Insert a 3/4 inch square X 36 inch long (19,1 mm square X 914,4 mm long) rod between the vanes of the impeller (2) to prevent impeller rotation. Re move the impeller nut (63) and washer (62). Screw the impeller knocker (not shown, supplied with pump) onto the rotor shaft.

PAGE E - 7MAINTENANCE AND REPAIR

Page 34

S SERIES PUMPS OM-06259

NOTE

The rotor shaft is tapered and forms a friction fit with the impeller. Screw the impeller knocker onto the shaft until it bottoms out.

Use two pry bars to exert pressure on the back of the impeller and strike the knocker sharply until the impeller breaks loose.

Do not use excessive force when striking the knocker. It is possible to drive the rotor and lower ball bearing (47) out of position during impeller removal. If this occurs, the motor must be disassembled and the low er bearing must be pressed back into place to achieve proper impeller clear ances (see Motor Disassembly and Mo tor Reassembly).

After the impeller is free; remove the impeller knocker and slide the impeller off the shaft. Use caution when removing the impeller; tension on the seal spring will be released. Inspect the impel ler for excessive wear or damage and replace as required.

If no further disassembly is required, proceed to the appropriate areas in PUMP END REASSEMB LY.

press fit into the seal plate. To remove the wear ring, drill two small holes horizontally through the ring 180 apart. Use a small chisel or mechanical cutting device to complete the cuts through the wear ring.

Use caution not to damage the seal plate when removing the wear ring.

If no further disassembly is required, proceed to the appropriate areas in PUMP END REASSEMB

LY.

Upper Seal Removal

(Figures E-1 and E-3)

Unless cracked or otherwise worn, it is not neces sary to remove the intermediate for access to the upper seal assembly (4).

NOTE

Do not attempt to loosen the hardware (12, 13, 45 and 46) securing the bearing cap (17) and the inter mediate at this time. The rotor shaft and bearings could be damaged

Remove the seal retaining ring (35) 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.

Lower Seal Removal

(Figures E-1 and E-3)

Carefully remove the spring retainer and seal spring. Lubricate the rotor shaft (39) and work oil under the bellows assembly. Slide the rotating por tion of the seal assembly (consisting of the bellows, retainer and rotating element) off the shaft.

To remove the stationary portion of the seal, re move the socket head capscrews (51) and sepa rate the seal plate (49) from the intermediate (48). Remove and discard the seal plate O‐ring (8). Place a clean cloth on a flat surface and place the seal plate 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.

Inspect the wear ring (65) for excessive wear or scoring and replace as required. The wear ring is a

Lubricate the rotor shaft and work oil under the bel lows. Slide the rotating portion of the seal assem bly (consisting of the bellows, retainer and rotating element) off the shaft.

To remove the stationary portion of the seal, 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.

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 pump end components at this time.

MAINTENANCE AND REPAIRPAGE E - 8

Page 35

OM-06259 S SERIES PUMPS

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 lists for numbers).

Cleaning And Inspection Of Pump Parts

(Figure E-1)

With the pump inverted, stuff a clean tissue into the stationary seal seat bore of the intermediate (48) or wrap a small rag around the shaft to prevent for eign material from entering the motor cavity.

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.

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.

Inspect the rotor shaft (39) for damaged threads, scoring, or nicks. Remove nicks and burrs with a fine file or emery cloth to restore original contours. If the shaft is bent or severely damaged, the rotor and shaft must be replaced as an assembly (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.

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.

Most cleaning solvents are toxic and

Install the shaft seals as illustrated in Figure E-3.

PAGE E - 9MAINTENANCE AND REPAIR

Page 36

S SERIES PUMPS OM-06259

ROTOR

SHAFT

ROTATING

ELEMENT

SPRING

RETAINER

STATIONARY

SEAL SEAT O‐RINGS

SEAL

PLATE

BELLOWS

RETAINER

SPRING

RETAINER

O‐RING

STATIONARY

SEAL SEAT

BELLOWS

RETAINER

SEAL

RETAINING RING

STATIONARY

ELEMENT

ROTATING

ELEMENT

SPRING

IMPELLER

Figure E-3. Upper And Lower Seal Assemblies

This seal is not designed for operation at temperatures above 122 F (50 C). Do not use at higher operating temperatures.

Upper Seal Installation

(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.

Clean the rotor shaft (39) and seal cavity area of the intermediate (48). 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 motor 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.

Lubricate the stationary seat O‐ring and position the stationary seat in the intermediate bore with the sealing face up. Cover the seal face with a clean tis sue and use your thumbs to press the stationary seat into the bore. Apply equal pressure on oppo site sides until the seat contacts the bore shoulder. Remove the tissue and inspect the seal face to en sure that it is clean and dry. If cleaning is neces sary, use clean tissue to wipe lightly in a circular pattern.

MAINTENANCE AND REPAIRPAGE E - 10

Page 37

OM-06259 S SERIES PUMPS

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 (35), and I.D. of the bellows. Inspect the seal face to ensure that it is clean and dry. If cleaning is neces sary, use a clean tissue to wipe in a circular pattern.

Positions the seal rotating portion on the lubricated shaft as shown in Figure E-3. Apply firm, steady pressure on the seal retainer and slide it down the shaft in one smooth motion until the seal faces con tact. Use caution not to roll or cut the bellows on the groove for the retaining ring.

Slide the seal spring over the shaft and bellows re tainer, and install the spring retainer. Install the seal retaining ring (35). 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 seal plate (49). The seal bore must be free of burrs and nicks which could damage the seal. Inspect the seal plate for cracks, distortion, or erosion and replace it if defective.

If removed, press a replacement wear ring (65) into the seal plate bore with the chamfered end toward the inside of the seal plate. Be sure the ring seats squarely against the bore shoulder.

Position this subassembly in the seal plate bore with the sealing face up, 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 circular 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.

Carefully position the seal plate and stationary seal components over the rotor shaft and against the in termediate. Be careful not to damage the station ary element already installed. Secure the seal plate to the intermediate using the socket head caps crews (51).

Unpack the rotating portion of the seal. Be certain the seal face of the rotating element is free of grit or surface damage. If the rotating element does not want to 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.

Positions the seal rotating portion on the lubricated shaft as shown in Figure E-3. Apply firm, steady pressure on the seal retainer and slide it down the shaft until the seal faces contact.

The wear ring must seat squarely in the seal plate bore or binding and/or exces sive wear will result.

Coat the seal plate O‐ring (8) with light oil and in stall it on the seal plate. Position the seal plate 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 seal plate bore and the O.D. of the of the seal seat. Keep the sealing face dry.

Slide the seal spring over the shaft and bellows re tainer and install the spring retainer. See Figure E-3 for proper order of seal assembly.

Impeller Installation

(Figure E-1)

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 completely dry. Do not apply lubri

PAGE E - 11MAINTENANCE AND REPAIR

Page 38

S SERIES PUMPS OM-06259

cants of any kind to the impeller bore or the tapered section of the shaft. Install the impeller (2) and im peller washer (62) on the rotor shaft (39).

After the impeller is installed, coat the threads of the rotor shaft with `Loctite Threadlocker No. 242' or equivalent compound. Install the impeller nut (63). Insert a rod between the vanes of the impeller to prevent shaft rotation, and torque the impeller nut to 300 ft. lbs. (3600 in. lbs. or 42 m. kg.).

Remove the rod 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 moval. If this occurs, the lower bearing must be pressed back into place (see Motor Disassembly and Motor Reassembly).

Diffuser And Suction Head Installation

(Figure E-1)

and nuts (59); torque the nuts to 120 ft. lbs. (1440 in. lbs. or 16,6 m. kg.).

Turn the impeller and check for free rotation. If the impeller scrapes, disassemble the suction head and check the wear ring (64) for proper installation.

Strainer Installation

(Figure E-1)

Inspect the strainer assembly (5) for cracks, distor tion or erosion and replace it if defective.

Carefully position the strainer on the diffuser (1). Pack the spacers (55) with heavy grease and as semble the spacers to the base plate (56) using the capscrews (57). (The grease will help to prevent the spacers from sliding off the capscrews.)

Remove any grease from the ends of the caps crews and apply `Loctite Threadlocker No. 242' or equivalent compound to the threads of the cap screws. Secure the complete strainer assembly using the capscrews (57). Make certain that the strainer seats properly against the shoulder of the diffuser.

Inspect and thoroughly clean the diffuser (1) and its gasket surfaces. Cement the diffuser gaskets (7 and 50) in place using `3M Gasket Adhesive No. 847' or equivalent compound.

Carefully position the diffuser on the intermediate (48). Install the hardware (52, 53 and 54). Coat the threads of the capscrews (52) with `Never‐Seez' and torque the nuts (53) to 120 ft. lbs. (1440 in. lbs. or 16,6 m. kg.).

Inspect and thoroughly clean the suction head (61) and its gasket surface. If removed, press a replace ment wear ring (64) into the suction head bore with the chamfered end toward the inside of the suc tion head. Be sure the ring seats squarely against the bore shoulder.

The wear ring must seat squarely in the suction head bore or binding and/or ex cessive wear will result.

Install the suction head gasket (6) over the studs (58) and carefully position the suction head over the studs. Coat the studs with `Never‐Seez' or equivalent compound. Install the lockwashers (60)

See LUBRICATION and FINAL ASSEMBLY be fore 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.

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.

MAINTENANCE AND REPAIRPAGE E - 12

Page 39

OM-06259 S SERIES PUMPS

attempting to open or service the pump assembly. Tag electrical circuits to pre vent accidental start‐up.

Terminal Housing And Power Cable Removal And Disassembly

(Figure E-1)

Total disassembly of the terminal housing and power cable (36) 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 (36) 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 deformed locknuts (38) securing the terminal housing assembly to the motor housing assembly (18).

(Figure E-2)

Carefully raise the terminal housing (16) from the motor housing until the terminals (1) are accessi ble. Loosen the allen head setscrews (21), and dis connect the motor leads from the terminal posts. Separate the terminal housing and power cable assembly (13) from the motor housing.

No further disassembly is required to test the stator or power cable.

To disconnect the power cable (13), remove the nuts (14) securing the terminal gland (12) to the ter minal housing (16). Slide the gland back along the power cable. Oil the bushing (8) and terminal hous ing 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 loos ened, the cable should pull out far enough to ex pose the bushing. Apply oil on the cable jacket and slide the bushing back along the cable. Quite of ten, pressure exerted on the bushing will deform

the cable jacket. If such happens, additional oil and effort will be required to remove the bushing.

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 (19) comes free of the terminal housing. This should permit access to the power cable con nections 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 resealed with heat shrink tubing before applying the silicone adhesive (see

Terminal Housing And Power Cable Reassemb ly).

To disconnect the power cable (13) from the termi nal housing, pull the terminal plate away from the terminal housing. When shipped from the factory, the connections between the power cable leads and the terminal collars (2) were encapsulated in heat‐shrink tubing (3) and bonded to the terminal plate with silicone adhesive (not shown). (In ser vice, the adhesive may have been replaced by pot ting compound during previous repair.) If damage is extensive and the terminal plate and terminals are to be replaced, simply cut the power cable leads above the terminal collars and heat‐shrink tubing, and discard the terminal plate and termi nals.

If damage is not extensive and it is necessary to re place the terminal plate or terminal components, carefully cut away the tubing and adhesive. Dis connect the power cable leads from the terminal posts, and separate the terminal plate from the ter minal housing. Unscrew the terminal posts (1), and remove the terminal collars (2), posts and dyna seal washers (20) from the terminal plate.

Remove the hardware (4 and 5) securing the green and yellow ground lead terminals (6 and 17) to the terminal housing. Reinstall the hardware in the ter minal housing.

See Terminal Housing/Power Cable Reassemb

ly if no further disassembly is required.

PAGE E - 13MAINTENANCE AND REPAIR

Page 40

S SERIES PUMPS OM-06259

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 (45 and 46) securing the intermediate (48) to the motor hous ing (18). Do not remove the hardware (12 and 13) around the rotor shaft at this time.

Hook a three‐leg‐sling in the intermediate flange holes and hoist the intermediate, rotor and shaft (39), bearing cap (17) and both ball bearings (31 and 47) 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 (15, 16 and 43).

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 surface. Leave the lifting slings attached and reduce the tension slightly. Remove the hardware (12 and 13) 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 (47) and the in termediate bore.

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 intermediate bore. Replace the shaft and rotor (as an assembly), the motor housing or intermediate if the proper bearing fit is not achieved.

The lower bearing (47) is secured to the shaft by a tight press fit. Install two 3/8-16 UNC x 6-inch long capscrews (not supplied) 180 apart in the tapped holes in the bearing cap (17). Use a bear ing puller in conjunction with the capscrews to re move the lower bearing and bearing cap as an as sembly.

Separate the bearing cap and gasket (14) from the lower ball bearing.

If replacement is required, use a bearing puller to remove the upper ball bearing from the rotor shaft.

Stator Removal

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.

Before removing the bearings from the rotor shaft, clean and inspect the bearings in place as follows.

(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.

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.

MAINTENANCE AND REPAIRPAGE E - 14

Page 41

OM-06259 S SERIES PUMPS

The motor housing (18) 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.

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

pound on the threads. Position the valve out of the way, next to the terminal housing (16, Figure E-2) so that there is enough room for the terminal hous ing to clear.

Hoisting Bail

(Figure E-1)

If the hoisting bail (21) requires replacement, re move the hardware (22, 23 and 24) securing the bail to the motor housing. Make sure the bushings (20) are in place when installing the hoisting bail.

MOTOR REASSEMBLY

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 lists for numbers).

(Figure E-1)

It is recommended that the relief valve assembly (29) 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 (30) to remove the pressure relief valve. If the nip 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

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 (18), 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.

PAGE E - 15MAINTENANCE AND REPAIR

Page 42

S SERIES PUMPS OM-06259

Thoroughly clean the inside of the motor housing with fresh solvent. The interior must be dry and free of dirt or lint.

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.

ings. Apply heat evenly to the outside of the hous ing; excessive heat is not required.

When the motor housing is sufficiently heated, po sition the stator so that slot in the stator aligns with the plate on the inside of the motor housing and so that the leads are in line with the terminal opening. Carefully lower the stator into the motor housing until fully seated against the housing shoulder. Be careful not to damage the stator lead insulation during reassembly. If the stator “cocks” in the mo tor housing, remove it and try again.

After the stator is fully and squarely seated against the motor housing shoulder, remove the expand able 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.

Bearing Installation

(Figure E-1)

Inspect the rotor shaft (39) for damaged threads, scoring in the seal area, and a nicked or damaged tapered end. If the bearings were removed, in spect the bearing areas for scoring or galling. Re move 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 separated, replace the shaft and rotor (a single assembly).

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.

Heat the motor housing with a torch to expand it enough for the stator to be installed; when heating the motor housing, make sure that the stator is clear to avoid a fire hazard, or damage to the wind

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 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.

MAINTENANCE AND REPAIRPAGE E - 16

Page 43

OM-06259 S SERIES PUMPS

Heat the upper bearing (31) to a uniform tempera ture no higher than 250F (120C). Slide the bear ing onto the shaft until it is fully seated against the shaft shoulder. Do this 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.

Clean the bearing cap (17) and position it over the lower bearing (47) before heating.

INSTALLATION OF SKF 5200 AND 5300 SERIES BEARINGS

DIRECTION OF

THRUST

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 250F (120C). 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.

PART NUMBER MARKINGS ARE LOCATED EITHER ON BEARING O.D. (OFFSET FROM CENTER) OR ON SIDE FACE OF BEARING. FOR EITHER TYPE, POSITION BEAR ING WITH TEXT AWAY FROM IM PELLER.

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.

Figure E-4. Bearing Installation

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 suitable sized sleeve and a press to reposition the bearings. Make certain that they are seated squarely against the shaft shoulders.

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

Rotor Installation

(Figure E-1)

Use fresh solvent to clean all gasket and O‐ring surfaces of the motor housing (18) and intermedi ate (48), 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.

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

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

precautions printed on solvent contain ers.

Carefully ease the rotor (39), bearing cap (17) and assembled bearings (31 and 47) into the interme

PAGE E - 17MAINTENANCE AND REPAIR

Page 44

S SERIES PUMPS OM-06259

diate (48) so that the lower bearing (31) seats squarely in the intermediate bearing bore.

Secure the gasket (14) to the cap with a light coat ing of gasket adhesive.

Position the intermediate over the bearing and align the mounting holes with those in the bearing cap. Apply `Never‐Seez' or equivalent compound to the threads of the capscrews (12). Install the capscrews and lockwashers (13); torque the caps crews evenly in a cross‐sequence to 20 ft. lbs. (240 in. lbs. or 2,8 m. kg.).

Motor Housing And Intermediate Reassembly

(Figure E-1)

Use fresh solvent to clean the bores and all gasket surfaces of the motor housing (18), completely re moving any old gasket and cement material. In spect the sealing surfaces for burrs, nicks and pits which could cause a poor seal, and repair or re place as required.

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.

Apply `3M Gasket Adhesive No. 847' or equivalent compound to the motor housing gaskets (15, 16 and 43). Position the gaskets on the motor hous ing, making sure the gaskets are properly seated and the adhesive holds them securely.

Install a three‐leg sling in the intermediate flange holes and lower the assembled intermediate and rotor assembly into the motor housing. Use cau tion to guide the upper bearing into the motor housing bearing bore. Tap the intermediate with a soft‐faced mallet until it mates tightly with the motor housing.

Apply `Never‐Seez' or equivalent compound on the threads of the motor housing studs (44). Secure the intermediate to the motor housing with the hardware (45 and 46); torque the nuts evenly in a cross sequence to 120 ft. lbs. (1440 in. lbs. or 16,6 m. kg.).

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.

(Figure E-2)

Use oil to lightly lubricate the outside of the pump power cable (13), and the bores of the terminal housing (16), terminal gland (12) and gland bush ing (8) for ease of assembly. Slide the terminal gland, gland bushing and terminal housing onto the cable, allowing approximately 3 ft. (1 m) of ca ble to extend beyond the terminal housing. Tempo rarily tape the green and yellow ground wires to the cable.

MAINTENANCE AND REPAIRPAGE E - 18

Page 45

OM-06259 S SERIES PUMPS

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 (2) were encapsulated in heat‐ shrink tubing (3), and bonded to the terminal plate (19) with silicone adhesive to provide a water‐tight seal. If this insulating material has been damaged or removed during maintenance, it must be re placed using materials and equipment approved by Gorman‐Rupp (see the Parts List Manual for re pair kits).

grease coated.

Assemble the terminal posts (1), dyna seal wash ers (20), and terminal collars (2) 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 (3) up over each of the power cable leads. Insert the leads in the terminal collars and secure them using the al len head setscrews (18). 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.

Carefully heat each tube with a commercially avail able hot air gun capable of producing 750F (399C), and shrink the tubes around the cable leads and terminal collars.

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 (19) 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).

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

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.

NOTE

Do not use a mold or reservoir with the silicone adhesive.

Silicone Sealant

Figure E-5. Silicone Adhesive Sealing

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

PAGE E - 19MAINTENANCE AND REPAIR

Page 46

S SERIES PUMPS OM-06259

minal posts as shown in Figure E-5. Remove any adhesive from gasketed surfaces.

All air pockets, voids or gaps in the sili cone sealant must be removed to en sure a water‐tight seal in the terminal

1 YELLOW - CONNECT TERMINAL TO GROUND

WHITE

(T1)

RED

(T3)

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.

INSIDE TERMINAL HOUSING

2 GREEN -TOGETHER IN ONE TERMINAL.

CONNECT TERMINAL TO GROUND INSIDE TERMINAL HOUSING

BLACK

(T2)

Figure E-6. Terminal Housing Wiring Connections

Sealing Terminal Plate 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 (or use the adhesive res ervoir). 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 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;

MAINTENANCE AND REPAIRPAGE E - 20

Page 47

OM-06259 S SERIES PUMPS

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.

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)

(Figure E-1)

Coat the threads of the motor housing studs (37) with `Never‐Seez' or equivalent compound, and secure the terminal housing assembly to the motor housing with the hardware (38); torque the nuts evenly in a cross sequence to 20 ft. lbs. (240 in. lbs. or 2,8 m. kg.). Tighten the nuts (14, Figure 2) draw ing the terminal gland (12) down into the terminal bore. Do not overtighten and damage the terminal gland or hardware.

NOTE

A .12 in. (3,05 mm) gap is required between the ter minal gland cap flange and the terminal housing when tighten the nuts.

See FINAL ASSEMBLY and VACUUM TESTING followed by LUBRICATION.

FINAL ASSEMBLY

(Figure E-1)

If the discharge flange (26) was removed from the motor housing, replace the discharge flange gas ket (15). Apply `Never‐Seez' or equivalent com pound on the flange studs (32), and secure the flange with the nuts (33).

After the terminal plate has been sealed, slide the terminal housing down the cable. Untape the ground leads and secure the terminals (6 and 17) to the terminal housing with the hardware (4 and

5). Be sure the leads 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.

Lubricate the upper bore of the terminal housing, and slide the gland bushing (8) into place. Slide the terminal gland (12) into place and install the nuts (14). Do not fully tighten the nuts at this time.

Attach the appropriate motor lead (T1, T2, T3) to each terminal post (1) using the allen head set screws (21).

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.

If the hoisting bail (21) was removed, install the bail bushings (20) and secure the bail to the motor housing with the hardware (22, 23 and 24).

Connect the discharge hose, and reposition the pump. If rigid piping or long hose is used, reposi tion the pump, then connect the piping.

VACUUM TESTING

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.

PAGE E - 21MAINTENANCE AND REPAIR

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S SERIES PUMPS OM-06259

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

Vacuum Pump

Venturi

Manometer

Tee

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 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

Submersible Pump

Quick Disconnect

Air Compressor

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

Table E-1. Vacuum Test Data

Pump

Model

S8B 30 8 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

the test indicates a leak which must be identified and corrected before putting the pump back into service.

Duration

when the pump is hot, pressure in the seal cavity can cause hot oil to be ejected as the plug is removed.

To check the seal cavity oil, lay the pump on its side and remove the seal cavity plug (9) in the interme diate. Tip the pump and drain off a small amount of 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.

Seal Cavity

Vacuum

(In. Hg.)

Duration

(Minutes)

MAINTENANCE AND REPAIRPAGE E - 22

Page 49

OM-06259 S SERIES PUMPS

To fill the seal cavity, remove the pipe plug (11) 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

Table E-2. Oil Quantity

Pump Model Seal Cavity Motor Cavity

S8B1 768 ounces (22,7 liters)224 ounces (6,6 liters)

Table E-3. Pump Oil Specifications

Specifications:

Type Premium high viscosity index, anti‐wear hydraulic oil..............................

Viscosity (SSU @ 104F [40C]) 110 to 155.........................................

Viscosity (SSU @ 210F [100C]) 40 to 50...........................................

Dielectric 26,000 (volts‐min)........................................................

Recommended supplier:

Gulf Oil Company Gulf Harmony AW Hydraulic Fluid MG 32............................