Gorman-Rupp Pumps SF4B User Manual

Page 1
ACDE
OM-06460-01
March 22, 2012
Rev. C 01‐09‐14
AND MAINTENANCE MANUAL
WITH PARTS LIST
SUBMERSIBLE PUMP
MODEL
SF4B
THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
e2012 The Gorman‐Rupp Company
Page 2
Register your new
Gorman‐Rupp pump online at
www.grpumps.com
Valid serial number and e‐mail address required.
RECORD YOUR PUMP MODEL AND SERIAL NUMBER
Please record your pump model and serial number in the spaces provided below. Your Gorman‐Rupp distributor needs this information when you require parts or service.
Pump Model:
Serial Number:
Page 3
TABLE OF CONTENTS
INTRODUCTION PAGE I - 1.................................................
SAFETY ‐ SECTION A PAGE A - 1............................................
INSTALLATION - SECTION B PAGE B - 1....................................
PREINSTALLATION INSPECTION PAGE B - 1............................................
PUMP SEALS PAGE B - 1.............................................................
LUBRICATION PAGE B - 1.............................................................
PUMP INSTALLATION PAGE B - 1......................................................
Pump Dimensions PAGE B - 1.....................................................
Pump Motor Specifications PAGE B - 1..............................................
Lifting PAGE B - 2.................................................................
Positioning the Pump PAGE B - 2...................................................
Piping PAGE B - 2................................................................
ELECTRICAL CONNECTIONS PAGE B - 3...............................................
Field Wiring Connections (Incoming Power) PAGE B - 3...............................
Dual Vlotage PAGE B - 3..........................................................
Motor Cable Grounding Test PAGE B - 3.............................................
Control Box Connections PAGE B - 4...............................................
Liquid Level Devices PAGE B - 5....................................................
OPERATION - SECTION C PAGE C - 1......................................
GENERAL INFORMATION PAGE C - 1..................................................
Pump Performance PAGE C - 1.....................................................
Control Box PAGE C - 4...........................................................
PUMP OPERATION PAGE C - 4........................................................
Liquid Temperature And Overheating PAGE C - 4.....................................
Impeller Rotation PAGE C - 5.......................................................
STARTING, STOPPING AND OPERATIONAL CHECKS PAGE C - 5.........................
Starting PAGE C - 5...............................................................
Stopping PAGE C - 6..............................................................
Operational Checks PAGE C - 6....................................................
COLD WEATHER PRESERVATION PAGE C - 7...........................................
LUBRICATION PAGE C - 7.............................................................
Draining Oil PAGE C - 7...........................................................
Condition of Oil Oil PAGE C - 7.....................................................
Adding Oil PAGE C - 7............................................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...............................................
PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................
GENERAL INFORMATION PAGE E - 1..................................................
Lifting PAGE E - 1.................................................................
i
Page 4
TABLE OF CONTENTS
(continued)
PARTS LISTS:
Pump Model Assembly PAGE E - 3.................................................
Motor Assemblies PAGE E - 5......................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 6.........................
PUMP END DISASSEMBLY PAGE E - 6.................................................
Preparing Pump for Disassembly PAGE E - 6........................................
Pump Casing Removal PAGE E - 7.................................................
Draining Oil From Seal Cavity 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 - 10..................................................
Lower Seal Installation PAGE E - 10..................................................
Impeller Installation PAGE E - 11.....................................................
Pump Casing Installation PAGE E - 11................................................
Final Assembly PAGE E - 11........................................................
MOTOR DISASSEMBLY PAGE E - 12....................................................
Hoisting Bail Removal PAGE E - 12..................................................
Terminal Housing Assembly Removal PAGE E - 12.....................................
Rotor Shaft and Bearing Removal PAGE E - 12........................................
Stator Removal PAGE E - 13........................................................
MOTOR REASSEMBLY PAGE E - 14.....................................................
Stator Installation PAGE E - 14......................................................
Bearing and Rotor Shaft Installation PAGE E - 15......................................
Terminal Housing Assembly Installation PAGE E - 16...................................
Hoisting Bail Installation PAGE E - 17.................................................
VACUUM TESTING PAGE E - 17........................................................
Seal Cavity Testing PAGE E - 17.....................................................
Seal and Motor Cavity Testing PAGE E - 18...........................................
LUBRICATION PAGE E - 19.............................................................
Seal Cavity PAGE E - 19............................................................
Motor Bearings PAGE E - 19........................................................
ii
Page 5

INTRODUCTION

OM-06460SF SERIES
Thank You for purchasing a Gorman‐Rupp SF 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 an ap propriate control box matching the voltage and other characteristics of the motor. The control box must also provide for proper operation of the motor protection devices such as the integral moisture and thermal switches. Control boxes and other control devices other than those integral to the pump motor are not covered in this manual.
Pump construction is cast iron, with ductile iron im peller and stainless steel shaft and hardware. The pump is designed to handle raw, unscreened sew age and effluents. The pump may be equipped with an integral guide shoe which, when mounted on guide rails in a wet well, engages an optional base elbow. The pump may also be equipped with a trash stand for floor mounting in a wet well. Op eration is the same for either installation.
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:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-2870
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:
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.
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 damage which could result from failure to follow the procedure.
The Gorman‐Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: (419) 755-1011
or:
NOTE
Instructions to aid in installation, operation, and maintenance or which clarify a procedure.
PAGE I - 1INTRODUCTION
Page 6

SAFETY - SECTION A

This information applies to the SF Se ries submersible pump indicated on the front cover of this manual.
OM-06460SF SERIES
In addition to this manual, see the sepa rate literature covering the control box, control accessories or other equipment shipped with this pump.
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.
Before attempting to install, operate, or service this pump, familiarize yourself with this manual, and with all other liter ature shipped with the pump. Unfamil iarity with all aspects of pump operation covered in this manual could lead to de struction of equipment, injury, or death.
This pump is designed to handle raw sewage and industrial wastes at tem peratures of 104_F (40_C); Do not apply at higher temperatures. Do not attempt to pump volatile, flammable, or corro sive liquids which may damage the pump or endanger personnel as a result of pump failure.
The electrical power used to operate this pump is high enough to cause inju ry or death. Obtain the services of a qu alified electrician to make all electrical connections.
The following precautions should be taken before attempting to open or ser vice the pump; otherwise, injury or death could result.
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).
Do not connect the pump motor directly 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 and that the incoming power matches the requirements of the pump and controls. Install and operate the control box in accordance with the National Electric Code and all local codes. Failure to follow the instructions
PAGE A - 1SAFETY
Page 7
in this warning could result in injury or death to personnel.
Do not attempt to lift this pump by the motor or control cables, or the piping. Attach proper lifting equipment to the lifting bail fitted on the pump.
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.
SF SERIESOM-06460
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.
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 start‐up.
PAGE A-2 SAFETY
Approach the pump cautiously after it has been running. Although the motor is cooled by dispersing heat through the motor housing cooling fins into the liq uid being pumped, normal operating temperatures can still be high enough to cause burns. The temperature will be
Page 8
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.
OM-06460SF SERIES
If this pump is used to handle sewage, take necessary precautions during maintenance and repair to prevent per sonal contamination which could result in illness.
Pumps and related equipment must be installed and operated according to all na tional, local and industry standards.
PAGE A - 3SAFETY
Page 9
SF SERIES OM-06460

INSTALLATION - SECTION B

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.
The motor in these pumps is not designed to be operated in air for more than 10 min utes without overheating. The pumps must be operated through liquid level controls to maintain the level of liquid in the wet well so that power to the motor is cut off when liq uid falls below the midpoint of the motor housing.
match the ratings on the control box and in coming power.
e. Carefully read all tags, decals, and markings
on the pump assembly, and perform all duties indicated.
f. Check for any oil leaks. If there is any indica
tion of an oil leak, see LUBRICATION in
MAINTENANCE AND REPAIR - SECTION E.
PUMP SEALS
This pump is equipped with two mechanical seals. The lower seal is lubricated by the liquid being pumped and prevents the liquid from entering the seal housing cavity from the pump end. The upper seal prevents oil from escaping from the seal hous ing into the motor housing and acts as backup pro tection in the event of lower seal failure.
LUBRICATION
Automatic liquid level controls are available from Gorman‐Rupp as options. For information on in stalling and operating these controls, see the tech nical data accompanying them.
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 and tighten loose attaching hard
ware.
c. Inspect the power cable for cuts or any other
obvious damage.
d. Check that amperes, phase, voltage, and
hertz indicated on the motor name plate
The seal cavity is fully lubricated when shipped from the factory. However, the lubrication level
must be checked before installing the pump (see LUBRICATION in MAINTENANCE AND REPAIR
- SECTION E). If the oil level is abnormally low, de
termine the cause before putting the pump into service.
The shaft bearings are permanently lubricated.
There is no other lubrication in the pump.
PUMP INSTALLATION
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.
Pump Motor Specifications
The motor furnished with this pump is a 60 Hz., Squirrel Cage, Induction Start, Class H Insulation Rated 365_F (180_C).
INSTALLATION
PAGE B - 1
Page 10
OM-06460 SF SERIES
See Table B-1 for motor specifications.
TABLE B-1. PUMP MOTOR SPECIFICATIONS
MODEL VOLTAGE/
PHASE
SF4B 460/575 4” 30.0 1750 36.6/29.3 246.0/197.0
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.
Positioning the Pump
SIZE MOTOR
H.P. LOCKED
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.
This pump may be mounted on guide rails or cables for use with optional discharge elbow/base plate kits, or it may be mounted on a trash stand with an optional discharge elbow.
MAX
RPM
fully seated in the baseplate.
To install a pump configured for a guide rail/guide cable application, engage the guide shoe at the top of the guide rails and use a suitable lifting de vice attached to the lifting handle to lower the pump into the wet well. When the pump and guide shoe engages the discharge elbow/baseplate, it will form an automatic seal.
If the pump is mounted on a trash stand, secure a discharge hose or pipe to the optional discharge elbow and use a suitable lifting device attached to the lifting handle to lower the pump into the wet well.
Make certain that the pump and stand sit level in the wet well.
Regardless of the installation configuration, the
maximum recommended submergence depth is 65 feet (20 meters).
After installation in the wet well, reel in any slack in the cables so that they are not dragged into the pump suction.
LOAD
AMPS
ROTOR
AMPS
If the pump is configured for a guide rail/guide cable application, the pump will be equipped with a rail guide shoe which connects to the discharge optional elbow/baseplate. When lowered into place, the pump is automatically and securely con nected to the elbow/baseplate and the piping sys tem. For information on installing the guide rails, see the literature accompanying them.
NOTE
When engaging the guide shoe and elbow/base plate, make sure that the connection is not impeded by mounting hardware, and that the guide shoe is
PAGE B - 2 INSTALLATION
Piping
NOTE
Refer to Pump Performance in OPERATION - SECTION C when determining the most efficient
piping installation.
No suction piping is required in a standard sub merged operation.
Either hose or rigid pipe may be used to make dis charge connections. The discharge line must be independently supported to avoid vibration and strain on the pump. For maximum pumping capac
Page 11
SF SERIES OM-06460
ity, keep the line as short and straight as possible. Elbows and fittings used in a discharge line in crease friction losses; 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.
Field Wiring Connections (Incoming Power)
Field wiring is not provided with this pump, and must be supplied by the user. The field wiring must 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-2.
TABLE B-2. MOTOR VOLTAGE LIMITS
NOMINAL VOLTAGE
PHASE MINIMUM
VOLTAGE
MAXIMUM
VOLTAGE
Motor Cable Grounding Test
Do not connect the pump power or con trol cables to the control box or incom ing voltage before verifying the pump ground. Otherwise, personnel will be exposed to serious injury or death.
Connect one lead of a lamp, bell or similar testing device to the motor cable green/yellow ground lead (s). Connect the second test lead to an unin sulated 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
The pump warranty is void if the motor is not operated through a control box ap proved by Gorman‐Rupp.
This pump is shipped completely wired for the volt age shown on the nameplate and is ready for op eration through an approved control box.
Ground the control box in accordance with the in structions accompanying it.
Ground the pump to the control box using the pow er cable ground(s) and ground check wire (if so equipped). Secure the ground wire(s) and ground check wire (if so equipped) to the grounding lug(s) inside the control box to ensure a thorough ground for the pump.
3460 414 506
Use conduit cable clamps to secure the incoming field wiring to the control box. Make certain all con nections are tight. If necessary, support the cable weight to prevent excessive strain on cable clamps and cable.
INSTALLATION
3575 517 632
Ground the pump using the power cable ground wire(s) before applying line po tential. Failure to properly ground the pump could result in damage to the pump or control and/or injury or death to personnel.
PAGE B - 3
Page 12
OM-06460 SF SERIES
Refer to Figures B-1 and connect the pump motor cable to the control box.
Figure B-1. Three Phase Power
Cable Connections
Control leads P1 and P2 provide the motor with thermal protection. Control leads W1 and W2 pro vide the motor with moisture protection. Refer to Figure B-3 and connect the pump control cable to the control box.
Liquid Level Devices
Optional controls available from Gorman‐Rupp may provide a means to automatically regulate the liquid level. These control boxes may be con nected to the following sensing devices which per form either filling or dewatering functions (see Fi gure B-3).
The internal wiring of the sensing devices are different for filling and dewatering func tions. Be sure to follow the instructions in cluded with the option before making con nections.
S 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.
Figure B-2. Control Cable Connections
The thermal protection contacts will auto matically reclose when the motor cools to the established safe operating tempera ture. Whenever automatic restarting is not desirable, connect only to controls which are wired for manual restart.
Refer to the appropriate wiring diagram accompa nying the control box when making electrical con nections.
S Bulb (Float) Type: a bulb raises or lowers
(floats) with the liquid level, thus activating an enclosed miniature switch.
Other types of liquid level devices may also be used. Consult the factory for the liquid level device best suited for your application.
Liquid level devices must be positioned far enough to allow 6 minutes between starts. If the pump motor cycles more than 10 starts per hour, it will over‐heat, resulting in damage to the motor windings or control box components.
PAGE B - 4 INSTALLATION
Page 13
SF SERIES OM-06460
PUMP
CONTROL BOX
TO LEVEL CONTROL CIRCUIT
IN MAIN CONTROL BOX
LIQUID LEVEL
RANGE
OFF
DEWATERING
ON (FILLING)
BULB (FLOAT TYPE)
Figure B-3. Liquid Level Devices
TO LEVEL CONTROL CIRCUIT
IN MAIN CONTROL BOX
LIQUID LEVEL
RANGE
DEWATERING
ON (FILLING)
DIAPHRAGM TYPE
PUMP
CONTROL BOX
OFF
INSTALLATION
PAGE B - 5
Page 14
SF SERIES OM-06460

OPERATION - SECTION C

GENERAL INFORMATION
Review all SAFETY information in Section A.
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
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.
In the performance curve which follows, perform ance is based on 70_F (21_C) clear water at sea level. The performance of your pump may be differ ent due to such factors as viscosity, specific grav ity, elevation, temperature and impeller trim.
NOTE
The curve applies to standard production models. 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 per formance.
Since operation of the pump motor is de
PAGE C - 1OPERATION
Page 15
OM-06460 SF SERIES
SF4B 460/575V 3P PERFORMANCE CURVE
PAGE C - 2 OPERATION
Page 16
SF SERIES OM-06460
Control Box
Control boxes are available as optional equipment from the factory. The control boxes contain con trols for starting and stopping the pump, and pro vide 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.
Since operation of the pump motor is dependent upon the quality and performance of the electrical controls, the pump warranty is valid only when controls have been specified or provided by The Gorman‐Rupp Company.
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 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.
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 10 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 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 10 times per hour. If the motor does not cool be tween starts it will overheat, resulting in damage to the motor windings.
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.
Overheated pumps can cause severe burns and injury. If the pump becomes overheated:
1. Stop the pump immediately.
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
PAGE C - 3OPERATION
Page 17
OM-06460 SF SERIES
burns and injuries. If overheating of the pump occurs:
1. Stop the pump immediately.
2. Ventilate the area.
3. Allow the pump to completely cool.
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.
Impeller Rotation
Check impeller rotation as follows before operation to ensure that the impeller is rotating in the correct direction.
While checking impeller rotation, secure the pump to prevent the power cable from coiling.
ry or death. Make certain that incoming power is off and locked out before inter changing motor leads.
DIRECTION OF
KICKBACK
AT STARTUP
Figure C-1. Checking Pump Rotation
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.
The electrical power used to operate this pump is high enough to cause inju
STARTING, STOPPING, AND OPERATIONAL CHECKS
Starting
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.
Do not start the pump more than 10 times per hour. If the pump motor does not cool
PAGE C - 4 OPERATION
Page 18
SF SERIES OM-06460
between starts, it will over‐heat, resulting in damage to the motor windings.
Stopping
Follow the instructions accompanying the control box for stopping the pump.
The integral thermal overload device will shut off the motor if the temperature rises above design limits. When the pump cools and the temperature falls below these limits, the motor will restart automatically. To avoid the hazards of an unexpected motor start‐up, do not at tempt to handle or service the pump un less all power to the motor has been shut off and locked out at the control box; otherwise, serious personal 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.
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.
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 liquid pressure input to 50% of the maxi mum permissible operating pressure shown in the pump performance curve.
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.
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 start the pump more than 10 times per hour. If the motor does not cool be tween starts it will overheat, resulting in damage to the motor windings.
PAGE C - 5OPERATION
Page 19
OM-06460 SF SERIES
Check the oil level(s) as indicated in the following
LUBRICATION section.
COLD WEATHER PRESERVATION
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 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.
If submerging does not thaw the pump, move it into a warm area until completely thawed.
On a new pump, check the oil level in the seal cav ity 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 month thereafter.
Before installing or removing the lubrication plugs, always clean the area around the plugs to prevent contamination.
Draining Oil
Refer to the Parts List in Maintenance and Repair
- Section E for drain plug location.
Lay the pump on its side with one of the pipe plugs (7) facing up. Clean any dirt from around the plug. Remove the plug slowly to release any pressure and install a short 3/8‐inch NPT nipple in the hole. Roll the pump and drain the seal oil into a clean container.
Condition Of Oil
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 (Mainte
nance and Repair - Section E).
Adding Oil
LUBRICATION
Refer to Maintenance and Repair - Section E for the oil capacity for filling the seal cavity in your pump.
The grade of lubricant used is critical to the opera
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
tion of this pump. Use premium quality submers ible pump oil as specified in Table E-2 in Mainte nance and Repair - Section E. Oil must be stored in a clean, tightly closed container in a reasonably dry environment.
gaged to be ejected with great force. Al low the pump to completely cool before servicing.
PAGE C - 6 OPERATION
When lubricating the seal cavity, position the pump vertically after draining the oil as indicated above
Page 20
SF SERIES OM-06460
in Draining Oil. Add premium quality submersible pump oil through the fill plug hole until the oil is lev el with the bottom of the plug hole.
Install and tighten the fill plug.
PAGE C - 7OPERATION
Page 21
SF SERIES OM-06460

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
PUMP FAILS TO START, OVERLOAD UNIT NOT TRIPPED (MANUAL MODE).
PUMP FAILS TO START, OVERLOAD UNIT NOT TRIPPED (AUTOMATIC 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.
Bearings 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.
ings.
PAGE D - 1
Page 22
OM-06460 SF SERIES
TROUBLESHOOTING CHART (cont'd)
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
MOTOR RUNS, BUT PUMP FAILS TO DELIVER RATED DISCHARGE.
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. Check impeller (see PUMP END
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.
REASSEMBLY in Maintenance and Repair, Section E).
rect, interchange any two motor leads at the control box (3 phase models, see Pump Rotation, Sec tion C).
PUMP RUNS WITH EXCESSIVE 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 23
SF SERIES OM-06460
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 B-1 in INSTALLATION; these values apply only when the voltage at the site is the normal voltage listed.
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.
Power Cable Continuity
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 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 should be as close as can be measured.
c. If readings indicate that continuity problems
exist in the motor or power cable, the motor and/or terminal housing assembly must be re paired before putting the pump into service.
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
TROUBLESHOOTING
PAGE D - 3
Page 24
OM-06460 SF SERIES
motor cable green/yellow ground lead. Touch 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 25
PUMP MAINTENANCE AND REPAIR - SECTION E
OM-06460SF SERIES
GENERAL INFORMATION
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 illustrations, 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.
Check TROUBLESHOOTING, Section B to deter mine causes and remedies of pump problems. Disassemble the pump only as far as required.
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.
PAGE E - 1MAINTENANCE AND REPAIR
Page 26

PARTS PAGE

SF SERIESOM-06460
ILLUSTRATION
Figure E-1. SF4B Pump Model Assembly
MAINTENANCE AND REPAIRPAGE E - 2
Page 27
OM-06460SF SERIES
SF4B Pump Model Assembly
Parts List
(From S/N 1504502 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 PUMP CASING
-ANSI 38218-309 11010 1
-DIN 38218-313 11010 1 2 IMPELLER SEE NOTE 3 IMPELLER WASHER 31514-017 17000 1 4 SOCKET HD CAPSCREW MBD1020 17000 1 5 WEAR RING 38691-368 11010 1 6 O‐RING 25152-277 --- 1 7 LOCK WASHER MJ12 17000 14
8 ADJUSTING SCREW MB1235 17000 4
8A HEX HD CAPSCREW MB1235 17000 4
9 SUCTION HEAD
-ANSI 38246-619 10000 1
-DIN 38246-620 10000 1
10 O‐RING 25152-276 --- 1 11 HEX HD CAPSCREW MB1245 17000 8 12 NAME PLATE 38814-074 17000 1 13 DRIVE SCREW BM#04-03 17000 4 14 MOTOR ASSY
-460/3 47111-824 --- 1
-575/3 47111-825 --- 1
15 10 METER TERMINAL HOUSING ASSY
12 METER TERMINAL HOUSING ASSY
15 METER TERMINAL HOUSING ASSY
25 METER TERMINAL HOUSING ASSY
35 METER TERMINAL HOUSING ASSY
50 METER TERMINAL HOUSING ASSY
16 LOCK WASHER MJ10 17000 4 17 HEX NUT MD10 17000 4 18 HEX HD CAPSCREW MB1235 17000 2 19 LIFTING BAIL ASSY 44713-048 17040 1 20 JAM NUT MAT12 17000 4 21 SEAL PLATE 38272-536 10000 1
22 O‐RING 25152-379 --- 1 23 FLAT HD CAPSCREW MF0520 17000 4
24 SHAFT SLEEVE O‐RING 25154-022 --- 1 25 SHAFT SLEEVE 31441-030 1706H 1
NUMBER
47367-714 --- 1
47367-716 --- 1
47367-718 --- 1
47367-720 --- 1
47367-722 --- 1
47367-724 --- 1
MAT'L CODE
QTY ITEM
NO.
26 SEAL ASSY 25285-856 --- 1 27 SPRING RETAINER 31161-042 17000 1 28 IMP ADJ SHIM SET 37J 17090 1 29 PIPE PLUG P04 17000 2
NOT SHOWN:
OPTIONAL:
PART NAME PART
NUMBER
INFINITY DECAL 38811-435 --- 1 G‐R DECAL GR-03 --- 1 TERM HOUSING O‐RING 25154-153 --- REF
ANSI SLIDE RAIL VERSION
GUIDE SHOE KIT 48156-559 --- 1
-GUIDE SHOE SEAL 31513-054 19020 1 SLIDE RAIL KIT 48156-024 --- 1 ALIGNMENT KIT 48786-551 --- 1 BASEPLATE KIT
-SHORT 48156-603 --- 1
-LONG 48156-604 --- 1 LIFTING CABLE KIT
-36' 48151-502 --- 1
-50' 48151-504 --- 1
DIN SLIDE RAIL VERSION
GUIDE SHOE KIT 48156-560 --- 1
-GUIDE SHOE SEAL 31513-054 19020 1 SLIDE RAIL KIT CONSULT FACTORY 1 ALIGNMENT KIT 48786-552 --- 1 BASEPLATE KIT
-SHORT CONSULT FACTORY 1
-LONG CONSULT FACTORY 1 LIFTING CABLE KIT
-36' 48151-502 --- 1
-50' 48151-504 --- 1
ANSI TRASH VERSION
STAND KIT 48786-209 --- 1 DISCH ELBOW KIT 48135-102 --- 1 INCREASER KIT 48135-502 --- 1
DIN TRASH VERSION
STAND KIT 48786-213 --- 1 DISCH ELBOW KIT 48135-106 --- 1
LIQUID LEVEL DEVICES:
DIAPHRAGM TYPE GRP48-03 --- 1
GRP48-06 --- 1 FLOAT TYPE 27471-180 --- 1 120V LIQUID LEVEL
CONTROL RELAY 27521-321 --- 1
MAT'L CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
NOTE: FOR IMPELLER P/N, CONTACT THE FACTORY WITH PUMP MODEL, S/N AND IMPELLER DIAMETER (FROM NAMEPLATE)
PAGE E - 3MAINTENANCE AND REPAIR
Page 28
ILLUSTRATION
SF SERIESOM-06460
Figure E-2. 47111-824 and -825 Motor Assemblies
MAINTENANCE AND REPAIRPAGE E - 4
Page 29
47111-824 and -825 Motor Assemblies
Parts List
OM-06460SF SERIES
ITEM NO.
1 MOTOR SUBASSEMBLY
2 BEARING 23257-012 --- 1 3 ROTOR/SHAFT ASSY 47112-088 --- 1 4 BEVELED SNAP RING 24121-555 --- 1 5 BEARING 23431-310 --- 1 6 O‐RING 25152-279 --- 1 7 PIPE PLUG P08 17000 2 8 INTERMEDIATE 38261-038 10000 1
9 10 SNAP RING S245 --- 1 11 LOCK WASHER MJ12 17000 8 12 HEX HD CAPSCREW MB1230 17000 8 13 MOISTURE DETECTOR 27479-009 --- 1 14 FEMALE TERMINAL 27236-054 --- 1 15 MALE TERMINAL 27236-454 --- 1 16 IMPELLER KEY MNR100820 17000 1 17 36” 18 AWG WIRE 18147-104 --- 1
NOT SHOWN (SUPPLIED WITH MOTOR SUBASSEMBLY):
INDICATES PARTS RECOMMENDED FOR STOCK
PART NAME
-460/3 47111-840 --- 1
--MOTOR HOUSING 38311-215 10000 1
--STATOR 47113-097 --- 1
--TERMINAL HOUSING STUD MC1042 17000 4
--VOLTAGE TAG 38816-460 --- 1
--ROTATION DECAL 38815-027 --- 1
-575/3 47111-841 --- 1
--MOTOR HOUSING 38311-215 10000 1
--STATOR 47113-098 --- 1
--TERMINAL HOUSING STUD MC1042 17000 4
--VOLTAGE TAG 38816-128 --- 1
--ROTATION DECAL 38815-027 --- 1
SEAL ASSY S1934 --- 1
WIRE CONNECTOR S1718 --- 3 POWER LEAD CONTACTS:
-208‐230/460/3 27216-003 --- 3
-575/3 27216-005 --- 3 POWER LEAD CONTACT HOUSINGS:
-BLACK 27216-034 --- 1
-WHITE 27216-035 --- 1
-RED 27216-036 --- 1 CONTROL LEAD CONTACT 27216-002 --- 3 CONTROL LEAD CONTACT HOUSINGS:
-ORANGE 27216-031 --- 1
-BLUE 27216-032 --- 1
-BROWN 27216-033 --- 1
PART NUMBER
MAT'L CODE
QTY
PAGE E - 5MAINTENANCE AND REPAIR
Page 30
SF SERIESOM-06460

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Review all SAFETY information in Section A.
This pump requires little service due to its rugged, minimum‐maintenance design. However, if it be comes necessary to inspect or replace the wearing parts, follow these instructions, which are keyed to the illustrations (see Figures E-1 and E-2) and the corresponding parts lists.
This manual will alert personnel to known proce dures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel. However, this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance per sonnel to ensure that only safe, established main tenance procedures are used, and that any proce dures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such prac tices.
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.
Select a suitable location, preferably indoors, to perform required maintenance. All work must be performed by qualified personnel.
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 cable(s) or terminal housing, see MO TOR DISASSEMBLY for terminal housing replace ment. If the problem is determined to be in the mo tor, proceed with PUMP END DISASSEMBLY, fol lowed by MOTOR 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.
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.
If this pump is used to handle sewage, take necessary precautions during maintenance and repair to prevent per sonal contamination which could result in illness.
Carefully inspect any O‐rings before removal and cleaning to determine if a proper seal and com pression existed prior to disassembly. If sealing was faulty or questionable, the cause must be de termined and corrected before reassembly. All O‐ rings must be replaced if disturbed.
PUMP END DISASSEMBLY
Preparing Pump for Disassembly
Use the hoisting bail to remove the pump from the wet well or sump. If installed in a trash application, remove the discharge piping and move the pump to a suitable location for disassembly.
MAINTENANCE AND REPAIRPAGE E - 6
Page 31
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.
If installed in a slide rail application, it is not neces sary to remove the guide shoe for most pump maintenance procedures. If removal of the guide shoe is desired, disengage the hardware securing the guide shoe to the pump casing and remove the guide shoe and guide shoe seal.
If installed in a trash application, it is not necessary to remove the optional discharge elbow for most pump maintenance procedures. If removal of the discharge elbow is desired, disengage the hard ware securing the elbow to the pump casing and remove the elbow and gasket.
OM-06460SF SERIES
Pump Casing Removal
(Figure E-1)
Position the pump assembly on a flat surface and use the lifting bail and lifting device to support the pump in a vertical position. Remove the hardware (7 and 11) securing the motor assembly (14) to the pump casing (1).
Using the lifting device, raise the motor assembly out of the pump casing. It may be necessary to tap around the circumference of the pump casing with a soft‐faced mallet to break the seal between the casing and motor. When the motor is free of the pump casing, position the motor and remaining pump end components horizontally on a flat sur face for further disassembly. Chock the pump to prevent rolling when positioned horizontally.
Remove the O‐ring (22) from the outer shoulder of the seal plate (21).
Draining Oil From Seal Cavity
(Figure E-2)
The seal cavity oil must be drained to prevent the oil from escaping as the impeller is removed.
If the pump is equipped with a trash stand, disen gage the hardware securing the pump to the stan before proceeding with pump disassembly.
Suction Head and Wear Ring Removal
(Figure E-1)
Position the pump horizontally on a flat work sur face and remove the hardware (7 and 8A) securing the suction head (9) to the pump casing (1).
Use a pair of suitable tools to pry the suction head and assembled wear ring (5) out of the pump cas ing.
Inspect the wear ring for excessive wear or scoring. If replacement is required, install two M12 x 1.75 x 76 mm long capscrews (not supplied) in the tapped holes in the suction head. Turn the screws evenly in an alternating sequence to press the wear ring out of the suction head.
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 one of the pipe plugs (7) facing up. Clean any dirt from around the plug. Remove the plug slowly to release any pressure and install a short 3/8‐inch NPT nipple in the hole. Roll the pump and drain the seal oil into a clean container. Inspect the oil for water, dirt, or cloudy condition which could indicate lower seal failure or poor O‐ring seal.
Impeller Removal
(Figure E-1)
Wedge a soft metal rod between the impeller vanes to prevent impeller rotation and use a hex key to re
PAGE E - 7MAINTENANCE AND REPAIR
Page 32
SF SERIESOM-06460
move the impeller screw (4). Remove the impeller washer (3). Remove the metal rod from between the vanes of the impeller.
NOTE
An alternate method of removing the impeller screw is to immobilize the impeller using a strap wrench. A hex key used in conjunction with an impact wrench can also be used to remove the impeller screw.
To remove the impeller, use two thin‐bladed screw drivers positioned 180_ apart to pry on the back of the impeller and “walk” the impeller off the shaft. Use increasingly larger screwdrivers (or wedges) as necessary. After the impeller comes free of the shaft, retain the impeller key (16, Figure E-2).
Remove the impeller adjusting shims (28). Tie and tag the shims for ease of reassembly.
If no further disassembly is required, proceed to the appropriate areas in PUMP END REASSEMB
LY.
Lower Seal Removal
(Figures E-1 and E-3)
Carefully remove the spring retainer (27) and seal spring. Slide the shaft sleeve (18) and rotating por tion of the seal off the shaft as a unit.
Apply oil to the sleeve and work it up under the rub ber bellows. Slide the rotating portion of the seal off the shaft sleeve.
Work a pair of stiff wires with hooked ends between the rotor shaft and the stationary seat and pull the stationary seat and O‐ring out of the seal plate (15).
NOTE
An alternate method of removing the stationary ele ment is to remove the screws (23) securing the seal plate (21) to the motor assembly (14). Pry the as sembled seal plate and stationary element off the shoulder of the intermediate (8, Figure E-2). Re move the O‐ring (10) and press the stationary ele ment and seat out of the seal plate from the back side.
Remove the seal sleeve O‐ring (24) from the rotor shaft.
If no further disassembly is required, proceed to the appropriate areas in PUMP END REASSEMB
LY.
Upper Seal Removal
(Figures E-2 and E-3)
With the pump end and lower seal removed, se cure the pump in an inverted position for further disassembly.
Remove the seal plate (21, Figure E-1) as de scribed above in Lower Seal Removal.
Remove the seal retaining ring (10) using snap ring pliers. Use caution when removing the retaining ring; tension on the seal spring will be released. Remove the spring centering washer and seal spring.
Lubricate the seal area of the rotor shaft (3) and work oil up under the bellows. Remove the hard ware (11 and 12) securing the intermediate (8) to the motor subassembly (1).
Carefully pull the assembled intermediate, rotor shaft (3) and bearings (2 and 5) out of the motor housing until the female terminal (14) can be ac cessed. Pull the female terminal off the male termi nal (15) and remove the intermediate, rotor shaft and bearings from the motor assembly. Remove the O‐ring (6) from the intermediate shoulder.
Remove the snap ring (4) from the groove in the in termediate and pull the assembled rotor shaft and bearings out of the intermediate. Cover the motor assembly with a clean rag to prevent foreign mate rial from entering the motor cavity.
With the rotor shaft and bearings removed, press the stationary seal element and O‐ring out of the in termediate from the back side.
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 33
OM-06460SF SERIES
PUMP END REASSEMBLY
NOTE
Reuse of old O‐rings or shaft seal parts will result in premature leakage or reduced pump performance. It is strongly recommended that new O‐rings and shaft seal assemblies be used during reassembly (see the parts lists for numbers).
Cleaning and Inspection of Pump Parts
(Figures E-1 and E-2)
Carefully inspect any O‐rings before removal and cleaning to determine if a proper seal existed prior to disassembly. If sealing was faulty or question able, the cause must be determined and corrected before reassembly. Replace any parts as required.
Thoroughly clean all reuseable parts with a soft cloth soaked in cleaning solvent. Remove all O‐ rings and clean the sealing surfaces.
precautions printed on solvent contain ers.
Inspect the rotor shaft (3, Figure E-2) for dam aged threads, scoring, or nicks. Remove nicks and burrs with a fine file or hand honing stone to restore original contours. If the shaft is bent or severely damaged, the rotor and shaft must be replaced as an assembly (see MOTOR DISASSEMBLY).
Neither of the shaft seal assemblies should be re used because wear patterns on the finished faces cannot be realigned during reassembly. This could result in premature failure. If necessary to reuse an old seal in an emergency, carefully wash all me tallic 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.
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
Inspect the seal components for wear, scoring, grooves, and other damage that might cause leak age. If any components are worn, replace the com plete seal; never mix old and new seal parts.
Install the shaft seals as illustrated in Figure E-3.
PAGE E - 9MAINTENANCE AND REPAIR
Page 34
SF SERIESOM-06460
ROTOR
SHAFT
ROTATING
ELEMENT
SPRING
SPRING
CENTERING
WASHER
STATIONARY
SEAL SEAT
BELLOWS AND
RETAINER ASSY
SHIM SET
STATIONARY
SEAL SEAT
O‐RING
BELLOWS AND
RETAINER ASSY
SEAL
RETAINING RING
SEAL PLATE
O‐RING
ROTATING
ELEMENT
SPRING
SPRING
RETAINER
Figure E-3. Upper And Lower Seal Assemblies
The seal assemblies are not designed for operation at temperatures above 104_F (40_C). Do not use at higher operating temperatures.
Upper Seal Installation
(Figures E-2 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 (3) and seal cavity area of the intermediate (8). 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 original con tours. If the shaft is bent or damaged, the complete rotor and shaft must be replaced as an assembly.
IMPELLER
Apply a light coating of oil to the bore of the inter mediate.
Position the intermediate with the impeller end down on some wood blocks tall enough to allow for installation of the rotor shaft through the intermedi ate.
Inspect the rotor shaft (3) and bearings (2 and 5) as indicated in Bearing and Rotor Shaft Installation in this section and replace any parts as necessary.
Slide the assembled shaft and bearings into the in termediate until the lower bearing seats squarely in the intermediate bore. Secure the rotor and shaft to the intermediate by installing the snap ring (4) in the groove in the intermediate bore.
Install a new O‐ring (6) on the shoulder of the inter mediate.
With the motor housing and stator positioned up side down, carefully lower the assembled inter mediate, rotor shaft and bearings into the motor housing until the female terminal (14) can be se curely attached to the male terminal (15) on the moisture sensor.
MAINTENANCE AND REPAIRPAGE E - 10
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OM-06460SF SERIES
Position the intermediate so the holes for the mounting hardware in the intermediate align with those in the motor housing and press the inter mediate into the motor housing until fully seated. Apply “Never‐Seez” or equivalent compound on the threads of the capscrews (12) and secure the intermediate to the motor housing with the hard ware (11 and 12). Torque the capscrews to 47 ft. lbs. (6,5 m. kg.).
Subassemble the O‐ring onto the stationary seat. Position this subassembly in the intermediate bore with the sealing face up and cover the seal face with a clean tissue. Use your thumbs to press the assembly into the bore. Apply equal pressure on opposite sides until the seat contacts the bore shoulder. Remove the tissue and inspect the seal face to ensure that it is clean and dry. If cleaning is necessary, use clean tissue to wipe lightly in a cir cular pattern.
Unpack the rotating portion of the seal. Be certain the seal face of the rotating element is free of grit or surface damage. Because the rotating element may not stay in the bellows retainer when turned upside down, place a small amount of grease at equal spaces on the back of the element and posi tion it in the bellows retainer. The grease should hold the element in position until the seal is in stalled. Assemble the drive grooves of the rotating element into the drive lugs of the bellows retainer.
Lubricate the I.D. of the bellows with water and slide the rotating subassembly onto the rotor shaft until the seal faces contact.
Slide the seal spring over the shaft and bellows re tainer and install the spring centering washer. In stall the seal retaining ring (10). See Figure E-3 for the proper order of seal assembly.
Lower Seal Installation
against the shaft shoulder. Use caution not to nick or damage the O‐ring on the shaft keyway.
Position the seal plate on a clean flat surface with the impeller side up.
Unpack the seal stationary seat and O‐ring. Apply a light coating of oil to the seal plate bore and the O.D. of the stationary seat O‐ring. Keep the sealing face dry.
Position the stationary seat and O‐ring in the seal plate bore with the sealing face up and cover the seal face with a clean tissue. Use your thumbs to press the assembly into the bore. Apply equal pressure on opposite sides until the seat contacts the bore shoulder. Remove the tissue and inspect the seal face to ensure that it is clean and dry. If cleaning is necessary, use clean tissue to wipe
lightly in a circular pattern.
NOTE
If the seal plate was not removed during disassem bly, cover the stationary element with a clean tissue and use your thumbs to press the seal stationary seat and O‐ring into the seal plate as described above. Remove the tissue and inspect the seal face to ensure that it is clean and dry.
Install a new O‐ring (10) on the shoulder of the in termediate (8, Figure E-2).
Carefully position the seal plate and stationary seal components on the rotor shaft. Align the holes in the seal plate for the capscrews (23) with those in the intermediate and slide the seal plate onto the shaft until fully seated against the intermediate. Be careful not to damage the stationary seat already installed in the seal plate. Apply “Neverseeze” or equivalent compound to the threads of the caps crews (23). Secure the seal plate to the intermedi ate by torquing the capscrews to 3.3 ft. lbs. (637 in. lbs. or 0,45 m. kg.).
(Figures E-1 and E-3)
Thoroughly clean the O‐ring surfaces and seal bore of the seal plate (21). 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.
Lubricate the seal sleeve O‐ring (24) with light oil and slide it onto the rotor shaft until it is seated
Unpack the rotating portion of the seal. Be certain the seal face of the rotating element is free of grit or surface damage. Because the rotating element may not stay in the bellows retainer when turned upside down, place a small amount of grease at equal spaces on the back of the element and posi tion it in the bellows retainer. The grease should hold the element in position until the seal is in stalled. Assemble the drive grooves of the rotating element into the drive lugs of the bellows retainer.
PAGE E - 11MAINTENANCE AND REPAIR
Page 36
SF SERIESOM-06460
Lubricate the I.D. of the bellows with water and slide the rotating subassembly over the shaft sleeve (18) until the seal face is just flush with the undercut end of the sleeve.
Slide the assembled shaft sleeve and rotating por tion of the seal and onto the rotor shaft until the pol ished faces contact. Continue to push the sleeve through the seal until it is fully seated against the shaft shoulder.
Install the seal spring over the bellows retainer and install the spring retainer (27). 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 in hole in the rotor shaft for the impeller screw (4).
Install the same thickness of adjusting shims (28) as previously removed. Install the impeller key (16, Figure E-2) in the rotor shaft keyway. Align the keyway of the impeller (2) with the shaft key and push the impeller onto the shaft until seated firmly against the upper impeller shim set.
A clearance of .020 to .040 inch (0,51 to 1,02 mm) between the impeller and the seal plate is recom mended for maximum pump efficiency. Measure this clearance and add or remove impeller adjust ing shims as required.
After the impeller is installed, coat the threads of the impeller screw (4) with `Loctite Threadlocker No. 242' or equivalent compound. Install the impel ler washer (3) and the impeller screw. Wedge a soft metal bar between the vanes of the impeller to pre vent rotation and torque the impeller screw to 27 ft. lbs. (3,7 m. kg.).
Remove the block of wood and turn the impeller to check for free rotation.
Suction Head and Wear Ring Installation
(Figure E-1)
The suction head (9) and wear ring (5) must be installed in the pump casing (1) before installing
the pump casing in order to set the impeller‐to‐ wear ring clearance.
If the wear ring was removed from the suction head, position the replacement wear ring in the suction head bore and use an arbor (or hydraulic) press to press the wear ring into the suction head until fully seated.
Install a new O‐ring (6) on the shoulder of the suc tion head. Position the suction head against the pump casing and use the hardware (7 and 8A) to press the suction head into the pump casing.
Adjust the impeller‐to‐wear ring clearance after installing the pump casing as described below.
Pump Casing Installation
(Figure E-1)
Before installing the pump casing, loosen the jam nuts (20) and unscrew the capscrews (8) from the seal plate until they no longer protrude through the pump casing side of the seal plate.
Install a new O‐ring (15) on the shoulder of the seal plate. Orient the pump casing (1) as shown in Fig ure E-1 and slide it over the seal plate shoulder until fully seated. Apply “Never‐Seez” or equivalent compound to the capscrews (11) and use the hardware (7 and 11) to draw the pump casing over the shoulder of the seal plate until the wear ring just touches the face of the impeller.
Finish the face clearance adjustment as described below.
Impeller Face Clearance Adjustment
(Figure E-1)
A clearance of .006 to .012 inch ( to mm) between the face of the impeller and the wear ring is recom mended for maximum pump efficiency.
Loosen the capscrews (11) securing the pump casing to the motor assembly. Measure the clear ance between the impeller and wear ring. If the clearance is too narrow, turn the screws (8) in an alternating pattern to push the pump casing and suction head away from the impeller until the prop er clearance is achieved. If the clearance is too wide, use the hardware (7 and 11) to draw the
MAINTENANCE AND REPAIRPAGE E - 12
Page 37
OM-06460SF SERIES
pump casing and suction head toward the impeller until the proper clearance is achieved.
When the face clearance is properly set, secure the adjusting screws (8) by tightening the jam nuts (20) against the back of the seal plate.
Final Assembly
If installed in a slide rail application and the pump guide shoe was removed for disassembly, install a new guide shoe seal and secure the seal and guide shoe to the pump casing with the previously re moved hardware.
If installed in a trash application, secure the pump to the trash stand with the previously removed hardware. If the discharge elbow was removed, re place the gasket and secure the discharge elbow to the pump casing with the previously remove hardware and reconnect the discharge piping.
attempting to open or service the pump assembly. Tag electrical circuits to pre vent accidental start‐up.
Carefully inspect any O‐rings before removal and cleaning to determine if a proper seal and com pression existed prior to disassembly. If sealing was faulty or questionable, the cause must be de termined and corrected before reassembly. Re place any parts as required.
Hoisting Bail Removal
(Figure E-1)
The hoisting bail (19) must be removed in order to remove the terminal housing assembly (15). To re move the hoisting bail, disengage the hardware (16 and 17) and separate the bail from the motor housing.
Terminal Housing Assembly Removal
Use a suitable lifting device to reposition the pump in the wet well or sump.
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 a Gorman‐ Rupp authorized Submersible Repair Center.
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
(Figure E-1)
The terminal housing assembly (9) may be re placed without disassembling the motor or pump end components.
With the pump secured in an upright position, re move the hardware (10 and 11) securing the termi nal housing assembly to the motor assembly (6). Carefully pull the terminal housing assembly out of the motor housing until the power and motor cable connections with the stator leads can be ac cessed.
The contacts on the ends of each cable lead are se cured in a plastic housing which mates with a cor responding housing on each of the stator leads. Carefully pull each of the cable lead housings apart from its corresponding stator lead housing and re move the terminal housing assembly from the pump.
Further disassembly of the terminal housing as sembly is not required. Individual parts are not sold separately.
See Terminal Housing Assembly Installation if no further disassembly is required.
PAGE E - 13MAINTENANCE AND REPAIR
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SF SERIESOM-06460
Rotor Shaft and Bearing Removal
(Figure E-2)
See PUMP END DISASSEMBLY, and remove all pump end and seal components.
With the pump end disassembled and the seal cav ity drained of oil, secure the pump in an inverted position. Remove the hardware (11 and 12) secur ing the intermediate (8) to the motor subassembly (1).
Carefully pull the assembled intermediate, rotor shaft (3) and bearings (2 and 5) out of the motor housing until the female terminal (14) can be ac cessed. Pull the female terminal off the male termi nal (15) and remove the intermediate, rotor shaft and bearings from the motor assembly. Remove the O‐ring (6) from the intermediate shoulder.
If the moisture sensor (13) requires replacement, unscrew it from the hole in the intermediate.
precautions printed on solvent contain ers.
Rotate the bearings by hand to check for rough ness or binding. If rotation is rough, replace the bearings.
The bearing tolerances provide a tight press fit onto the shaft and a snug slip fit into the motor housing and intermediate bearing bores. Replace the shaft and rotor (as an assembly), the motor housing or intermediate if the proper bearing fit is not achieved.
If replacement is required, use a bearing puller to remove the upper and lower bearings from the ro tor shaft.
If no further disassembly is required, cover the mo tor housing with a clean, lint free cloth to avoid con tamination by dirt or other foreign material.
Stator Removal
Remove the snap ring (4) from the groove in the in termediate and pull the assembled rotor shaft and bearings out of the intermediate.
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.
Clean the bearings thoroughly in fresh cleaning solvent. Dry the bearings with filtered compressed air and coat with light oil.
(Figure E-2)
Stator replacement requires specialized equipment, experience with electric mo tors, and at least two people to perform the task. Therefore, it is recommended that stator replacement be performed only by the factory or a Gorman‐Rupp Authorized Submersible Repair Center, or that the mo tor housing and stator be replaced as an assembly (refer to the parts list, page E-5 for the appropriate part number).
Do not remove the stator (not shown) unless it is defective (open windings, insulation resistance low, or stator core damaged). If the stator must be removed, position the motor housing upside down on a flat work surface.
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
Position an expandable tool, such as a split disc, approximately 2 inches (51 mm) down inside the stator and expand it tightly and squarely on the I.D. Attach a suitable lifting device to the lifting eye of the tool, and raise the motor housing and stator as sembly approximately 1 inch (25 mm) off the work surface.
MAINTENANCE AND REPAIRPAGE E - 14
Page 39
OM-06460SF SERIES
Using two propane heat torches of the type de signed to melt ice or burn weeds from sidewalks and driveways, apply heat quickly and evenly to the outside of the motor housing; excessive heat is not required. When the stator begins to move, al low the motor housing to drop onto the work sur face, and raise the lifting device to continue to pull the stator out of the motor housing until free.
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.
MOTOR REASSEMBLY
Do not attempt to rewind the stator. Wind ing tolerances and materials are closely controlled by the manufacturer and any deviation can cause damage or operating problems. Replace the stator, or return it to one of The Gorman‐Rupp Authorized Sub mersible Repair Centers or The Gorman‐ Rupp factory, if defective.
NOTE
Reuse of old O‐rings or shaft seal parts will result in premature leakage or reduce pump performance. It is strongly recommended that new O‐rings and shaft seal assemblies be used during reassembly (see the parts list for numbers).
Stator Installation
(Figure E-2)
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 at least two people to promote efficient installation of the stator.
Clean all O‐ring surfaces of the motor housing. In spect the sealing surfaces for burrs, nicks and pits which could cause a poor seal and replace defec tive parts as required.
Thoroughly clean the inside of the motor housing with fresh solvent. The interior must be dry and free of dirt or lint.
Most cleaning solvents are toxic and flammable. Use them only in a well ven tilated area; free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent contain ers.
After the motor housing is thoroughly cleaned, po sition it on a flat surface and secure it in an inverted position. Do not unwrap the stator 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.
The O.D. of the stator must be painted with GE Glyptal insulating paint just prior to being installed in the motor housing. The paint should still be wet when the stator is installed.
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
PAGE E - 15MAINTENANCE AND REPAIR
Page 40
SF SERIESOM-06460
turns. Tape the stator leads 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.
Using two propane heat torches of the type de signed to melt ice or burn weeds from sidewalks and driveways, heat the motor housing 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 windings. Apply heat evenly to the outside of the housing; exces sive heat is not required.
When the motor housing is sufficiently heated, po sition the stator so that the leads are in line with the terminal housing opening. Carefully lower the sta tor into the motor housing until fully seated against the housing shoulder. This should be done quickly to prevent the stator from sticking in the housing before it is fully seated. Be careful not to damage the stator lead insulation during reassembly.
After the stator is fully and squarely seated on the motor housing shoulder, remove the expandable disc tool. Untape the stator leads.
Cover the motor housing with a clean, lint‐free cloth while the rotor is being assembled.
Bearing and Rotor Shaft Installation
bent or damaged, or if the laminations are sepa rated, replace the shaft and rotor (a single assem bly).
To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place. It is strongly recommended that the bearings be replaced any time the shaft and rotor assembly is removed.
The bearings may be heated to ease installation. An induction heater, hot oil bath, electric oven, or hot plate may be used to heat the bearings. Bear 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.
Slide the snap ring (4) over the shaft with the bev eled edge of the snap ring facing the rotor.
Heat the bearings (2 and 5) to a uniform tempera ture no higher than 250_F (120_C). Slide the bear ings onto the shaft, one at a time, until they are fully seated against the shaft shoulders. This should be done quickly, in one continuous motion, to prevent the bearings from cooling and sticking on the shaft.
(Figure E-2)
If the moisture sensor (13) was removed for re placement, screw the new sensor into the hole in the intermediate until fully seated. If removed, install a new male terminal (15) on the sensor and position it so the moisture sensor female terminal (14) can be easily attached.
Inspect the rotor shaft (3) for damaged threads, scoring in the seal area, and a nicked or damaged keyway. If the bearings were removed, inspect the bearing areas for scoring or galling. Remove nicks and burrs with a fine file or emery cloth. Inspect the rotor area for separated laminations. If the shaft is
Use caution when handling hot bear ings to prevent burns.
If heating the bearings is not practical, use a suit ably sized sleeve and an arbor (or hydraulic) press to install the bearings on the shaft.
When installing the bearings onto the shaft, never press or hit against the outer
MAINTENANCE AND REPAIRPAGE E - 16
Page 41
OM-06460SF SERIES
race, balls, or ball cage. Press only on the inner race.
After the bearings have been installed and allowed to cool, check to ensure that they have not moved out of position in shrinking. If movement has oc curred, use a suitably sized sleeve and a press to reposition the bearings. Make certain that they are seated squarely against the shaft shoulders.
Use fresh solvent to clean all O‐ring surfaces of the motor housing and intermediate (8). Inspect the sealing surfaces for burrs, nicks and pits which could cause a poor seal. Repair or replace as re quire.
Most cleaning solvents are toxic and flammable. Use them only in a well ven tilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent contain ers.
Position the intermediate with the impeller end down on some wood blocks tall enough to allow for installation of the rotor shaft through the intermedi ate.
Slide the assembled shaft and bearings into the in termediate until the lower bearing seats squarely in the intermediate bore. Secure the rotor and shaft to the intermediate by installing the snap ring (4) in the groove in the intermediate bore.
Install a new O‐ring (6) on the shoulder of the inter mediate.
With the motor housing and stator positioned up side down, carefully lower the assembled inter mediate, rotor shaft and bearings into the motor housing until the female terminal (14) can be se curely attached to the male terminal (15) on the moisture sensor.
Position the intermediate so the holes for the mounting hardware in the intermediate align with those in the motor housing and press the inter mediate into the motor housing until fully seated. Apply “Never‐Seez” or equivalent compound on the threads of the capscrews (12) and secure the
intermediate to the motor housing with the hard ware (11 and 12). Torque the capscrews to 47 ft. lbs. (6,5 m. kg.).
Terminal Housing Assembly Installation
(Figure E-1)
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 startup. Obtain the ser vices of a qualified electrician to make electrical connections.
Secure the pump in upright position with the hoist ing bail and terminal housing assembly removed. Clean the area round the motor housing opening with fresh cleaning solvent, being carful not to al low any dirt, debris or cleaning solvent to enter the motor housing.
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.
Make sure that the terminal housing O‐ring sup plied with the replacement terminal housing as sembly is securely installed on the shoulder of the terminal housing and that it is clean and undam aged. Check to ensure that the power and control cable ground leads are securely attached to the in side of the terminal housing body.
Make sure the contacts on the ends of the power and control cable leads are firmly installed in their respective housings and position the terminal
PAGE E - 17MAINTENANCE AND REPAIR
Page 42
SF SERIESOM-06460
housing over the opening in the top of the motor housing.
Check to ensure that the contacts on the ends of the motor stator leads are firmly installed in their re spective housings. Check to ensure that any wire connectors installed on the stator leads are tight and secured with heat shrink tubing.
The plastic housings on the ends of the power and control cable leads are color‐coded to match the housings on the leads coming off the stator. Match each cable lead housing with its corresponding stator lead housing and firmly press them together until they lock in place.
When all of the cable lead housings are securely locked into the stator lead housings, slide the ter minal housing assembly down over the studs in the top of the motor housing. Secure the terminal housing to the motor housing by tightening the hardware (10 and 11) in an alternating pattern until the terminal housing is fully seated in the motor housing. Torque the hex nuts (10) to 27 ft. lbs. (3,7 m. kg.).
After installing the motor housing, perform the vac uum check described below to ensure the water‐ tight integrity of the pump.
Reconnect the power and control cable leads to the control box. Check pump rotation as described in OPERATION, Section C, before putting the pump back into service.
Hoisting Bail Installation
(Figure E-1)
If the hoisting bail (19) was removed in order to re move the terminal housing assembly (15) position the bail over the motor housing so the holes for the mounting hardware align. Apply “Never‐Seez” or equivalent compound to the threads of the caps crews (18) and secure the bail to the motor hous ing with the hardware (7 and 18). Torque the caps crews to 64 ft. lbs. (8,8 m. kg.).
VACUUM TESTING
To ensure the water‐tight integrity of the pump, the motor and seal cavities must be vacuum tested any time the seal(s) and/or motor are serviced.
Use a manometer with a range of 30 to 0 to 30 inch es of mercury to perform the test. Do not use a vac uum gauge. Vacuum gauges are not sensitive enough to detect minor leaks.
It is recommended that a vacuum pump be used to draw the vacuum on the cavities. If a vacuum pump is not available, a compressor/venturi system may be used. If the compressor/venturi cannot draw the higher vacuum level shown in Table E-1, draw the motor cavity vacuum down as far as the system will allow, then draw the seal cavity down so the dif ferential between the two cavities is the same as the differential between the vacuum readings shown in the table.
Vacuum Pump
Venturi
Air Compressor
Manometer
S.O. Valve
Tee
Quick Disconnect Fitting
Figure E-4. Vacuum Test System
Seal Cavity Testing
If the water‐tight integrity of the motor was not dis turbed during disassembly, the seal cavity can be tested without testing the motor.
Quick Disconnect Fitting
Full-Closing Ball-Type Shutoff Valve
Drain all of the oil from the seal cavity before per forming the test. Oil within the cavity will be drawn into the system, resulting in damage to the vacuum pump or manometer.
MAINTENANCE AND REPAIRPAGE E - 18
Motor Vacuum Test Plate
Submersible Pump
Seal Cavity Fill/Drain
Page 43
OM-06460SF SERIES
See Figure E-4 and connect the vacuum pump or compressor/venturi system directly to the pump at the hole for the seal cavity drain plug (7, Figure E-2).
Draw the seal cavity vacuum down to not more than 10 In. Hg. and hold for 10 minutes. If no change in vacuum reading is detected, proceed with LUBRICATION.
Do not draw the seal cavity vacuum below 10 In. Hg. Lower vacuum can cause sepa ration of the seal faces and/or unseating of the upper seal stationary seat, resulting in seal leakage.
Make from commercially available steel plate.
.438” (11,1 mm) dia. drill thru. Tap .250‐18 NPT.
Seal and Motor Cavity Testing
Connect the vacuum pump or compressor/venturi system to the pump as shown in Figure E-4.
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 differential between the two cavities is the same as the differ ential between the vacuum readings shown in the table.
To vacuum test the motor cavity, the terminal hous ing assembly must be replaced with a test plate. Make the test plate as shown in Figure E-5 below, install the terminal housing O‐ring under the test plate, then proceed with vacuum testing.
1.5 in.
(38,1 mm)
45_ x 1/8” (3,1 mm) Chamfer
12 mm dia. drill thru (4) holes equally spaced on a 4.72 (120 mm) diameter bolt circle.
Figure E-5. Motor Vacuum Test Plate
Install full‐closing ball‐type shutoff valves with quick‐disconnect fittings in the pipe plug holes in 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.
Table E-1. Vacuum Test Data
5.5 in.
(139,7 mm)
.75 in.
(19,1 mm)
3.749 - 3.750 in
(95,22 - 95,25 mm)
Install terminal housing O‐ring for test.
Figure E-4 shows a simple schematic for setting up either a vacuum pump or a venturi/compressor test system.
Table E-1 shows the vacuum to be drawn on each cavity, and the duration to maintain each vacuum reading. Any change in vacuum reading during the test indicates a leak which must be identified and corrected before putting the pump back into service.
Motor Cavity
Vacuum
(In. Hg.)
Duration
(Minutes)
Seal Cavity
Vacuum
(In. Hg.)
20 3 30 1
Duration
(Minutes)
PAGE E - 19MAINTENANCE AND REPAIR
Page 44
SF SERIESOM-06460
LUBRICATION
Seal Cavity
Check the oil level in the seal cavity before initial startup, after the first two weeks of operation, and every month thereafter.
Check the oil level only when the pump is cool. If the oil level plug is removed when the pump is hot, pressure in the seal cavity can cause hot oil to be ejected as the plug is removed.
To check the seal cavity oil, clean any dirt from around the seal cavity drain plug (7, Figure E-2).
Table E-2. Pump Oil Specifications
Remove the plug, and screw a short 1/4 inch NPT nipple into the hole. Plug the open end of the nipple with your finger. Tip the pump and drain off a small amount of oil into a transparent cup, and stand the pump up again. If the oil level is abnormally low, or the color milky or dark, refer to Draining Oil From Seal Cavity in this section for instructions and troubleshooting tips. If the oil is clear, remove the nipple, top off the seal cavity with oil, and reinstall the level plug.
When lubricating a dry (overhauled) pump, posi tion the pump upright and fill the seal cavity until oil reaches the bottom of the oil drain plug hole with approximately 110 ounces (3,2 liters) of oil.
The grade of lubricant used is critical to the opera tion of this pump. Use premium quality hydraulic oil as specified in Table E-2.
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............................
Acceptable alternate suppliers:
Gulf Oil Company Gulf Harmony 32 AW..............................................
Texas Oil Company Rando HD 32 or HD AZ 32........................................
Sun Oil Company Sunvis 816 or 916.................................................
BP (Also Boron) Energol‐HLP 32.....................................................
Shell Oil Company Tellus 32, Tellus T‐23 or T32.......................................
ARCO Duro 32...................................................................
Exxon (Also Esso) Nuto H 32........................................................
Petro‐Canada Harmony HVI 22......................................................
Motor Bearings
The motor bearings are permanently sealed and no additional lubrication is required.
MAINTENANCE AND REPAIRPAGE E - 20
Page 45
For U.S. and International Warranty Information,
Please Visit www.grpumps.com/warranty
or call:
U.S.: 419-755-1280
International: +1-419-755-1352
For Canadian Warranty Information,
Please Visit www.grcanada.com/warranty
or call:
519-631-2870
THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA
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