GORMAN-RUPP SM Series, SM3C65-X6 Installation, Operation And Maintenance Manual

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Page 1

ACU

OM-06520-02

November 11, 2013

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

SM SERIES PUMPS

THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO

GORMAN‐RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

MODELS

SM3C65-X6

ALL VOLTAGES

www.grpumps.com

e2013 The Gorman‐Rupp Company

Page 2

Gorman‐Rupp pump online at

www.grpumps.com

Valid serial number and e‐mail address required.

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

Please record your pump model and serial number in the spaces provided below. Your Gorman‐Rupp distributor needs this information when you require parts or service.

Pump Model:

Serial Number:

Page 3

TABLE OF CONTENTS

INTRODUCTION PAGE I - 1.................................................

SAFETY - SECTION A PAGE A - 1...........................................

INSTALLATION - SECTION B PAGE B - 1....................................

RETAINING “PERMISSIBILITY” PAGE B - 1..............................................

GORMAN‐RUPP MSHA PUMP INSPECTION FORM PAGE B - 2............................

Pump Model Designation PAGE B - 3...............................................

PREINSTALLATION INSPECTION PAGE B - 3............................................

Lubrication PAGE B - 3............................................................

PUMP INSTALLATION PAGE B - 4......................................................

Pump Specifications PAGE B - 4....................................................

Pump Dimensions PAGE B - 4.....................................................

Lifting PAGE B - 5.................................................................

Positioning the Pump PAGE B - 5...................................................

PIPING PAGE B - 6...................................................................

CONTROL BOX PAGE B - 6...........................................................

Enclosure PAGE B - 6.............................................................

Grounding Methods PAGE B - 10....................................................

Field Wiring Connections (Incoming Power) PAGE B - 11...............................

Pump Power Cable Connections PAGE B - 12.........................................

LIQUID LEVEL CONTROL PAGE B - 13..................................................

OPERATION - SECTION C PAGE C - 1......................................

CONTROL BOX FUNCTION PAGE C - 1.................................................

Component Function PAGE C - 1...................................................

PUMP OPERATION PAGE C - 1........................................................

Liquid Temperature And Overheating PAGE C - 2.....................................

Checking Pump Rotation PAGE C - 2...............................................

STARTING PAGE C - 3................................................................

STOPPING PAGE C - 3................................................................

OPERATIONAL CHECKS PAGE C - 4...................................................

COLD WEATHER PRESERVATION PAGE C - 4...........................................

LUBRICATION PAGE C - 4.............................................................

Draining Oil PAGE C - 4...........................................................

Condition of Oil PAGE C - 4........................................................

Adding Oil PAGE C - 4............................................................

TROUBLESHOOTING - SECTION D PAGE D - 1..............................

ELECTRICAL TESTING PAGE D - 2.....................................................

Test Equipment PAGE D - 3........................................................

Voltage Imbalance PAGE D - 3.....................................................

Motor And Motor Power Cable Continuity PAGE D - 3.................................

Insulation Resistance PAGE D - 4...................................................

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

STANDARD PERFORMANCE CURVE PAGE E - 1........................................

PARTS LISTS

Pump Model PAGE E - 3..........................................................

Submersible Motor Assemblies PAGE E - 5..........................................

PUMP END DISASSEMBLY PAGE E - 6.................................................

Page 4

TABLE OF CONTENTS

(continued)

Strainer and Suction Head Removal PAGE E - 7......................................

Draining Oil From Seal Cavity PAGE E - 7............................................

Positioning Pump For Disassembly PAGE E - 7.......................................

Impeller Removal PAGE E - 7......................................................

Lower Seal Removal PAGE E - 7....................................................

Upper Seal Removal PAGE E - 8...................................................

PUMP END REASSEMBLY PAGE E - 8..................................................

Cleaning And Inspection Of Pump Parts PAGE E - 8..................................

Upper Seal Installation PAGE E - 9..................................................

Seal Plate Installation PAGE E - 10...................................................

Lower Seal Installation PAGE E - 11..................................................

Impeller Installation PAGE E - 12.....................................................

Strainer Installation PAGE E - 12.....................................................

MOTOR DISASSEMBLY PAGE E - 12....................................................

Terminal Housing And Power Cable Removal And Disassembly PAGE E - 13..............

Shaft and Rotor Removal PAGE E - 13...............................................

Stator Removal PAGE E - 14........................................................

MOTOR REASSEMBLY PAGE E - 14.....................................................

Stator Installation PAGE E - 15......................................................

Shaft And Rotor Installation PAGE E - 15.............................................

Terminal Housing And Power Cable Reassembly And Installation PAGE E - 16............

FINAL ASSEMBLY PAGE E - 18.........................................................

LUBRICATION PAGE E - 18.............................................................

Seal Cavity PAGE E - 18............................................................

Pump Oil Specifications PAGE E - 19.................................................

Motor Bearings PAGE E - 19........................................................

Page 5

SM SERIES

OM-06520

INTRODUCTION

Thank You for purchasing a Gorman‐Rupp pump. Read this manual carefully to learn how to safely

install and operate your pump. Failure to do so could result in personal injury or damage to the pump.

This pump is an S Series model. The basic material of construction is CD4MCu stainless steel, with 316 stainless steel rotor shaft, motor housing and hard ware. The pump is designed to handle industrial chemical and low pH resistance materials. The in tegral electric motor must be operated through the control box furnished with the pump as standard equipment. The pump and control comply with MSHA schedule 2G regulations, and have been approved for use in hazardous locations by the Pennsylvania Department of Environmental Re sources (D.O.E.R.).

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.

The following are used to alert maintenance per sonnel to procedures which require special atten tion, 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.

If there are any questions regarding the pump or its application which are not covered in this man ual or in other literature accompanying this unit, please contact your Gorman Rupp distributor, or The Gorman‐Rupp Company:

The Gorman‐Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901-1217

Phone: (419) 755-1011

or:

Gorman‐Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631-2870

Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. These instructions describe the requirements and the possi ble damage which could result from failure to follow the procedure.

NOTE

Instructions to aid in installation, operation, and maintenance or which clarify a procedure.

PAGE I - 1INTRODUCTION

Page 6

SM SERIES

OM-06520

SAFETY - SECTION A

This information applies to SM Series submersible motor driven pumps.

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 open or service the pump:

1. Familiarize yourself with this man ual.

2. Lock out incoming power to the control box to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4. Close the discharge valve (if used).

The pump is designed to be operated through the control box furnished with the pump. The control box provides overload protection and power control. Do not connect the pump motor directly to the incoming power lines.

alified electrician to make all electrical connections. Make certain that the pump and enclosure are properly grounded. Be sure that the incoming power matches the voltage and phase of the pump and control before connect ing the power source. Do not run the pump if the voltage is not within the lim its.

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.

All electrical connections must be in ac cordance with MSHA Schedule 2G. If there is a conflict between the instruc tions provided and MSHA specifica tions, MSHA specifications shall take precedence. All electrical equipment supplied with this pump was in confor mance with MSHA requirements in ef fect on the date of manufacture. Failure to follow applicable specifications, or substitution of electrical parts not supplied or approved by the manufac turer, can result in severe injury or death.

The electrical power used to operate this pump is high enough to cause inju ry or death. Obtain the services of a qu

This pump is not designed to pump vol

PAGE A - 1SAFETY

Page 7

atile, explosive, or flammable materials. Refer to the chart in Installation, Section B for the basic materials of construction for each pump covered in this manual. 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 application data.

Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Do not attempt to lift this pump by the motor or control cables, or the piping. Attach proper lift ing equipment to the lifting bail fitted on the pump. Lift the pump or component only as high as necessary and keep per sonnel away from suspended objects.

SM SERIESOM-06520

After the pump has been installed, make certain that the pump and all piping or hose connections are secure before op eration.

Approach the pump cautiously after it has been running. Although the motor is cooled by the liquid being pumped, nor mal operating temperatures can be high enough to cause burns. The tempera ture will be especially high if operated against a closed discharge valve. Never operate against a closed discharge valve for long periods of time.

Do not open the control box in an explo sive atmosphere. When sealed, the con trol box is explosion proof to prevent the ignition of combustible gases. Opening the box in an explosive atmosphere could result in fire or explosion.

PAGE A - 2 SAFETY

Page 8

INSTALLATION - SECTION B

OM-06520SM SERIES

Review all SAFETY information in Section A.

This section is intended only to summarize recom mended installation practices for the pump and control box. If there are any questions concerning your specific application, contact your Gor man‐Rupp distributor or the Gorman‐Rupp Com pany

All functions performed by the customer on the pump or control must be done in accordance with MSHA schedule 2G regulations to ensure the ex plosion‐proof integrity. No alterations of original design may be made without the consent of the Gorman‐Rupp Company and MSHA.

To retain “Permissibility” of this equipment, the following conditions shall be satisfied:

1. GENERAL SAFETY. FREQUENT INSPECTION

SHALL BE MADE. ALL ELECTRICAL PARTS, INCLUDING THE PORTABLE CABLE AND WIR ING, SHALL BE KEPT IN A SAFE CONDITION. THERE SHALL BE NO OPENINGS INTO THE CASINGS OF THE ELECTRICAL PARTS. A PERMISSIBLE DISTRIBUTION BOX SHALL BE USED FOR CONNECTION TO THE POWER CIRCUIT UNLESS CONNECTION IS MADE IN FRESH INTAKE AIR. THE MACHINE FRAME SHALL BE EFFECTIVELY GROUNDED. THE POWER WIRES SHALL NOT BE USED FOR GROUNDING. THE OPERATING VOLTAGE MUST MATCH THE VOLTAGE RATING OF THE MOTOR(S) 10%.

2. SERVICING. EXPLOSION PROOF ENCLO

SURES SHALL BE RESTORED TO THE STATE OF ORIGINAL SAFETY WITH RESPECT TO ALL FLAME ARRESTING PATHS, LEAD EN TRANCES, ETC., FOLLOWING DISASSEMBLY FOR REPAIR OR REBUILDING, WHETHER BY THE OWNER OR AN INDEPENDENT SHOP.

3. FASTENING. ALL BOLTS, NUTS, SCREWS, AND OTHER MEANS OF FASTENING, AND ALSO THREADED COVERS, SHALL BE IN PLACE, PROPERLY TIGHTENED AND SE CURED.

4. RENEWALS AND REPAIRS. INSPECTIONS, REPAIRS, OR RENEWALS OF ELECTRICAL PARTS SHALL NOT BE MADE UNLESS THE PORTABLE CABLE IS DISCONNECTED FROM THE CIRCUIT FURNISHING POWER, AND THE CABLE SHALL NOT BE CONNECTED AGAIN UNTIL ALL PARTS ARE PROPERLY REASSEM BLED. SPECIAL CARE SHALL BE TAKEN IN MAKING RENEWALS OR REPAIRS. LEAVE NO PARTS OFF. USE REPLACEMENT PARTS EX ACTLY LIKE THOSE FURNISHED BY THE MANUFACTURER. WHEN ANY LEAD EN TRANCE IS DISTURBED, THE ORIGINAL LEADS OR EXACT DUPLICATES THEREOF SHALL BE USED AND STUFFING BOXES SHALL BE REPACKED IN THE APPROVED MANNER.

5. CABLE REQUIREMENTS. A FLAME RESIS TANT PORTABLE CABLE BEARING A MSHA  ASSIGNED IDENTIFICATION NUMBER, ADE QUATELY PROTECTED BY AN AUTOMATIC CIRCUIT INTERRUPTING DEVICE, SHALL BE USED. SPECIAL CARE SHALL BE TAKEN IN HANDLING THE CABLE TO GUARD AGAINST MECHANICAL INJURY AND WEAR. SPLICES IN PORTABLE CABLES SHALL BE MADE IN A WORKMANLIKE MANNER, MECHANICALLY STRONG, AND WELL INSULATED. ONE TEM PORARY SPLICE MAY BE MADE IN ANY TRAIL ING CABLE. SUCH TRAILING CABLE MAY ONLY BE USED FOR THE NEXT 24 HOUR PE RIOD. NO TEMPORARY SPLICE SHALL BE MADE IN A TRAILING CABLE WITHIN 25 FEET OF THE MACHINE, EXCEPT CABLE REEL EQUIPMENT. CONNECTIONS AND WIRING TO THE OUTBY END OF THE CABLE SHALL BE IN ACCORDANCE WITH RECOGNIZED STANDARDS OF SAFETY.

PAGE B - 1INSTALLATION

Page 9

OM-06520 SM SERIES

GORMAN-RUPP MSHA PUMP INSPECTION FORM

INSPECTOR____________________________ DATE____________

MODEL NO.____________________________ SERIAL NO.____________

UNIT ELECTRICAL RATING:

H.P.________, VOLTS________, PUMP AMPS________, HERTZ________

STARTER X/P NO: XP3026-1 (CONTROL WITHOUT FLOAT)

18-XPA040007-0 (CONTROL WITH FLOAT)

MOTOR CABLE:

___No. 12; 7 Conductor; Type SPC; .89 + .03 O.D.; Heavy Jacketed; Royal – MSHA 122; ___No. 8; 9 Conductor; Type SPC; 1.05 + .03 O.D.; Heavy Jacketed; Royal – MSHA 122; ___No. 6; 9 Conductor; Type SPC; 1.25 + .04 O.D.; Heavy Jacketed, Royal – MSHA 122;

Length______________________

ITEM AREA OF INSPECTION ACC. REJ. CORRECTED

1. Are lock washers (or equivalent) provided for all ex plosion proof enclosure fastenings?

2. Are all plane joints securely fastened so that a .005-inch feeler gauge cannot be inserted?

3. Is motor plug secured with lock clip?

4. Are all electrical connections secure?

5. Are all electrical connections insulated where neces sary and per appropriate drawing?

6. Are packing glands properly packed so that 1/8-inch clearance remains between packaging nut and stuffing box?

7. Are packing nut and cable grip secured with lock wire and lead seal?

8. Was pump leak tested?

9. Was pump and control electrically tested?

10. Was pump water tested?

11. Are pump, cable, and control assembled together properly per appropriate drawing?

Comments:

NOTE: Fill out form completely and “rejections” must be corrected and re-inspected. Inspec tor must initial and date when corrective action was taken. 10/9/87

Form CD GL-02128 Rev 6/05 Doc# 152708

PAGE B - 2 INSTALLATION

This form not to be revised without approval of MSHA.

Page 10

OM-06520SM SERIES

Pump Model Designation

Following is a description of the model numbering system for SM Series pumps. These submersible pumps are available in a range of sizes. Refer to the following chart to identify the size for your specific pump model.

Pump Model

Series

3 C 1 460/3- X6

Pump Hydraulics

Discharge Size

Pump Construction

Voltage/Phase

H.P. (If Shown)

Review all SAFETY information in Section A.

PREINSTALLATION INSPECTION

and that the electrical connections are tight and free of corrosion.

f. Compare the amperes, phase, voltage and

hertz indicated on the motor nameplate to the ratings indicated for the control box.

g. Carefully read all tags, decals, and markings

on the pump assembly and the control box, and perform all duties as indicated.

h. Check the pump and motor for any oil leaks.

An oil leak may indicate a cut O ring or other damage.

i. If the pump and control box have been stored

for more than 12 months, some of the compo nents or lubricants may have exceeded their maximum shelf life. These must be inspected or replaced to ensure maximum pump serv ice.

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

The pump and control box were inspected and tested before shipment from the factory. Before in stallation, inspect the pump for damage which may have occurred during 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. Since gaskets tend to shrink after dry ing, check for loose hardware at mating sur faces.

c. The standard pump is furnished with 50 feet

(15,2 m) of power cable. Inspect the cable for cuts or damage.

d. Inspect the control box for cracks, dents, and

other obvious damage.

e. Check that all control box components are se

curely attached to their mounting surfaces,

Lubrication

This pump series utilizes one lubrication cavity, lo cated just behind the seal plate. It is filled with pre mium quality submersible pump oil which lubri cates two shaft seals. The motor operates in air and requires no lubrication.

The lower shaft seal prevents liquid from entering the lubrication cavity, while the upper shaft seal prevents oil leakage into the motor. The upper seal also acts as backup protection in the event of lower seal failure.

The lubrication cavity was fully lubricated when shipped from the factory. Check the oil level before installing the pump (see LUBRICATION in MAIN TENANCE AND REPAIR). An additional quart of oil has been provided with the pump to “top off” the oil cavity. If the oil level is abnormally low, deter mine the cause before putting the pump into serv ice.

PAGE B - 3INSTALLATION

Page 11

OM-06520 SM SERIES

PUMP INSTALLATION

Pump Specifications

See Tables B-1 and B-2 for pump specifications.

Table B-1. Pump Specifications

Voltage/

Model

SM3C 460/3

Pump Model

Phase

575/3

Motor

Horse

power

60 3450 10.8

Table B-2. Additional Specifications

Voltage/

Phase

Pump Speed (RPM)

Approximate Weight

Lbs. (kg) Seal Cavity

Pump 50Ft. Cable

Full

Load

Amperes

8.6

Load

Amperes

4.0

3.2

Oil Capacity

Ounces

(Liters)

Locked

Rotor

Amperes

56 45

Filling Position

Discharge

Size

(NPT)

3 INCH

(H)orizontal

(V)ertical

SM3C 460/3

575/3

Pump Dimensions

105 (47,6) 23 (10,4) 16 (0,47) H

When installing or servicing the pump or controls, follow all requirements for the installation of wiring or electrical equipment as outlined in the National Electric Code. Follow all MSHA safety requirements. Failure to observe these requirements could result in injury or death to personnel.

Do not allow the free end of the power

cable to enter the liquid being pumped. The free end of the cable must be kept dry to prevent liquid from wicking through the cable and into the motor.

NOTE

Refer to the performance curve in Section E, MAIN TENANCE AND REPAIR when determining the

most efficient piping installation.

PAGE B - 4 INSTALLATION

Page 12

Table B-3. MSHA Specifications And Approval Data

OM-06520SM SERIES

Model No.

SM3C65‐X6 460/3 SM3C65‐X6 575/3

Lifting

Pump unit weights can vary depending on the ma terial of construction and length of cable on the unit. Check the shipping tag on the unit packaging for the actual weight, and use lifting equipment with appropriate capacity. Remove all customer‐ installed equipment such as suction and dis charge hoses or piping before attempting to lift ex isting, installed units.

MSHA No Cable P/N Trailing Cable Motor Cable

XP-3185-1 XP-3185-1

47351-011 47351-011

No. 8, 3 Conductor, Type G‐GC, 0.97” $ .03” O.D., Protected By An Instantaneous Trip Circuit Breaker, Set At 200 Amps Max. MSHA Flame Resistance, 600/2000 Volt, 90_C. Max. Length: 500 Ft. ‐ Customer Furnished Note: Instantaneous Trip Amps Set At 200 Amps Max.

Positioning the Pump

G‐R P/N 47351-011. #12 AWG., 7 Conductor Type SPC, 0.89” "

0.03” O.D., Yellow Jack et. 90_C 600/2000 Volt Royal ‐ MSHA Flame Resistant, Max. Cable Length: - Combined Trailing Cable And Pump Motor Cable Not To Exceed 500 Ft.

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.

Refer to Table B-2 for the approximate maximum weight for each pump.

This pump is designed to operate fully or partially submerged. It may also be operated in air for ex tended periods. The rotating parts are oil lubri cated, and the motor is cooled by a constant flow of liquid or air discharged through internal passages.

The pump will operate if positioned on its side, but this is not recommended because the motor torque could cause the pump to roll during opera tion.

The pump should be independently secured and supported by the lifting device fitted on the pump. If the application involves a lot of debris, protect the pump from excessive wear and clogging by sus pending it in a perforated barrel or culvert pipe. If the bottom is heavily sludge covered, rest the pump on support blocks or suspend it from a raft or similar device near the surface of the liquid. See Figure B-1 for typical pump installations.

PAGE B - 5INSTALLATION

Page 13

OM-06520 SM SERIES

BY BAIL IN PERFORATED CULVERT PIPE ON SUPPORTS

Figure B-1. Typical Pump Installations

All liquid entering the pump must pass through a strainer screen. Any spherical solids which pass through the screen will pass through the pump.

PIPING

No suction piping is required in a standard sub merged application.

SM Series pumps are provided with a suction strainer to prevent large solids from clogging the impeller. On high discharge head applications, the strainer can be removed, and the pump suction “staged” to the discharge of another pump, allow ing one pump to feed the other.

To determine the size of the discharge connection, see Table B-1, Pump Specifications. Either hose or rigid pipe may be used. To facilitate mobil ity and maintenance, it is recommended that the discharge line be fitted with a quick disconnect fit ting near the pump. The discharge line must be in dependently supported to avoid strain and vibra tion on the pump.

the use of elbows and fittings which increase fric tion losses through the discharge piping system.

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.

CONTROL BOX

This pump is driven by an integral 60 hertz, 6 HP motor. It is designed to operate through the control box furnished with the pump.

The pump motor is designed to be oper ated through the control box furnished with the pump. The control box provides overload protection and power control. Do not connect the pump motor directly to the incoming power lines.

Enclosure

For maximum pumping capacity, keep the dis charge as short and straight as possible. Minimize

PAGE B - 6 INSTALLATION

The control box is a NEMA type 10, MSHA certified enclosure. The enclosure is not designed to be

Page 14

OM-06520SM SERIES

watertight, and should not be submerged. See

Figure B-2 for enclosure dimensions and callouts.

Secure the control box vertically on a level surface, above flood level. The box should be easily acces sible to the operator, and located close enough to the pump to avoid excessive voltage drop due to cable length (see Pump Power Cable Connec

Table B-4. Control Box Specifications

Model Voltage/ Control Box

Phase

SM3C 460/3 13.0 14.3 17.6 XP-3185-1

SM3C 575/3 10.4 14.3

Part No.

47631-148

47631-149

Mtg. Plate

Part No.

47882-005

47882-006 XP-3185-111.4

tions). After the box is installed, make certain the front cover latches properly.

Failure to mount the control box vertically on a level surface may affect operation of the pump controls.

Relay

Rating

(Amps)

Hold Amps

Trip Amps

MSHA

Cert. No.

PAGE B - 7INSTALLATION

Page 15

OM-06520 SM SERIES

Figure B-2. Control Box Assembly

PARTS LIST - EXTERNAL PARTS

47631-148 (460V) AND 47631-149 (575V) CONTROL BOXES

(See Figure 3 For Internal Control Box Parts)

ITEM

PART NAME PART

NO.

1 HEX HD CAPSCREW 21632-597 ----- 14 2 LOCKWASHER J06 15991 14 3 FLAT WASHER KE06 15991 14 4 PACKING GLAND NUT 31874-017 13045 2

5 LEAD SEAL 21188-002 ----- 2

6 WIRE - 14 INCH 31311-004 17990 2

7 ROPE PACKING 31313-010 22120 1

8 PACKING WASHER 31133-109 13150 4

9 GROUND LUG 27222-004 ----- 2 10 HEX HD CAPSCREW B0402 15991 4 11 LOCKWASHER J04 15991 4 12 ENCLOSURE 38383-001 13045 1 13 FL HD MACH SCREW Y0602 15991 4 14 MOUNTING BRACKET 33657-002 13090 2

15 ENCL COVER ASSY 42114-074 ----- 1

-ENCLOSURE COVER 38383-401 13015 1

-ON/OFF HANDLE 38421-012 13040 1

-HANDLE SETSCREW GA0501 1/2 15990 1

-SHAFT ASSY 41881-276 24150 1

NUMBER

MAT'L CODE

QTY ITEM

NO.

PART NAME PART

NUMBER

-SHAFT BUSHING 31513-031 13155 1

-BUSHING SETSCREW GA#10-01S 15990 1

-WIRING DECAL 2613GM ----- 1

16 MTG PLT ASSY (460V) 47882-005 ----- 1

MTG PLT ASSY (575V) 47882-006 ----- 1 17 MSHA CERT PLATE 2613GL 17020 1 18 DRIVE SCREW BM#04-03 17000 4 19 HEX HD CAPSCREW B0608 15991 4 20 LOCKWASHER J06 15991 4 21 HEX NUT D06 15991 4 22 CABLE CLAMP 38116-603 13040 4 23 RUB BRKT PROTECTOR 33573-001 19990 4 24 CHAIN - 3/16 X 12 41158-009 15991 2 25 HEX HD CAPSCREW B0604 15991 2 26 LOCKWASHER J06 15991 2 27 ASSEMBLY PLATE 2613GG 17020 1 28 DRIVE SCREW BM#04-03 17000 2 29 MSHA APPROVAL PLATE 2613ES 17020 1 30 DRIVE SCREW BM#04-03 17000 2 31 PENN DOER APPL PLATE 2613FL 17020 1 32 DRIVE SCREW BM#04-03 17000 4

MAT'L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

PAGE B - 8 INSTALLATION

Page 16

OM-06520SM SERIES

Figure B-3. Electrical Mounting Plate Assembly

PARTS LIST

47882-005 (460V) AND 47882-006 (575V) MOUNTING PLATE ASSEMBLIES

(See Figure 2 For External Control Box Parts)

ITEM NO.

PART NAME

PART NUMBER

MAT'L CODE

1 SWITCH BRACKET 34512-027 ----- 1 2 CUTLER HAMMER SWITCH 27341-211 ----- 1 3 TERMINAL S1790 ----- 2 4 WIRE 14 GA. X 36.5 IN. LG. 38746-027 ----- 1 5 TERMINAL BLOCK END 27233-021 ----- 1 6 TERMINAL BLOCK NOT REQUIRED ----7 TERMINAL BLOCK 27233-203 ----- 5 8 MOUNTING PLATE 33287-011 ----- 1 9 G E CAPACITOR 27571-332 ----- 1

10 RELAY/SHUNT TRIP (460V) 27541-483 ----- 1

RELAY/SHUNT TRIP (575V) 27541-495 ----- 1 11 CAPACITOR BRACKET 27581-904 ----- 1 12 RD PHILLIP MACH SCREW 21771-551 ----- 2 13 RD PHILLIP MACH SCREW 21771-552 ----- 4 14 RD PHILLIP MACH SCREW 21771-553 ----- 2 15 RD PHILLIP MACH SCREW 21771-542 ----- 1

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

PAGE B - 9INSTALLATION

Page 17

OM-06520 SM SERIES

Figure B-4. Mounting Plate Wiring Schematic

Grounding Methods

Electrically ground the installation before before connecting the field wiring to the control box. Install a grounding terminal to the enclosure and connect it to a properly embedded electrode.

The material used for the electrode must be an ex cellent conductor of electricity, such as copper. If iron or steel is used, it must be galvanized or other

a) PLATE ELECTRODE b) DRIVEN ELECTRODE c) BURIED ELECTRODE

SOIL

1/4 INCH (6,4 MM) STEEL PLATE 2 SQ. FEET (1858,1 SQ. CM) SURFACE AREA (MINIMUM)

SOIL

3/4 INCH (19,1 MM) NOMINAL DIAMETER (MINIMUM)

wise metal plated to resist corrosion. Do not coat the electrode with any material of poor conductiv ity, such as paint or plastic.

The electrode must conform to the recommenda tions of N.E.C. ARTICLE 250. Follow all installation requirements of the N.E.C., and all applicable codes. See Figure B-5 for some suggested grounding methods.

SOIL

ROCK

FEET (2,4 M)

3/4 INCH (19,1 MM) NOMINAL DIAMETER (MINIMUM) 8 FEET (2,4 M) LONG

Figure B-5. Suggested Grounding Methods

a. Plate Electrode: An iron or steel plate, 1/4

inch (6,4 mm) thick, completely impeded in the ground. The plate must present a surface area of at least 2 square feet (1858,1 sq. cm).

PAGE B - 10 INSTALLATION

b. Driven Electrode: A rod or pipe, 3/4 inch

(19,1 mm) in diameter minimum, 8 feet (2,4 m) long, completely driven into the ground.

Page 18

c. Buried electrode: If rock or stone prevents

embedding the full 8 foot (2,4 m) length of the ground rod, bury it horizontally in a trench.

OM-06520SM SERIES

Space the ground rod or plates at least 6 feet (1,8 m) from any other electrode or ground rod, such as those used for signal circuits, ra dio grounds, lightning rods, etc.

The earth surrounding the ground rod or plate must contain enough moisture to make a good electrical connection. In dry or sandy ar eas, pour water around the rod, or consult qualified personnel to devise a method of im proving the connection.

The electrical power used to operate this pump is high enough to cause inju ry or death. Make certain that the control box is properly grounded after installa tion.

Field Wiring Connections (Incoming Power)

The trailing cable from the power source to the control box must be furnished by the customer. The cable must be flame resistant, protected by an instantaneous circuit breaker, and meet the specifications indicated in Table B-2 in this sec tion.

The pump control is designed to regulate a 460 or 575 volt, 3 phase, 60 hertz power supply (see Table 4 for control box specifications). The field wiring must be properly sized to ensure an adequate volt age supply. The voltage available at the motor must be within the range indicated in Table B-5.

To calculate the voltage available at the motor, pro ceed as follows:

a. Measure the incoming voltage across lines 1

& 2, 2 & 3, and 1 & 3 while the pump is oper ating at full capacity. See the wiring dia grams in this section for power supply con nections.

b. Next, subtract the motor cable voltage drop

(see Table 6, Pump Power Cable Specifica tions).

c. Do not continue to operate the pump if this

voltage is not within the recommended limits. Obtain the services of a qualified electrician to determine the correct field wiring size and other details to insure an adequate voltage supply to the pump.

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. 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.

Table B-5. Pump Motor Voltage Limits

Nominal

Voltage Phase

460 3 420 500

575 3 520 630

Use the packing gland nuts to secure and seal the incoming field wiring to the control box. make cer tain all connections are tight and that cable entry points are rainproof. Support the cable weight, if required, to prevent excessive strain on cable clamps and cable.

Minimum

Voltage

Maximum

Voltage

NOTE

After the power cables have been connected to the

PAGE B - 11INSTALLATION

Page 19

OM-06520 SM SERIES

control box, the packing gland nuts must be wired and sealed before operation. See Terminal Hous ing And Power Cable Reassembly in Section E for instructions.

Pump Power Cable Connections

er supply to the control box has been otherwise cut off and locked out, before connecting power or accessory cables.

The standard pump is provided with a 50 foot (15,2 meters) power cable (see table 6 for power cable specifications). If a longer cable is required, an op tional cable assembly must be ordered from the factory. Splicing of the power cable is not recom mended by the Gorman‐Rupp Company due to safety and warranty considerations.

Never attempt to alter the length or re pair any power cable with a splice. The pump motor and cable must be com pletely waterproof. Injury or death may result from alterations.

Table B-6. Pump Power Cable Specifications Model SM3C65

Resistance

(ohms) at

Cable

AWG Pump Model

SM3C 460/3

NOTE: *Amp Rating at 30_C (86_F). Applies only to type SPC cable. Refer to manufacturer's

When necessary to change or connect the pump power cable to the control box, make certain the in coming power is OFF and LOCKED OUT. Make certain the control box is PROPERLY GROUNDED and that the electrical data on the control matches the motor name plate data.

Voltage/

Phase

575/3

specifications for other cable.

**Amp Rating at 40_C (104_F). Applies only to type SPC cable. Refer to manufacturer's

specifications for other cable.

Cable

Size

12 0.89

O.D.

Inches

(mm)

(22,6)

Conductor

Dia.

Inches

(mm)

.10

(2,5)

Amp

Rating

(See Note

below)

30 SPC 1.72 3.72

Connect the pump power cable to the control box as shown Figure B-6. Use conduit or cable clamps to secure the power and accessory cables

to the control box. Make certain that all connec tions are tight and that cable entry points are rainproof.

Cable

Type

25_C

(77_F) per

1000 ft.

(305 m)

Voltage

Drop per

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

2.96

PAGE B - 12 INSTALLATION

Page 20

OM-06520SM SERIES

Figure B-6. Pump Power Cable Connection Diagram (All Models)

PUMP POWER CABLE CONNECTION INSTRUCTIONS

1. Run the pump cable through the packing gland nuts and washers (the concave side of the washer should toward the packing) at the bottom of the control.

2. Connect the white, black, and red power leads to terminals “T1”, “T2”, and “T3”, re spectively.

3. Connect the green ground lead to terminal “GRD”.

4. Connect the yellow ground check lead to ter minal “GC”.

5. Connect the blue control lead to terminal “P1”.

6. Connect the orange control lead to terminal “P2”.

gland nut to the enclosure. Use the hole in the hex nut and the hole at the top left of the enclo sure to prevent loosening of the nut.

LIQUID LEVEL CONTROL

The standard pump is not furnished with a means to automatically regulate liquid level. However, the pump may be controlled to perform dewatering functions by using an optional control box avail able from the factory. The control utilizes a bulb‐type sensing device, where a bulb raises or lowers (floats) with the liquid level, thus activating an enclosed miniature switch.

Refer to Figure B-7 for a typical bulb‐type float in stallation.

7. Install the packing in the gland with the wash ers on each side, and tighten the packing gland nut. With the nuts tight and the packing fully compressed, there must be a minimum space of 1/8 inch between the bottom of the nut and the enclosure.

8. Use the seal wire (P/N 31311-004) and lead seal (P/N 21188-002) to secure the packing

The float must be positioned to allow 10 minutes between starts. If the pump motor cycles more than 6 starts per hour, it will over‐heat, resulting in damage to the mo tor windings or control box components.

PAGE B - 13INSTALLATION

Page 21

OM-06520 SM SERIES

PUMP

CONTROL BOX

TO LEVEL CONTROL CIRCUIT

IN MAIN CONTROL BOX

LIQUID LEVEL

RANGE

OFF

DEWATERING

ON (FILLING)

BULB (FLOAT TYPE)

Figure B-7. Liquid Level Devices

PAGE B - 14 INSTALLATION

Page 22

SM SERIES

OM-06520

OPERATION - SECTION C

Review all SAFETY information in Section A.

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

CONTROL BOX FUNCTION

A control box is provided to facilitate operation of the pump. It contains controls for starting and stop ping the pump, and provides overload protection for the pump motor.

Since operation of the pump motor is de pendent upon the quality and performance of the electrical controls, the pump warran ty is valid only when controls have been specified or provided by the Gor man‐Rupp Company.

permit pump operation. The circuit breakers will open or “trip” automatically in the event of a short circuit overload current, or thermal excess within the pump motor or electrical system. When tripped, move the control handle to OFF and back to ON to reset the circuit breakers.

D The control box contains an integral safety

switch which automatically “trips” the circuit breakers when the cover is removed. Never remove the cover in an explosive atmos phere. Make certain incoming power is OFF and LOCKED OUT.

D The motor is thermally protected by a ther

mostat within the stator. In the event of motor overheating, the thermostat will open and automatically “trip” the control box circuit breakers. The motor will not restart until the circuit breakers are reset.

NOTE

If the circuit breaker trips, do not reset it immedi ately. Wait at least ten minutes before resetting the control handle back to the ON position. If the over load unit continues to trip, operational problems ex ist. See TROUBLESHOOTING .

PUMP OPERATION

Component Function

The control box contains the following hand oper ated switches and controls:

D The control handle operates the control

box circuit breakers. In the OFF position, the control handle opens the circuit breakers to interrupt incoming power through the con trol box and prevent pump operation. In the ON position, it closes the circuit breakers to

OPERATION PAGE C - 1

This pump is designed to handle most non volatile, non flammable liquids encountered in mine dewatering. Do not attempt to pump volatile, explosive, or flammable materials, or any liquids which may damage the pump or endan ger personnel as a result of pump fail ure.

Page 23

OM-06520

SM SERIES

Liquid Temperature And Overheating

The maximum liquid temperature for this pump is 120_F (102.2_C). Do not apply the pump at higher operating temperatures.

If overheating does occur, stop the pump immedi ately and allow it to cool before servicing it. Ap

proach any overheated pump cautiously.

Checking Pump Rotation

Check the direction of pump rotation before opera tion to ensure that the impeller is rotating in the cor rect direction.

Suspend the pump from the lifting device fitted on the pump. Turn the pump on momentarily and note the direction of twist. For correct rotation and op eration, the twist must be in a counterclockwise direction when viewed from the top (see Figure C-1).

Overheated pumps can cause severe burns and injuries. If overheating of the pump occurs:

1. Stop the pump immediately.

2. Ventilate the area.

3. Allow the pump to cool.

4. Check the temperature before servicing.

5. Vent the pump slowly and cau tiously.

6. Refer to instructions in this manual before restarting the pump.

Secure the pump during rotation to pre vent coiling of the power cable.

If the pump twists clockwise on start, interchange any two motor leads at the control box.

The electrical power used to operate this pump is high enough to cause inju ry or death. Make certain that incoming power is off and locked out before inter changing motor leads.

OPERATIONPAGE C - 2

Page 24

SM SERIES

DIRECTION OF

KICKBACK

AT STARTUP

OM-06520

STOPPING

To stop the pump, turn the control handle OFF, thereby opening the circuit breaker.

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.

NOTE

It is recommended that a check valve or throttling valve be installed in the discharge line if there is any possibility of siphoning or back flow when the pump is shut off.

OPERATIONAL CHECKS

Figure C-1. Checking Pump Rotation

STARTING

After the pump and control box have been in stalled, start the pump as follows.

NOTE

Before actual operation, check the direction of im peller rotation to ensure that the pump is properly wired. See Checking Pump Rotation in this sec tion.

Never start the pump more than 6 times per hour. If the pump motor does not cool be tween starts, it will over heat, resulting in damage to the motor windings or control box components.

Move the control handle to the ON position. The pump motor will start running, and pumping should begin. Since the pump is submerged, prim ing is not required.

Check the pump for proper operation when it is first started and periodically thereafter to identify minor problems.

Check the pump for unusual noises or excessive vibration while it is operating. If noise or vibration is excessive, stop the pump and refer to the troubleshooting chart for possible causes.

Check the pump strainer screen for clogging caused by stones, sticks, or other debris. Clean the strainer screen when required. In some cases, stopping the pump momentarily may back flush the strainer screen, purging most of the debris from it. If this fails to clean the screen, remove the pump from the sump and remove the debris manu ally (see PUMP END DISASSEMBLY in Section E).

Never introduce air or steam pressure into the pump casing or piping to remove a blockage. This could result in personal injury or damage to the equipment. If backflushing is absolutely neces sary, liquid pressure must be limited to 50% of the maximum permissible operating pressure shown on the pump performance curve (see MAINTE NANCE AND REPAIR, Section E).

Check the pump for overheating. The pump could overheat if operated against a closed discharge valve, or if subjected to repeated start cycles.

OPERATION PAGE C - 3

Page 25

OM-06520

SM SERIES

COLD WEATHER PRESERVATION

In freezing temperatures, the pump will not freeze as long as it is submerged in liquid. If the pump casing is not submerged, or if the liquid begins to freeze, remove the pump from the sump or wet well and allow it to dry thoroughly. Run the pump for two or three minutes to dry the inner walls.

If the pump freezes, move it into a warm area until completely thawed, or submerge it into the liquid. If the liquid is near freezing, the pump must be sub merged for an extended period of time. Start the pump and check for shaft rotation. if still frozen, al low additional thawing time before attempting to restart.

Do not attempt to thaw the pump by us ing a torch or other source of flame. This could damage gaskets or heat the oil within the pump above the critical point and cause the pump to rupture or ex plode.

LUBRICATION

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.

On a new pump, check the oil level in the seal cav ity before initial startup, after the first two weeks of operation, and every month thereafter.

Before installing or removing the lubrication plug(s), always clean the area around the plug(s) to prevent contamination.

Draining Oil

Refer to the parts list in MAINTENANCE AND RE PAIR, Section E for drain plug location.

Remove the drain plug slowly to release any pres sure. Install a short pipe nipple in the hole. Place a clean container under the plug and using a hoist, tilt the pump at an angle of approximately 60_.

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 (refer to

MAINTENANCE AND REPAIR, Section E).

Adding Oil

Refer to Table B-2 in INSTALLATION for the oil ca pacity and position for filling the seal cavity in the pump.

The grade of lubricant used is critical to the opera tion of this pump. Use premium quality submers ible pump oil as specified in the following table. Oil must be stored in a clean, tightly closed container in a reasonably dry environment.

When lubricating the seal cavity, remove the lubri cation plug as indicated in Draining Oil, and posi tion the pump as indicated in Table B-2 in INSTALLATION. Add premium quality submers ible pump oil (See Table C-1) through this plug hole. If the pump is to be positioned vertically or at an angle, fill the cavity to the bottom of the plug hole. If the pump is to be positioned horizontally, completely fill the cavity.

Install and tighten the lubrication plug.

OPERATIONPAGE C - 4

Page 26

SM SERIES

Table C-1. Pump Oil Specifications

Specifications:

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

Viscosity (SSU @ 104_F [40_C]) 110 to 155.........................................

Viscosity (SSU @ 210

F [100_C]) 40 to 50...........................................

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

Recommended supplier:

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

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

OM-06520

OPERATION PAGE C - 5

Page 27

TROUBLESHOOTING - SECTION D

Review all SAFETY information in Section A.

The following precautions should be taken before attempting to service the pump; otherwise, injury or death could result.

1. Familiarize yourself with this man ual and with all other literature shipped with the pump.

2. Lock out incoming power to the pump or control box to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4. Check the temperature before opening any covers, plates or plugs.

5. Close the discharge valve (if used).

OM-06520SM SERIES

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 troubleshoot, test and/or service the electrical compo nents of this pump.

NOTE

Many of the probable remedies listed below re quire use of electrical test instruments; for specific procedures, see ELECTRICAL TESTING following the chart.

Table B‐1 Troubleshooting Chart

TROUBLE CAUSE REMEDY

PUMP FAILS TO START, CIRCUIT BREAKER NOT TRIPPED

CIRCUIT BREAKER TRIPS

Power source incompatible with control box.

No voltage at line side of cir cuit breaker.

Open circuit in motor wind ings or power cable.

Defective motor power cable.

Low or high voltage, or exces sive voltage drop between pump and control box.

Defective insulation in motor windings.

Impeller jammed due to de bris or insufficient clearance.

Bearing(s) frozen.

Correct power source.

Check power source for blown fuse, open overload unit, broken lead, or loose connec tion.

Check continuity.

Check for and replace defective unit.

Measure voltage at control box. Check that wiring is correct type, size, and length. (See Field Wiring Connections, Operations And Maintenance Manual.

Check insulation resistance; check continuity.

Disassemble pump and check impeller.

Disassemble pump and check bearing(s).

TROUBLESHOOTING PAGE D - 1

Page 28

Table B‐1 Troubleshooting Chart (continued)

TROUBLE CAUSE REMEDY

SM SERIESOM-06520

MOTOR RUNS, BUT PUMP FAILS TO DE LIVER RATED DIS CHARGE

Discharge head too high.

Low or incorrect voltage.

Discharge throttling valve par tially closed; check that valve is installed improperly.

Discharge line clogged or re stricted; hose kinked.

Liquid being pumped too thick.

Strainer screen or impeller clogged.

Insufficient liquid in sump or tank.

Worn impeller vanes; exces sive impeller clearance.

Pump running backwards.

Reduce discharge head, or install staging adaptor and additional pump.

Measure control box voltage, both when pump is running and when shut off.

Open discharge valve fully; check piping in stallation.

Check discharge lines; straighten hose.

Dilute liquid if possible.

Clear clog(s). Stop pump; back flow may flush away debris.

Stop pump until liquid level rises.

Check impeller and clearance. See PUMP END REASSEMBLY.

Check direction of rotation and correct by in terchanging any two motor leads at control box. (See Pump Rotation, Section C).

PUMP RUNS WITH EXCESSIVE NOISE OR VIBRATION

Pumping entrained air.

Damaged or unbalanced im peller.

Discharge piping not properly supported.

Impeller jammed or loose.

Pump cavitation.

Motor shaft or bearings defec tive.

ELECTRICAL TESTING

If you suspect that pump malfunctions are caused by defects in the motor, power cable or control box, perform the following checks to help isolate the de fective part.

Check liquid level in sump; check position of pump and liquid level sensing device(s).

Replace impeller.

Check piping installation.

Check impeller.

Reduce discharge head, or restrict flow on low head applications.

Disassemble pump and check motor and bearings.

Obtain the services of a qualified elec trician to troubleshoot, test and/or ser vice the electrical components of this pump.

TROUBLESHOOTINGPAGE D - 2

Page 29

Be certain to refer to the wiring diagram(s) before reconnecting any electrical compo nents which have been disconnected.

Test Equipment

A volt/amp/ohmmeter and megohmeter of ade quate range and quality will be required to conduct the following electrical tests. The suggested equip ment indicated below is commercially available, or an equivalent substitute may be used.

Equipment Use

Ammeter/ Voltmeter

Ohmmeter To measure resistance

To check AC Voltage and current (amperage)

(ohms) to ground

OM-06520SM SERIES

be the same at each condition, as accurate ly as the meter will read. Nominal amperage values are listed in Table 1, but these apply only when the actual voltage at the site is the nominal voltage listed.

c. If the voltages are balanced with the pump

off, but are unbalanced when the pump is running, a thorough check of the power source, all interconnecting cables, and the pump motor is required to isolate the defect.

Motor And Motor Power Cable Continuity

To check continuity, zero‐balance the ohmmeter set at the RX1 scale, and test as follows:

a Disconnect the motor power cable leads

from the control box and connect the test leads to any two of the three power cable leads (not to the green ground lead or yellow ground check lead). If there is a high resis tance reading on the ohmmeter, there is an open or broken circuit cause a break in the power cable or motor windings, or by a bad connection between the motor and the pow er cable. Switch one test lead to the third power lead, and test again.

Voltage Imbalance

Each phase of the incoming three‐phase power must be balanced with the other two as accurately as a commercial voltmeter will read. If the phases are balanced, check out the motor as described below. If the phases are out of balance, contact your power company and request that they correct the condition.

a. Use a voltmeter, amprobe, or equivalent me

ter to read the voltage across terminals 1 & 2, 2 & 3, and 1 & 3 in the control box. All three measured voltages must be the same, as accurately as the meter will read. If possible, measure the voltage with the pump off, with the pump running but out of the water, and with the pump running in the water at full load. All the measured voltages at each con dition must be the same.

b. Use an amprobe or equivalent meter to

measure the current draw of each phase while the pump is running at full load and at no load. All three amperage readings must

b. If an open or broken circuit is indicated,

check the power cable for obvious damage, and replace as necessary (see MAINTE NANCE AND REPAIR). If there is no appar ent damage to the motor cable, remove the terminal housing (see MAINTENANCE AND REPAIR) and check the continuity of each power cable lead at the terminal posts.

c. If an open circuit still exists after each lead

(terminal) has been tested and tightened, then the entire motor power cable must be replaced. Splicing or other means of repair are not recommended.

d. If no break is found in the power cable,

check the motor leads for continuity. If the test reading indicates an open or broken cir cuit, there is an open circuit in the motor.

NOTE

It is recommended that a pump with a defective mo tor be returned to Gorman‐Rupp, or to one of the Gorman‐Rupp authorized Submersible Repair en ters.

TROUBLESHOOTING PAGE D - 3

Page 30

Insulation Resistance

To check insulation, zero‐balance the ohmmeter set at the RX100K scale, and test as follows:

a. Disconnect the motor power cable leads

from the control box. Connect one test lead to the power cable green ground lead, and touch the other test lead to each of the three power leads in turn.

b. The reading obtained will indicate resis

tance values in both the power cable and the motor windings. If the resistance reading is infinity (1), the insulation is in good condi

SM SERIESOM-06520

tion. If the reading is between infinity (1) and 1 megohm, the insulation is acceptable but should be rechecked periodically. If the reading is less than 1 megohm, the insula tion should be checked more closely; a reading of zero indicates that the power cable or the motor is grounded.

c. To determine whether the power cable or

the motor is grounded, remove the terminal housing (see MAINTENANCE AND RE PAIR), disconnect the motor leads from the motor terminals, and test the power cable leads and motor leads separately.

TROUBLESHOOTINGPAGE D - 4

Page 31

SM SERIES OM-06520

PUMP MAINTENANCE AND REPAIR - SECTION E

MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE.

STANDARD PERFORMANCE FOR PUMP MODEL

SM3C65-X6 (All Voltages)

Based on 70_F (21_C) clear water at sea level. Since pump installations are seldom identical, your performance may be different due to such factors as viscosity, specific gravity, elevation, tempera ture, and impeller trim.

MAINTENANCE & REPAIR PAGE E - 1

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 performance or part numbers.

Page 32

OM-06518 S SERIES

ILLUSTRATION

PARTS PAGE

Figure E-1. Pump Model SM3C65-X6 (All Voltages)

MAINTENANCE & REPAIRPAGE E - 2

Page 33

SM SERIES OM-06520

PARTS LIST

Pump Model SM3C65-X6 (All Voltages)

(From S/N 1546391 Up)

ITEM NO.

1 SUCTION HEAD 38246-031 1718H 1 2 IMPELLER 38618-702 1718H 1 3 SEAL ASSEMBLY 46512-071 --- 1 4 DRIVE SCREW BM#04-03 17090 16 5 CW OF PA APPROVAL PLATE 2613FL 17040 1 6 MSHA APPROVAL PLATE 2613ES 17040 2 7 NAMEPLATE 2613DD 17040 1 8 FLANGE GASKET 38687-045 19370 1

9 DISCHARGE FLANGE 38641-006 17070 1 10 HEX NUT D08 17090 5 11 SUBMERSIBLE MOTOR ASSEMBLY:

12 O‐RING 25154-270 --- 1 13 LOCK WASHER J06 17090 6 14 HEX NUT D06 17090 6 15 HEX NUT 22561-165 --- 1 16 KEY N0302-1/2 17090 1 17 FLAT WASHER KB08 17090 1 18 NYLOCK CAP SCREW BT0806 17090 3 19 STRAINER SCREEN ASSEMBLY 46611-010 24170 1 20 HOISTING BAIL 31926-009 17130 1 21 STUD C0806 17090 1 22 COUPLING NUT 31811-019 17130 1 23 IMP ADJ SHIM SET 2Y 17090 REF 24 SHAFT SLEEVE 13878 17090 1 25 SPRING RETAINER 8793 17090 1

NOT SHOWN:

OPTIONAL:

PART NAME

460V 47111-096 --- 1 575V 47111-097 --- 1

460V CONTROL BOX 47631-148 --- 1 575V CONTROL BOX 47631-149 --- 1

STAGING ADAPTOR KIT 48272-015 --- 1 460V FLOAT CONTROL BOX 47631-171 --- 1 575V FLOAT CONTROL BOX 47631-172 --- 1

PART NUMBER

MAT'L CODE

QTY

INDICATES PARTS RECOMMENDED FOR STOCK

MAINTENANCE & REPAIR PAGE E - 3

Page 34

OM-06518 S SERIES

ILLUSTRATION

Figure E-2. Submersible Motor Assemblies

MAINTENANCE & REPAIRPAGE E - 4

Page 35

SM SERIES OM-06520

PARTS LIST

Submersible Motor Assemblies

ITEM

PART NAME PART

NO.

1 SEAL PLATE: 38272-350 1718H 1 2 FH MACH SCREW Y#10-03 17090 2 3 MECH SEAL 25276-031 --- 1 4 MOTOR BUSHING 31173-017 23010 1

5 BALL BEARING 23425-007 --- 1 6 SNAP RING S1831 --- 1 7 STATOR:

460V 47113-817 --- 1

575V 47113-818 --- 1 8 ROTOR & SHAFT ASSY 47112-811 --- 1 9 BALL BEARING 23257-009 --- 1

10 SPRING WASHER S1554 --- 1 11 STUD C0809 17090 3 12 HEX HEAD CAP SCREW B0511 17090 4 13 LOCK WASHER J05 17090 4

14 SUB PUMP CABLE 47351-011 --- 1 15 HOSE CLAMP 26518-766 --- 1 16 CABLE GRIP ASSY 27111-816 --- 1 17 SET SCREW GA0402 17090 1 18 TERMINAL HOUSING 38381-225 17040 1

19 O‐RING 25154-149 --- 1 20 MACHINE SCREW X#10-01-1/2 14990 2 21 LOCK WASHER AK#10 15991 2

NUMBER

INDICATES PARTS RECOMMENDED FOR STOCK

MAT'L CODE

QTY ITEM

NO.

22 WIRE CONNECTOR S1718 --- 5 23 MOTOR HOUSING 38311-069 17040 1 24 FLAT WASHER KB04 17040 1 25 NYLOCK CAP SCREW BT0403 17040 1 26 LOCK CLIP 33645-008 17040 1 27 PIPE PLUG 38649-022 17090 1 28 ALLEN HD SET SCREW GA0501-1/4 15990 1 29 BEARING SPACER 21161-401 --- 1 30 INTERMEDIATE 38261-024 13040 1

31 O‐RING 25152-258 --- 1 32 PIPE PLUG P04 17090 1

33 O‐RING S2194 --- 1 34 STUD C0611 17090 6 35 ADJUSTING SHIM SET 2X 17090 1 36 RETAINING RING 24124-332 --- 1 37 CERTIFICATION PLATE 2613GX 17040 1 38 DRIVE SCREW BM#04-03 17090 4 39 SET SCREW GA0401 17090 1 40 14” LG SST WIRE 14964-103 --- 1 41 LEAD SEAL 21188-002 --- 1

NOT SHOWN:

PART NAME PART

NUMBER

DOW CORING SILICONE ADHESIVE (10.1 OZ.)

18771-106 --- 1

MAT'L CODE

QTY

MAINTENANCE & REPAIR PAGE E - 5

Page 36

OM-06520SM SERIES

PUMP END DISASSEMBLY

Review all SAFETY information in Section A.

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

All functions performed by the customer on the pump or control must be done in accordance with MSHA, schedule 2G regulations to ensure the ex plosion‐proof integrity. No alterations of original design may be made without the consent of the Gorman‐Rupp Company and MSHA.

Before attempting to service the pump or control, terminate the power supply to the control box. Close the discharge throttling valve, if so equipped.

hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Do not attempt to lift this pump by the motor or control cables, or the piping. Attach proper lift ing equipment to the lifting bail fitted on the pump. Lift the pump or component only as high as necessary and keep per sonnel away from suspended objects.

Use the hoisting bail to remove the pump from the wet well or sump, and move it to a location where the discharge line can be removed. It is not neces sary to disconnect a flexible discharge hose before removing the pump. If rigid discharge piping is used, disconnect the piping before attempting to move the pump.

Select a suitable location, preferably indoors, to perform the degree of maintenance required. If the motor housing is to be opened, the work must be done in a clean, well‐equipped shop. All mainte nance functions must be done by qualified person nel.

Check the chart in TROUBLESHOOTING, Section D of this manual, to determine the nature of the pump problem. If the problem is mechanical in na ture, such as worn pump parts, seal replacement, lubrication, etc., refer to PUMP END DISASSEM BLY for instructions.

If the problem is electrical, complete disassembly may not be required. Refer to Electrical Testing in TROUBLESHOOTING, Section D, and have a qualified electrician check the control box, cable and terminal housing. If the problem is determined to be in the motor, proceed with PUMP END DIS ASSEMBLY, followed by MOTOR DISASSEMBLY. Otherwise, see Terminal Housing And Power Ca

ble Disassembly.

Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that

PAGE E - 6 MAINTENANCE AND REPAIR

Carefully inspect any O‐rings or gaskets before re moval and cleaning to determine if a proper seal and compression existed prior to disassembly. If sealing was faulty or questionable, the cause must be determined and corrected before reassembly. All gaskets and most O‐rings must be replaced if disturbed. Repair gaskets and O‐rings are listed in the Parts List manual.

Page 37

SM SERIESOM-06520

Strainer and Suction Head Removal

(Figure E-1)

To remove the strainer (19), raise the pump slightly, or lay it on its side and disengage the hardware (18).

With the strainer removed, disengage the hard ware (13 and 14). Pry the suction head (1) out of the motor assembly (11). Remove the suction head O‐ring (12).

If the impeller (2) is clogged, the debris can usually be removed without further disassembly.

Draining Oil From Seal Cavity

(Figure E-1)

If any further disassembly is to be performed on the pump, the seal oil cavity must be drained.

and personnel to safely handle the pump until it is secured. If inverting the pump is not practical, lay the pump on its side and secure it to prevent roll ing.

Impeller Removal

(Figure E-1)

Wedge a soft metal rod between the vanes of the impeller (2) and the studs (34, Figure E-2) to pre vent shaft rotation. Remove the impeller nut (15) and washer (17). Remove the metal rod used to prevent shaft rotation.

Install three 10-32 UNC-2B by 2‐inch long cap screws (not supplied) in the holes in the impeller. Use the capscrews and a suitable puller to pull the impeller from the shaft. Use caution when remov ing the impeller; tension on the seal spring will be released. Retain the impeller key (16).

Remove the impeller adjusting shim set (23). For ease of reassembly, tie and tag the shims or mea sure and record their thickness.

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.

With the pump in a vertical position, clean any dirt from around the pipe plug (32, Figure E-2) and re move the plug. Install a short 3/8 inch NPT nipple in the hole. Tip 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 gasket seal.

Positioning Pump For Disassembly

(Figure E-1)

It is recommended that the pump be positioned upside‐down during disassembly. To hold the pump in the inverted position, screw a pipe into the discharge flange (9) and clamp it in a large vise, or remove the discharge flange and secure the flange studs to a bench or work stand. Be careful not to damage the terminal housing (18, Figure E-2) while in this position. Use adequate equipment

Lower Seal Removal

(Figures E-1 and E-3)

Remove the spring retainer (25) and seal spring. Carefully pull the sleeve (25) and rotating portion of the lower seal assembly off the shaft as a unit.

Remove the spring retainer (26), and seal spring. Carefully pull the sleeve (25) and rotating portion of the lower seal assembly off the shaft as a unit.

Lubricate the sleeve adjacent to the seal, and work oil up under the rubber bellows. Slide the rotating portion of the seal off the sleeve.

See Figure 2 and remove the flat head machine screws (2). Slide the seal plate (1) and the station ary portion of the lower seal assembly off the shaft as a unit. Remove the seal plate O‐ring (33).

Position the seal plate on a flat surface with the im peller side down. Carefully press the stationary portion of the seal out of the seal plate from the back side.

The rotating and stationary seal elements are pre cision finished and subject to wear. The complete seal should be replaced with each overhaul to en

MAINTENANCE AND REPAIR PAGE E - 7

Page 38

OM-06520SM SERIES

sure trouble‐free operation. However, if the old seal must be reused, wrap the seal faces individually in clean tissue paper to prevent damage to the seal ing surfaces.

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)

The intermediate (30) and upper seal assembly (3) must be removed as a unit to determine if the upper seal assembly is leaking, and to replace the seal if it is leaking.

Carefully pull straight up on the impeller end of the rotor shaft until the assembled intermediate, seal, bearings (5 and 9), and shaft and rotor assembly (8) are free from the motor housing (23).

Inspect the rotor, stator, and inside of the motor housing for evidence of upper seal leakage. If no leakage is observed, the seal can be reused. How ever, if leakage is apparent, the intermediate and seal assembly must be separated from the rotor and shaft assembly. Cover the motor housing with a clean cloth after inspection to prevent contami nation.

during removal.

Remove the intermediate O‐ring (31).

If no further disassembly is required, proceed to

PUMP END REASSEMBLY.

NOTE

If the motor housing components are to be serv iced, see MOTOR DISASSEMBLY in this section. Do not reassemble the pump end components at this time.

If no further disassembly is required, proceed to

PUMP END REASSEMBLY.

PUMP END REASSEMBLY

NOTE

Reuse of old O‐rings, gaskets, or shaft seal parts will result in premature leakage or reduced pump performance. It is strongly recommended that new gaskets and shaft seal assemblies be used during reassembly (see the parts lists for numbers).

Cleaning and Inspection of Pump Parts

If the seal assembly does not require replacement, proceed to Cleaning And Inspection Of Pump Parts, followed by Upper Seal Installation.

If seal replacement is required, place the interme diate, seal, bearings, and shaft and rotor assembly on a clean, dry work surface, and remove the re taining ring (36) using snap ring pliers. Use caution when removing the retaining ring; tension of the seal spring will be released. Remove the adjusting shims (35). Tie and tag the shims, or measure and record their thickness for ease of reassembly.

Carefully slide the intermediate and seal assembly off the shaft as a unit. Use a hammer and punch (or other suitable tool) to tap the seal assembly out of the intermediate from the back side.

NOTE

The seal assembly will be damaged or destroyed

PAGE E - 8 MAINTENANCE AND REPAIR

NOTE

The upper seal assembly will be damaged or de stroyed if removed from the intermediate. If the seal was not removed from the intermediate, clean and inspect all pump end parts as follows, then reinstall the seal assembly and intermediate as a unit.

Thoroughly clean all reusable parts with a soft cloth soaked in cleaning solvent. Use a clean cloth lightly dampened with solvent to clean the lower end of the motor housing, intermediate, and seal plate. Do not allow the solvent to enter the motor.

Page 39

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.

SM SERIESOM-06520

mediate O‐ring (31) and lightly lubricate it with oil. Check to insure that the wavy washer (10) and mo tor bushing (4) are properly positioned, and slide the rotor and shaft assembly, bearings, intermedi ate and seal assembly into the motor housing until fully seated.

If a new seal is to be installed, do not unwrap it until time of installation. Cleanliness of seal compo nents is critical, especially the seal faces.

Remove all O‐rings and gaskets, and clean the sealing surfaces of dirt or gasket material. Be care ful not to scratch the surfaces.

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

TOR DISASSEMBLY).

Upper Seal Installation

(Figures E-2 and E-3)

If the upper seal assembly was not removed from the intermediate at disassembly, replace the inter

Clean the rotor shaft and seal cavity area of the in termediate (30). Be sure the area is dry and free of lint and dirt. Do not permit cleaning solvent or de bris to fall into the motor cavity.

Install a new O‐ring (31) in the groove in the inter mediate and lightly lubricate it with oil. Carefully slide the intermediate over the shaft until it is fully seated over the lower bearing (5).

Check to insure that the wavy washer (10) and mo tor bushing (4) are properly positioned, and care fully lower the intermediate, bearings, and shaft and rotor assembly into the motor housing. Press the intermediate into the motor housing until fully seated against the motor bushing.

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

MAINTENANCE AND REPAIR PAGE E - 9

Page 40

INTERMEDIATE

BELLOWS

RETAINER

ADJUSTING

SHIMS

RETAINING

RING

STATIONARY

ELEMENT

SEAL PLATE

ROTATING ELEMENT

ROTOR

AND

SHAFT

ASSY

OM-06520SM SERIES

SPRING

STATIONARY

ELEMENT

BELLOWS

ROTATING ELEMENT

STATIONARY

SEAT

STATIONARY

SEAT O‐RINGS

BELLOWS

BELLOWS RETAINER

SHAFT

SLEEVE

IMPELLER

KEY

Figure E‐3. Upper And Lower Seal Assemblies

The seals are not designed for operation at temperatures above 160_F (71_C). Do not use at higher operating temperatures.

If all of the original motor parts are being reused, the same thickness of shims (35) as previously re moved may be installed. However, if new motor parts are being installed that will affect parts “stackup”, or if the thickness of shims removed at disassembly is unknown, it will be necessary to measure the seal bore in the intermediate to deter mine the required shim thickness. This distance is measured from the bottom of the bore in the inter mediate to the motor side of the retaining ring (36). Select the required combination of shims to obtain a seal working height of 0.720 to 0.780.

Lubricate the shaft and the outer edge of the seal assembly with a light coating of oil, and press the seal assembly into the intermediate bore until fully seated. Use a suitably sized sleeve which contacts

SPRING

ADJUSTING

SHIMS

SPRING RETAINER

IMPELLER

only the outer metal edge to press the seal into

place. Exert even pressure around the metal edge to prevent cocking or damage.

Press only on the outer edge of the seal as sembly to prevent damage to the polished surfaces of the rotating and stationary seal faces.

Install the required thickness of shims (35) and se cure with the retaining ring (36).

Seal Plate Installation

(Figure E-2)

Thoroughly clean the seal plate with cleaning sol vent. The seal seat bore must be free of burrs and nicks which could damage the seal seat O‐rings.

Coat the O‐ring (33) with light oil and install it on the seal plate shoulder. Press the seal plate into the

PAGE E - 10 MAINTENANCE AND REPAIR

Page 41

SM SERIESOM-06520

motor housing until fully seated. Be careful not to damage the O‐ring. Secure the seal plate to the in termediate with the flat head machine screws (2).

Lower Seal Installation

(Figures E-1 and E-3)

Thoroughly clean the sealing surfaces and seal bore of the the seal plate (1, Figure E-2). The seal bore must be free of burrs and nicks which could damage the seal.

NOTE

When installing seal components, use hand pres sure only. A push tube cut from a length of plastic pipe will aid in installing seal components.

Do not unwrap the seal until time of installation. Cleanliness of seal components is critical, espe cially the seal faces.

Be sure the bore in the seal plate (where the sta tionary seat fits) and rotor shaft are clean, dry, and free of dirt or lint. Inspect the bore for burrs or nicks that might cut the seal O‐ring or prevent a good seal. Apply a light coating of oil to the shaft and seal plate bore.

The lower seal is not normally reused because wear patterns on the finished faces cannot be re aligned during reassembly. This could result in pre mature failure. If necessary to reuse an old seal in an emergency, carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.

Handle the seal parts with extreme care to prevent damage. Be careful not to contaminate precision 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 concentric pattern to avoid scratching the faces.

faces to ensure that they are free of any foreign matter.

To ease installation of the seal, lubricate the bel lows and O‐rings with water or a very small amount of light lubricating oil, and apply a drop of light lubricating oil on the finished faces. Assemble the seal as shown in Figure E-3.

NOTE

When pressing seal components onto the impeller shaft, use hand pressure only. A push tube cut from a length of plastic pipe will aid in installing seal components. The I.D. of the push tube should be approximately the same size as the I.D. of the seal spring.

Unpack the stationary seal seat and element. Sub assemble the element into the seat, and place a clean tissue over the seal face. Apply a light coat of oil to the seat O‐ring, and use your fingers to press the seat and element into the bore. Apply equal pressure on opposite sides of the seat until the as sembly bottoms against the bore shoulder. Re move the tissue and inspect the seal face to ensure that it is clean and dry. If cleaning is necessary, use a clean tissue to wipe lightly in a concentric pattern.

Position the seat in the bore with the sealing face up and cover it with a clean tissue. Use your thumbs to press the seat into the bore. Apply equal pressure on opposite sides of the seat until it con tacts the bore shoulder. Remove the tissue and check the sealing face to ensure that it is clean and dry. If cleaning is necessary, use clean tissue to wipe lightly in a concentric pattern.

Unpack the rotating portion of the seal. Be certain the sealing face of the rotating element is free of grit or surface damage. Place a small amount of grease at equal spaces on the back of the element, and assemble the drive grooves of the rotating ele ment into the drive lugs of the bellows retainer. The grease should hold the element in position until the seal is installed.

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.

If a replacement seal is being used, remove it from the container and inspect the precision finished

MAINTENANCE AND REPAIR PAGE E - 11

Apply a light coating of oil to the seal seating sur face on the shaft sleeve and I.D. of the bellows. Po sition the rotating seal portion on the sleeve with the seal face toward the chamfered end of the sleeve. Apply firm, steady pressure, with clean hands, on the seal retainer until it slides down the sleeve.

Page 42

OM-06520SM SERIES

Slide the sleeve and rotating portion of the seal over the shaft until the sleeve seats squarely against the shaft shoulder. Continue to press on the seal retainer until the seal slides over the shaft and the seal faces contact.

Slide the seal spring over the shaft and bellows re tainer and install the spring retainer (25).

After the impeller is installed, lubricate the seal cav ity as described in Lubrication at the end of this section.

Impeller Installation

(Figure E-1)

Inspect the impeller (2) for cracks, broken vanes, or wear from erosion, and replace it if damaged.

Install the same thickness of impeller adjusting shims (23) as previously removed onto the rotor shaft. Install the impeller key (16) in the rotor shaft keyway, align the impeller keyway and press the impeller onto the shaft until it seats firmly against the adjusting shims.

For maximum pump efficiency, there should be a clearance of .008 to .015 inch (.20 to .38 mm) be tween the impeller and the suction head (1). Install the suction head with a new O‐ring (12). Apply `Never‐Seez' or equivalent compound to the suc tion head studs and secure the suction head by torquing the hardware (13 and 14) in an alternating pattern to 20 ft. lbs. (240 in. lbs. or 2.8 m. kg.). Use a feeler gauge to measure the clearance, then add or remove impeller adjusting shims as required.

NOTE

The impeller and suction head must be fully seated to obtain an accurate face clearance measurement.

Strainer Installation

(Figure E-1)

Inspect the strainer screen for cracks or broken welds. Straighten or reweld as required. Inspect the studs in the motor housing for stripped threads and other damage. Replace and retighten before reassembly.

Install the strainer screen (19) and secure it with the capscrews (18). Tighten the capscrews just enough to draw the strainer screen down tightly, but not tight enough to distort it.

See LUBRICATION and FINAL ASSEMBLY be fore putting the pump back into service.

MOTOR DISASSEMBLY

Disassembly of the motor is rarely required except to replace the motor rotor, stator, bearings, or inter mediate. Do not disassemble the motor unless it is necessary and a clean, well‐equipped shop is available.

NOTE

It is recommended that a pump with a defective mo tor be returned to Gorman‐Rupp, or to one of the Gorman‐Rupp authorized Submersible Repair Centers

Motor repairs must be performed in accor dance with MSHA specifications regarding the permissibility of this equipment. Refer to Installation, Page B-1.

After the impeller clearance has been set, coat the threads of the rotor shaft with `Loctite Threadlocker No. 242' or equivalent compound. Install the impel ler flat washer (17) and nut (25). Immobilize the im peller as described in Impeller Removal and torque the impeller nut to 60 ft. lbs. (720 in. lbs. or 8,3 m. kg.).

PAGE E - 12 MAINTENANCE AND REPAIR

Page 43

SM SERIESOM-06520

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

Do not remove the control box cover in an explosive atmosphere. When sealed, the control box is explosion proof to pre vent the ignition of combustible gases. Opening the box in an explosive atmo sphere could cause fire or explosion.

Terminal Housing And Power Cable Removal And Disassembly

(Figure E-2)

Total disassembly of the terminal housing and power cable is not always required. Disassemble and replace only the parts proven defective by in spection or testing. See Electrical Testing in TROUBLESHOOTING.

The terminal housing and power cable may be serviced without disassembling the motor housing or pump end.

connectors (22) are accessible. Cut or unwrap the tape from around the connectors, then remove the connectors to disconnect the pump power cable leads from the motor leads.

Remove the O‐ring (19) from the terminal housing. No further disassembly is required to test the stator or power cable.

To remove the power cable (14) and grip (16), dis engage the hardware (20 and 21) and disconnect the green ground lead and the yellow ground check lead from the terminal housing. Cut the ad hesive from around the power cable leads in the bottom of the grip body. Remove the setscrew (17) which locks the cable grip body in place in the ter minal housing. Cut and remove the seal wire (40) which retains the cable grip to the terminal hous ing. Unscrew the cable and grip as an assembly from the terminal housing.

To remove the cable grip assembly from the power cable, remove the hose clamp (15) and unscrew the grip nut from the cable grip body. Pull the cable, cable grip mesh, and rubber grommet from the grip body.

Apply oil to the cable O.D. and work it up under the grommet. Slide the grommet off the cable. Com press the wire mesh of the cable grip and slide the mesh and grip nut off the cable.

Shaft And Rotor Removal

(Figure E-2)

See PUMP END DISASSEMBLY, and remove all pump end and seal components (including the in termediate, rotor and shaft assembly).

Do not remove the terminal housing in an explosive atmosphere. The terminal housing and its O‐Ring must remain in tact to retain the permissibility of this equipment. Removing the housing in an explosive atmosphere could cause fire or explosion.

To remove the terminal housing, disengage the hardware (12 and 13) securing the terminal hous ing (18) to the motor housing (23). Carefully pull the terminal housing from the motor housing until the

MAINTENANCE AND REPAIR PAGE E - 13

With the pump end disassembled and the terminal housing removed, secure the pump in an inverted position. To facilitate disassembly, disengage the hardware (10 and 22 Figure E-1) and remove the hoist bail (20) from the motor housing.

After removing the shaft and bearings, clean and inspect the bearings in place as follows.

To prevent damage during removal from

Page 44

OM-06520SM SERIES

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.

Clean the bearings thoroughly in fresh cleaning solvent. Dry the bearings with filtered compressed air and coat with light oil.

Most cleaning solvents are toxic and flammable. Use them only in a well‐vent ilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent contain ers.

Rotate the bearings by hand to check for rough ness or binding. If rotation is rough, replace the bearings.

Stator Removal

(Figure E-2)

Do not remove the stator (7) unless it is defective (open windings, insulation resistance low, or stator core damaged). If the stator must be removed, re move the terminal housing as indicated in Termi

nal Housing And Power Cable Removal and Disassembly. Disengage the hardware (24 and

25) and remove the lock clip (26). Remove the pipe plug (27) and setscrew (28).

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 lifting device to the lifting eye of the tool, and raise the assembly approximately one inch off the work surface. Take care not to damage the sta tor end turns. Use a soft‐faced mallet to rap alter nate edges of the motor housing and “walk” the stator out. Continue this process until the stator clears the motor housing.

NOTE

It may be necessary to heat the motor housing to permit stator removal.

These bearings are permanently sealed and require no additional lubrication ex cept a coating of light oil on external sur faces to ease reassembly. External sur faces must be kept free of all dirt and for eign material. Failure to do so could dam age the bearings or their mating surfaces.

The bearing tolerances provide a tight press fit

onto the shaft and a snug slip fit into the motor

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

If the bearings require replacement, use a suitable puller to remove them from the shaft. Remove the snap ring (6).

Remove the wavy spring washer (10) and motor bushing (4).

After the stator has been removed, wrap it in clean, dry rags or other suitable material. The stator must be kept clean and dry. When handling the stator, do not set it on the end windings; lay it on its side.

Do not attempt to rewind the stator. Wind ing tolerances and materials are closely controlled by the manufacturer, and any deviation can cause damage or operating problems. Replace the stator, or return it to one of the Gorman‐Rupp authorized sub mersible repair centers or the Gor man‐Rupp factory, if defective.

MOTOR REASSEMBLY

NOTE

Reuse of old O‐rings, gaskets, shaft seal parts may result in premature leakage or reduce pump per formance. It is strongly recommended that new

PAGE E - 14 MAINTENANCE AND REPAIR

Page 45

SM SERIESOM-06520

gaskets and shaft seal assemblies be used during reassembly (see the parts lists for numbers).

Stator Installation

(Figure E-2)

Clean all gasket and O‐ring surfaces, completely removing any old gasket and cement material. 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 (23) with fresh solvent. The interior must be dry and free of dirt or lint.

Do not unpack the stator until the motor housing has been prepared for stator installation. The sta tor must be kept clean and dry. When handling 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.

“cocks” in the motor housing, remove it and try again. If necessary, heat the motor housing with a torch to expand it enough for the stator to be in stalled; when heating the motor housing, make certain that the stator is clear to avoid damage to the windings. Apply heat evenly to the inside of the motor housing; excessive heat is not required. 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 and untape or remove the protective sleeve from the stator leads. Install and tighten the setscrew (28) securing the stator in place. Torque the setscrew to 7.5 ft. lbs. (90 in. lbs. or 1 m. kg.). Apply `Loctite Pipe Sealant With Teflon No. 592' on the threads of the pipe plug (27) and install it over the setscrew. Secure the pipe plug with the lock clip (26) and hardware (24 and 25).

Cover the motor housing with a clean, lint‐free cloth while the rotor is being assembled.

Shaft And Rotor Installation

(Figure E-2)

Inspect the rotor shaft for damaged threads, scor ing in the seal area, and a nicked or damaged keyway. If the bearings were removed, inspect the bearing areas for scoring or galling. Remove nicks and burrs with a fine file or emery cloth. Inspect the rotor area for separated laminations. If the shaft is bent or damaged, or if the laminations are sepa rated, replace the shaft and rotor (a single assem bly).

Install the snap ring (6) in the groove on the shaft.

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 lifting device to the lifting eye of the tool, and carefully lift the assembly. Take care not to damage the stator end turns. Slip a sleeve over the stator leads, or tape them together to protect them during installation.

With the motor housing in an inverted position, po sition the stator so that the leads are in line with the terminal opening, and carefully lower the stator into the motor housing until it bottoms. If the stator

MAINTENANCE AND REPAIR PAGE E - 15

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

Page 46

OM-06520SM SERIES

ings should never be heated with a direct flame or directly on a hot plate.

NOTE

If a hot oil bath is used to heat the bearings, both the oil and the container must be absolutely clean. If the oil has been previously used, it must be thor oughly filtered.

Heat the bearings to a uniform temperature no higher than 250_F (120_C) and slide the bearings

onto the shaft, one at a time, until they are fully seated. This should be done quickly, in one con tinuous motion, to prevent the bearings from cool ing and sticking on the shaft.

Use caution when handling hot bear ings to prevent burns.

After the bearings have been installed and allowed to cool, check to ensure that they have not moved away from the shaft shoulders in shrinking. If movement has occurred, use a suitable sized sleeve and a press to reposition the bearings against the shaft shoulders.

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

Terminal Housing And Power Cable Reassembly And Installation

(Figure E-2)

Clean the exterior of the power cable with warm water and mild detergent, and check for obvious physical damage. Check the cable for continuity and insulation resistance (see Electrical Testing in TROUBLESHOOTING). Do not attempt repairs except to cut off either end of the cable; splicing is not recommended. Reinstall any wire tags or ter minals which may have been removed.

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

Install the wavy spring washer (10) in the bottom of the motor housing bearing bore. Carefully lower the rotor and shaft and assembled bearings into the motor housing until the upper bearing (9) seats squarely against the wavy washer.

Refer to Upper Seal Installation in PUMP END REASSEMBLY for installation of the intermediate and upper seal assembly.

PAGE E - 16 MAINTENANCE AND REPAIR

Never attempt to alter the length or re pair any power cable with a splice. The pump motor and cable must be com pletely waterproof. Injury or death may result from alterations.

Use oil to lightly lubricate the outside of the pump power cable (14) and the I.D. of the rubber cable grip bushing for ease of assembly. Slide the cable grip nut onto the cable. Compress the wire mesh on the cable grip, and slide it onto the cable, allow ing approximately 1 ft. of cable to extend beyond the mesh. Slide the rubber cable grip bushing and cable grip body onto the cable. Apply `Loctite Pipe Sealant With Teflon No. 592' or equivalent com

Page 47

SM SERIESOM-06520

pound on the tapered pipe threads of the cable grip body.

Feed the pump power cable leads into the terminal housing (18) and screw the cable grip body into the threaded housing bore until tight. Slide the ca ble grip bushing down the power cable into the ta pered top of the grip body. Be sure there is suffi cient cable lead length to permit wire connection, and that the trimmed end of the outer cable insula tion is recessed approximately 1/8 inch (3.2 mm) in the bottom of the grip body. This creates a reservoir in the bottom of the cable grip into which the power cable sealant can be applied.

Compress the wire mesh of the cable grip as sembly and slide it down the cable until it seats on top of the rubber bushing. Tighten the cable grip nut on the cable body.

Connect the green ground lead and the yellow ground check lead to the terminal housing and se cure them with the hardware (20 and 21). These two wires must be connected to separate points in the terminal housing. Make sure each terminal makes good contact with the housing.

material a minimum of 1 hour to dry (or until a skin forms on the adhesive). This must be done before testing or final assembly.

Install a new O‐ring (19) on the terminal housing. Refer to the wiring diagram in INSTALLATION, Section B, then connect the correct power cable leads to the stator leads with the connectors (22). Be sure the orange and blue cable leads are con nected to the red coded (thermal overload) stator leads. After installing the connectors, wrap each connection with underwater tape (G‐R part num ber 18666-068) to seal it and prevent the connec tor from working loose. Start the tape between the connectors and double back, then stretch the tape and wrap it around all of the leads and connectors.

Install the terminal housing in the motor housing and secure with the hardware (12 and 13). Be care ful not to cut or damage the O‐ring (19). Tighten the capscrews evenly and alternately around the ter minal housing, and torque them to 11 ft. lbs. (132 in. lbs. or 1.5 m. kg.).

The cable leads must be sealed in the cable grip body to prevent moisture from entering the motor. When shipped from the factory, the power cable leads were sealed in the cable grip body and termi nal housing with adhesive. If a replacement cable is being installed, the power cable must be resealed in the terminal housing.

Do not attempt to operate this pump un less the power cable leads are properly sealed in the terminal housing. Mois ture entering the terminal housing could cause a short circuit, resulting in pump damage and possible serious in jury or death to personnel.

To seal the power cable leads, secure the terminal housing upside‐down, and use `Dow Corning Silic on Adhesive No. 737' to seal around all leads where they enter the terminal housing. Do not al low any air pockets, voids or gaps. Do not apply more than a 1/4“ (6,3 mm) thick layer and allow the

The cable grip must be retained to the terminal housing as follows to retain permissibility for this equipment. Fail ure to seal the parts as specified may re sult in explosion.

Make sure the cable grip body is tight in the termi

nal housing and secure it to the terminal housing as follows (see Figure E-4).

a. There are two tapped holes in the terminal

housing located 90_ apart. One hole will be used for installing the long locking setscrew (17); the other will be plugged with the short setscrew (39). Apply `Loctite Pipe Sealant With Teflon No. 592' to both setscrews before installation.

Make sure the cable grip body is tight in the terminal housing. Note the location of the tapped hole which is blocked by the hex body. Unscrew the hex body until the hole is clear, and install the small setscrew (39).

Retighten the cable grip body, and install the longer setscrew (17) which locks the body in place.

MAINTENANCE AND REPAIR PAGE E - 17

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OM-06520SM SERIES

b. Drill a 1/16 inch (1,6 mm) diameter hole (B) in

the cable grip body approximately 45_ coun terclockwise from hole A in the terminal hous ing. If the old cable grip is being reused, the existing hole may be reused if it is in the cor rect location.

KNURLED AND RIBBED TYPE CABLE GRIP INSTALLATION HEX TYPE

NUT

LOCKING

SETSCREW

45_

RIBBED NUT

HEX

BODY

1 ”

DIA .

FOR

TYP.

c. Insert the seal wire (40) through hole B and

equalize the wire length. Twist the wire ends approximately 10 turns and insert one end of the wire through hole A. Draw tight and twist the wire ends approximately 10 turns.

CABLE GRIP INSTALLATION

FOR

KNURLED NUT

Figure E-4. Safety Seal Installation

d. Make sure the cable grip nut is tight. Drill a

1/16 inch (1,6 mm) diameter hole (C) through the flange on the cable grip adjacent to hole B in the hex body.

e. Insert one end of the twisted wire through hole

C and draw tight. Twist the ends two turns and push them through the lead seal (41).

f. Wrap the ends of the wires once around the.

twisted length from A to C from opposite di rections, and push the wire ends through the lead seal again. Clamp the seal to secure the wire ends.

FINAL ASSEMBLY

(Figure E-1)

If the hoist bail (20) was removed, secure it to the motor housing with the hardware (10 and 22).

If the discharge flange (9) was removed from the motor housing, replace the discharge flange gas ket (8). Apply `Never‐Seez' or equivalent com

pound on the flange studs, and torque the nuts (10) to 11 ft. lbs. (132 in. lbs. or 1.5 m. kg.).

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

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, lay the pump on its side with the level plug up. Remove the plug, and screw

PAGE E - 18 MAINTENANCE AND REPAIR

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SM SERIESOM-06520

a short 1/4 inch NPT nipple into the hole. Plug the

the level plug. open end of the nipple with your finger. Tip the pump upright, drain off a small amount of oil into a transparent cup, and lay the pump on its side again. If the oil level is abnormally low, or the color

When lubricating a dry (overhauled) pump, add

approximately 1 US pint (0,47 liter) of lubricant (see

Table 1 for lubricant specifications). 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 grade of lubricant used is critical to the opera

tion of this pump. Use uninhibited transformer oil

as specified in the following table.

Table E-1. Pump Oil Specifications

Specifications:

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

Viscosity (SSU @ 104_F [40_C]) 110 to 155.........................................

Viscosity (SSU @ 210_F [100_C]) 40 to 50...........................................