GORMAN-RUPP PUMPS S Series Maintenance And Repair Instructions
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GORMAN-RUPP PUMPS S Series Maintenance And Repair Instructions

Manual part 3 of 3 maintenance and repair instructions with troubleshooting
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PUBLICATION NUMBER MR-04314
July 27, 1995
Rev. A 05‐15‐12
S SERIES PUMPS
S4G and S4J
All Materials And Voltages
THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO
www.grpumps.com
D
GORMAN‐RUPP OF CANADA LIMITED
ST. THOMAS, ONTARIO, CANADA
Printed in U.S.A.
e
1995 The Gorman‐Rupp Company

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  • Page 1 PUBLICATION NUMBER MR-04314 July 27, 1995 Rev. A 05‐15‐12 S SERIES PUMPS S4G and S4J All Materials And Voltages THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO www.grpumps.com GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A. 1995 The Gorman‐Rupp Company...
  • Page 2 Register your new Gorman‐Rupp pump online at www.grpumps.com Valid serial number and e‐mail address required. RECORD YOUR PUMP MODEL AND SERIAL NUMBER Please record your pump model and serial number in the spaces provided below. Your Gorman‐Rupp distributor needs this information when you require parts or service. Pump Model: Serial Number:...

  • Page 3: Table Of Contents

    MR-04314 S SERIES PUMPS INTRODUCTION Thank You for purchasing a Gorman‐Rupp S quire special attention, to those which could dam­ Series Pump. Read this manual carefully to learn age equipment, and to those which could be dan­ how to safely maintain and service your pump. Fail­...
  • Page 4 S SERIES PUMPS MR-04314 RECORDING MODEL AND who operate and maintain their equipment as de­ scribed in this and the other accompanying litera­ SERIAL NUMBERS ture. The integral electric motor must be operated Please record the pump model, serial number, volt­...

  • Page 5: Safety - Section A

    4. Close the discharge valve (if throughout this manual to Gorman‐ used). Rupp S Series submersible motor driv­ en pumps. This manual will alert personnel to This pump is not designed to pump vol­ known procedures which require spe­...
  • Page 6 S SERIES PUMPS MR-04314 phase of the pump and control before tion of electrical parts not supplied or connecting the power source. Do not approved by the manufacturer, can re­ run the pump if the voltage is not within sult in severe injury or death and void the limits.

  • Page 7: Troubleshooting - Section B

    MR-04314 S SERIES PUMPS TROUBLESHOOTING - SECTION B Review all SAFETY information in Section A. 5. Close the discharge valve (if used). The following precautions should be The electrical power used to operate taken before attempting to service the this pump is high enough to cause inju­...
  • Page 8 S SERIES PUMPS MR-04314 Table 1. Trouble Shooting Chart (cont.) TROUBLE POSSIBLE CAUSE PROBABLE REMEDY (AUTOMATIC MODE) Float type sensing device(s) tangled Check installation for free move­ or obstructed. ment of float. (CONT'D.) Defective liquid level sensing de­ Repair or replace defective unit(s).

  • Page 9: Electrical Testing

    MR-04314 S SERIES PUMPS Table 1. Trouble Shooting Chart (cont.) TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP RUNS WITH Pumping entrained air. Check liquid level in sump; check position of pump and liquid level EXCESSIVE NOISE OR VIBRATION sensing device(s). Damaged or unbalanced impeller.

  • Page 10: Motor And Power Cable Continuity

    S SERIES PUMPS MR-04314 be the same at each condition, as accurate­ place the tubing or potting and allow adequate dry­ ly as the meter will read. Nominal amperage ing time before putting the pump back into service. values are listed in Table 1, but these apply (See Power Cable Reassembly, Section E).

  • Page 11: Pump Maintenance And Repair - Section C

    MR-04314 S SERIES PUMPS PUMP MAINTENANCE AND REPAIR - SECTION C GENERAL INFORMATION formed by a Gorman‐Rupp authorized Submersible repair facility or the factory. Review all SAFETY information in Section A. Any repairs to the motor assembly per­ formed by the customer or an unautho­...
  • Page 12 S SERIES PUMPS MR-04314 SECTION DRAWING Figure C-1. Typical S4G And S4J Series Pump Assembly PAGE C - 2 MAINTENANCE AND REPAIR...

  • Page 13: Terminal Housing And Cable Assembly

    MR-04314 S SERIES PUMPS Typical S4G And S4J Series Pump Assembly Parts Identification List Refer to the separate Parts List Manual for serviceable parts, part numbers and quantities. ITEM ITEM PART NAME PART NAME DIFFUSER HEX NUT IMPELLER NAME PLATE...
  • Page 14 S SERIES PUMPS MR-04314 SECTION DRAWING Figure C-2. Terminal Housing And Cable Assembly PAGE C - 4 MAINTENANCE AND REPAIR...

  • Page 15: Terminal Housing And Cable Assembly Parts Identification List

    MR-04314 S SERIES PUMPS Terminal Housing And Cable Assembly Parts Identification List Refer to the separate Parts List Manual for serviceable parts, part numbers and quantities. ITEM PART NAME TERMINAL GLAND CABLE - 50 FT CABLE GRIP STUD HEX NUT...

  • Page 16: Pump End Disassembly

    S SERIES PUMPS MR-04314 PUMP END DISASSEMBLY lift it, make certain that they are posi­ tioned so as not to damage the pump, and so that the load will be balanced. References are to Figure C-1 and Figure C-2. Select a suitable location, preferably indoors, to Review all SAFETY information in Section A.
  • Page 17 MR-04314 S SERIES PUMPS (45). Remove the piece of wood from between the vanes of the impeller and remove the capscrews. Install the impeller puller (supplied with the pump) Let the pump cool before removing the and pull the impeller from the rotor shaft. Use cau­...

  • Page 18: Pump End Reassembly

    S SERIES PUMPS MR-04314 Carefully inspect any O‐rings or gaskets before re­ Disassembly in this section. Do not at­ moval and cleaning to determine if a proper seal tempt to loosen the hardware (40 and 41) and compression existed prior to disassembly. If securing the bearing cap (8) before refer­...
  • Page 19 MR-04314 S SERIES PUMPS Install the shaft seals as illustrated in Figure C-3. ROTOR STATIONARY SHAFT CUP SEAT STATIONARY LOWER MOTOR ELEMENT HOUSING BELLOWS AND ROTATING RETAINING ASSY ELEMENT SPRING SPRING SEAL RETAINER RETAINING RING STATIONARY STATIONARY SEAL SEAT ELEMENT...
  • Page 20 S SERIES PUMPS MR-04314 Unpack the rotating portion of the seal. Be certain the bore. Remove the tissue and inspect the seal the seal face of the rotating element is free of grit or face to ensure that it is clean and dry. If cleaning is surface damage.

  • Page 21: Motor Disassembly

    MR-04314 S SERIES PUMPS Install the same thickness of impeller adjusting Strainer Installation shims (17) as previously removed. Install the im­ (Figure C-1) peller key (52). Align the keyway of the impeller (2) and push the impeller onto the shaft until seated Inspect the strainer assembly (47) for cracks, dis­...
  • Page 22 S SERIES PUMPS MR-04314 Terminal Housing And Power Cable to cut the bushing into small pieces or cut the cable. Removal And Disassembly (Figure C-1) Push approximately 6 inches (152 mm) of the pow­ er cable into the terminal housing so that the termi­...
  • Page 23 MR-04314 S SERIES PUMPS Shaft And Rotor Disassembly avoid contamination of the stator by dirt or other foreign materials. (Figure C-1) Bearing Removal See PUMP END DISASSEMBLY, and remove all (Figure C-1) pump end and seal components. With the pump end disassembled, secure the...

  • Page 24: Motor Reassembly

    S SERIES PUMPS MR-04314 housing and bearing bore. Replace the shaft and rotor (as an assembly), the motor housing or inter­ mediate if the proper bearing fit is not achieved. Do not attempt to rewind the stator. Wind­ If replacement is required, use a bearing puller to ing tolerances and materials are closely remove the upper ball bearing from the rotor shaft.
  • Page 25 MR-04314 S SERIES PUMPS the stator O.D. Both processes must be done quick­ NOTE ly and at approximately the same time to allow the Remove any drops of varnish from the ends of the stator to slide into the motor housing before the stator before installation to ensure proper stack‐up...
  • Page 26 S SERIES PUMPS MR-04314 forced out as the stator is installed. Use soft rags to hot plate may be used to heat the bearings. Bear­ absorb any paint that accumulates between the sta­ ings should never be heated with a direct flame or tor and the housing, then use paint thinner to thor­...
  • Page 27 MR-04314 S SERIES PUMPS reposition the bearings. Make certain that they are Apply `Never‐Seez' or equivalent compound to the seated squarely against the shaft shoulders. threads of the capscrews (40). Use two of the caps­ crews and dyna seal washers (41) to draw the low­...
  • Page 28 S SERIES PUMPS MR-04314 tor housing to the upper motor housing with the vices of a qualified electrician to make hardware (9 and 10); torque the nuts evenly in a electrical connections. cross sequence to 60 ft. lbs. (720 in. lbs. or 8,3 m.
  • Page 29 MR-04314 S SERIES PUMPS bonded to the terminal plate (22) with silicone NOTE adhesive to provide a water‐tight seal. If this insu­ If the optional probe wire and moisture detector are lating material has been damaged or removed dur­ used, the brown probe wire lead (W1) should be ing maintenance, it must be replaced using mate­...
  • Page 30 S SERIES PUMPS MR-04314 the terminal housing could cause a short circuit, resulting in pump damage and possible serious injury or death to personnel. All air pockets, voids or gaps in the sili­ cone sealant must be removed to en­...

  • Page 31: Final Assembly

    MR-04314 S SERIES PUMPS Position the lower terminal plate gasket (21) on the with the skin. Read and follow all warn­ terminal plate (22). Refer to Figure C-5. Attach the ings and recommendations accompa­ appropriate motor lead (T1, T2, T3, P1 and P2) to nying the potting kit.

  • Page 32: Lubrication

    S SERIES PUMPS MR-04314 vacuum tested any time the seal(s) and/or motor will allow, then draw the seal cavity down so the dif­ are serviced. ferential between the two cavities is the same as the differential between the vacuum readings Drain all of the oil from both the seal and motor shown in the table.
  • Page 33 MR-04314 S SERIES PUMPS See Table C-2 for quantity of lubricant when lubri­ seal cavity can cause hot oil to be cating a dry (overhauled) pump. See Table C-3 for ejected as the plug is removed. lubricant specifications. To check the seal cavity oil, lay the pump on its side The grade of lubricant used is critical to the opera­...

  • Page 34: The Gorman-Rupp Company

    For U.S. and International Warranty Information, Please Visit www.grpumps.com/warranty or call: U.S.: 419-755-1280 International: +1-419-755-1352 For Canadian Warranty Information, Please Visit www.grcanada.com/warranty or call: 519-631-2870 THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA...

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