GORMAN-RUPP PUMPS S Series Setup guide

PUBLICATION NUMBER MR-04314
July 27, 1995
Rev. A 05‐15‐12
THE GORMAN‐RUPP COMPANY DMANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
e1995 The Gorman‐Rupp Company
S SERIES PUMPS
S4G and S4J
All Materials And Voltages

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:

MR-04314 S SERIES PUMPS
PAGE I - 1INTRODUCTION
INTRODUCTION
Thank You for purchasing a Gorman‐Rupp S
Series Pump. Read this manual carefully to learn
how to safely maintain and service your pump. Fail
ure to do so could result in personal injury or dam
age to the pump.
A set of three manuals accompanies your pump.
The Installation/Operation Manual contains essen
tial information on installing and operating the
pump, and on making electrical connections. The
Parts List Manual provides a performance curve, a
pump model cross‐section drawing, and parts list
for your pump.
This Maintenance and Repair Manual provides
troubleshooting and maintenance instructions re
quired to properly diagnose operational problems,
and to service the pump components. Pump motor
maintenance may be performed only by a Gor
man‐Rupp authorized Submersible repair facility,
or the factory. Otherwise, the pump warranty will be
negated, and damage to the pump, and injury or
death to personnel can result. Contact the factory
for the authorized repair facility closest to you.
As described on the following page, this manual
will alert personnel to known procedures which re
quire special attention, to those which could dam
age equipment, and to those which could be dan
gerous to personnel. However, this manual cannot
possibly anticipate and provide detailed precau
tions for every situation that might occur during
maintenance of the unit. Therefore, it is the respon
sibility of the owner/maintenance personnel to en
sure that only safe, established maintenance pro
cedures are used, and that any procedures not ad
dressed in this manual are performed only after es
tablishing that neither personal safety nor pump in
tegrity are compromised by such practices.
If there are any questions regarding the pump
which are not covered in this manual or in other lit
erature accompanying the unit, please contact
your Gorman‐Rupp distributor or the Gorman‐
Rupp Company:
The Gorman‐Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
CONTENTS
SAFETY - SECTION A
TROUBLESHOOTING - SECTION B
ELECTRICAL TESTING PAGE B - 3........................................................
Test Equipment PAGE B - 3...........................................................
Voltage Imbalance PAGE B - 3........................................................
Motor and Power Cable Continuity PAGE B - 4..........................................
Insulation Resistance PAGE B - 4......................................................
PUMP MAINTENANCE AND REPAIR - SECTION C
GENERAL INFORMATION PAGE C - 1.....................................................
Lifting PAGE C - 1....................................................................
TYPICAL PUMP ASSEMBLY PAGE C - 2....................................................
PUMP ASSEMBLY PARTS IDENTIFICATION LIST PAGE C - 3.................................
TERMINAL HOUSING AND CABLE ASSEMBLY PAGE C - 4...................................
TERMINAL HOUSING AND CABLE ASSEMBLY PARTS IDENTIFICATION LIST PAGE C - 5.......
PUMP END DISASSEMBLY PAGE C - 6....................................................
PUMP END REASSEMBLY PAGE C - 8.....................................................
MOTOR DISASSEMBLY PAGE C - 11......................................................
MOTOR REASSEMBLY PAGE C - 14.......................................................
FINAL ASSEMBLY PAGE C - 21...........................................................
VACUUM TESTING PAGE C - 21..........................................................
LUBRICATION PAGE C - 22...............................................................

MR-04314S SERIES PUMPS
PAGE I - 2 INTRODUCTION
RECORDING MODEL AND
SERIAL NUMBERS
Please record the pump model, serial number, volt
age, and motor frame size in the spaces provided
below. Your Gorman‐Rupp distributor needs this
information when you require parts or service.
Pump Model:
Serial Number:
Voltage:
Phase:
WARRANTY INFORMATION
The warranty provided with your pump is part of
Gorman‐Rupp's support program for customers
who operate and maintain their equipment as de
scribed in this and the other accompanying litera
ture. The integral electric motor must be operated
through the control furnished with the pump as
standard equipment. Please note that should the
equipment be abused or modified to change its
performance beyond the original factory specifica
tions, the warranty will become void and any claim
will be denied.
All repairs to the pump motor must be performed
by a Gorman‐Rupp authorized Submersible repair
facility or the factory. Any repairs to the motor as
sembly performed by the customer or an unautho
rized repair facility negates motor warranty.
The following are used to alert personnel to procedures which require special attention, to those which
could damage equipment, and to those which could be dangerous to personnel:
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure re
quired and the injury which will result
from failure to follow the procedure.
Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.
Hazards or unsafe practices which COULD
result in minor personal injury or product or
property damage. These instructions de
scribe the requirements and the possible
damage which could result from failure to
follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.

MR-04314 S SERIES PUMPS
PAGE A - 1SAFETY
SAFETY - SECTION A
The following information applies
throughout this manual to Gorman‐
Rupp S Series submersible motor driv
en pumps.
This manual will alert personnel to
known procedures which require spe
cial attention, to those which could
damage equipment, and to those which
could be dangerous to personnel. How
ever, this manual cannot possibly antici
pate and provide detailed instructions
and precautions for every situation that
might occur during maintenance of the
unit. Therefore, it is the responsibility of
the owner/maintenance personnel to
ensure that only safe, established main
tenance procedures are used, and that
any procedures not addressed in this
manual are performed only after estab
lishing that neither personal safety nor
pump integrity are compromised by
such practices.
This manual contains essential informa
tion on troubleshooting and maintain
ing the pump. In addition to this manual,
see the separate literature covering in
stallation and operation, pump parts,
and any optional equipment shipped
with the pump.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Lock out incoming power to the
control box to ensure that the
pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Close the discharge valve (if
used).
This pump is not designed to pump vol
atile, explosive, or flammable materials.
Do not attempt to pump any liquids for
which 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.
Before connecting any cable to the con
trol box, be sure to ground the control
box. Refer to the Control Box manual for
the suggested grounding methods.
The pump motor is designed to be oper
ated through the control box furnished
with the pump. The control box provides
overload protection and power control.
Do not connect the pump motor directly
to the incoming power lines.
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

S SERIES PUMPS MR-04314
PAGE A-2 SAFETY
phase of the pump and control before
connecting the power source. Do not
run the pump if the voltage is not within
the limits. If the overload unit is tripped
during pump operation, correct the
problem before restarting the pump.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Make certain that the control
handle on the control box is in the OFF
position and locked out, or that the pow
er supply to the control box has been
otherwise cut off and locked out, before
attempting to open or service the pump
assembly. Tag electrical circuits to pre
vent accidental start‐up.
Never attempt to alter the length or re
pair any power cable with a splice. The
pump motor and cable must be com
pletely waterproof. Injury or death may
result from alterations.
All electrical connections must be in ac
cordance with The National Electric
Code and all local codes. If there is a
conflict between the instructions pro
vided and N.E.C. Specifications, N.E.C.
Specifications shall take precedence.
All electrical equipment supplied with
this pump was in conformance with
N.E.C. requirements in effect on the
date of manufacture. Failure to follow
applicable specifications, or substitu
tion of electrical parts not supplied or
approved by the manufacturer, can re
sult in severe injury or death and void
warranty.
After the pump has been installed, make
certain that the pump and all piping or
hose connections are secure before op
eration.
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 attempt to lift the pump by the
motor power cable or the piping. Attach
proper lifting equipment to the lifting
device fitted to the pump. If chains or
cable are wrapped around the pump to
lift it, make certain that they are posi
tioned so as not to damage the pump,
and so that the load will be balanced.
Obtain the services of a qualified elec
trician to troubleshoot, test and/or ser
vice the electrical components of this
pump.

MR-04314 S SERIES PUMPS
TROUBLESHOOTING PAGE B - 1
TROUBLESHOOTING - SECTION B
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).
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 1. Trouble Shooting Chart
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO START,
OVERLOAD UNIT NOT
TRIPPED
(MANUAL MODE)
(AUTOMATIC MODE)
Power source incompatible with con
trol box.
No voltage at line side of circuit
breaker.
Open circuit in motor windings or
power cable.
Defective motor power cable.
Motor defective.
Liquid level device or control circuits
improperly connected to main con
trol box.
Level sensing device(s) improperly
positioned.
Level sensing device(s) fouled with
mud or foreign material.
Correct power source.
Check power source for blown fuse,
open overload unit, broken lead, or
loose connection.
Check continuity.
Replace cable.
Check for and replace defective unit.
Check wiring diagrams; correct or
tighten connections.
Position device(s) at proper level.
Clean sensing device(s).

S SERIES PUMPS MR-04314
TROUBLESHOOTINGPAGE B - 2
Table 1. Trouble Shooting Chart (cont.)
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
(AUTOMATIC MODE)
(CONT'D.)
Float type sensing device(s) tangled
or obstructed.
Defective liquid level sensing de
vice(s) or control panel.
Check installation for free move
ment of float.
Repair or replace defective unit(s).
OVERLOAD UNIT TRIPS Low or high voltage, or excessive
voltage drop between pump and
control box.
Defective insulation in motor wind
ings or power cable; defective wind
ings.
Impeller jammed due to debris or
insufficient clearance.
Bearing(s) frozen.
Measure voltage at control box.
Check that wiring is correct type,
size, and length. (See Field Wiring
Connections, Section B).
Check insulation resistance; check
continuity.
Disassemble pump and check im
peller.
Disassemble pump and check
bearing(s).
MOTOR RUNS, BUT
PUMP FAILS TO
DELIVER RATED
DISCHARGE
Discharge head too high.
Low or incorrect voltage.
Discharge throttling valve partially
closed; check valve is installed im
properly.
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; excessive im
peller 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 installation.
Check discharge lines; straighten
hose.
Dilute liquid by heating 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 cor
rect by interchanging any two motor
leads at control box. (See Pump
Rotation, Section C).

MR-04314 S SERIES PUMPS
TROUBLESHOOTING PAGE B - 3
Table 1. Trouble Shooting Chart (cont.)
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP RUNS WITH
EXCESSIVE NOISE OR
VIBRATION
Pumping entrained air.
Damaged or unbalanced impeller.
Discharge piping not properly sup
ported.
Impeller jammed or loose.
Motor shaft or bearings defective.
Pump cavitation.
Check liquid level in sump; check
position of pump and liquid level
sensing device(s).
Replace impeller.
Check piping installation.
Check impeller.
Disassemble pump and check mo
tor and bearings.
Reduce discharge head, or restrict
flow on low head applications.
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.
Obtain the services of a qualified elec
trician to troubleshoot, test and/or ser
vice the electrical components of this
pump.
Be certain to refer to the wiring diagram(s)
in the Installation Section of this manual be
fore 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 To check AC Voltage
and current (amperage)
Ohmeter To measure resistance
(ohms) to ground
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

S SERIES PUMPS MR-04314
TROUBLESHOOTINGPAGE B - 4
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 caused by a break in
the power cable or motor windings, or by a
bad connection between the motor and the
power cable. Switch one test lead to the
third power lead, and test again.
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.
NOTE
When shipped from the factory, the connections be
tween the power cable leads and the terminal posts
were encapsulated in heat shrink tubing and
bonded to the terminal plate to provide a water tight
seal. In service, these connections may have been
potted by the pump operator. Do not cut the tubing
or potting away unless absolutely necessary.
Check the continuity of each lead from the motor
side of the terminal plate. If the continuity is good,
there is no need to remove the tubing or potting ma
terial. If there is no continuity through the lead, re
move the tubing or potting from only that terminal,
and check for a loose connection. Be sure to re
place the tubing or potting and allow adequate dry
ing time before putting the pump back into service.
(See Power Cable Reassembly, Section E).
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
Centers.
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
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.

MR-04314 S SERIES PUMPS
PAGE C - 1MAINTENANCE AND REPAIR
PUMP MAINTENANCE AND REPAIR - SECTION C
GENERAL INFORMATION
Review all SAFETY information in Section A.
Do not attempt to service the pump as
sembly unless all power to the motor
has been shut off at the control box;
otherwise, injury or death could result.
Use a lifting device with sufficient ca
pacity. If slings or chains are used to
move the pump or components, make
sure that the load is balanced; other
wise serious personal injury or death
could result.
The maintenance and repair instructions in this
manual are keyed to the sectional views, Figures
C-1 or C-2, and the corresponding parts identifi
cation lists. Refer to the separate Parts List Manual
for replacement parts.
Select a suitable location, preferably indoors, to
perform required maintenance. All work must be
performed by qualified personnel.
All repairs to the pump motor must be per
formed by a Gorman‐Rupp authorized
Submersible repair facility or the factory.
Any repairs to the motor assembly per
formed by the customer or an unautho
rized repair facility negates the warranty.
This Maintenance and Repair Manual provides
troubleshooting and maintenance instructions re
quired to properly diagnose operational problems,
and to service the pump components. Pump motor
maintenance may be performed only by a Gor
man‐Rupp authorized Submersible repair facility,
or the factory. Otherwise, the pump warranty will be
negated, and damage to the pump, and injury or
death to personnel can result. Contact the factory
for the authorized repair facility closest to you.
Check TROUBLESHOOTING, Section B to deter
mine causes and remedies of pump problems.
Disassemble the pump only as far as required.
Lifting
Use lifting equipment with a capacity of at least
five times the weight of the pump, including the
weight of any options or customer‐installed acces
sories. Contact the factory or refer to the pump
Specification Data Sheet for the weight of your
pump. Discharge hose or piping must be removed
before attempting to lift the pump.

S SERIES PUMPS MR-04314
MAINTENANCE AND REPAIRPAGE C - 2
SECTION DRAWING
Figure C-1. Typical S4G And S4J Series Pump Assembly

ITEM
NO. PART NAME
ITEM
NO. PART NAME
MR-04314 S SERIES PUMPS
PAGE C - 3MAINTENANCE AND REPAIR
Typical S4G And S4J Series Pump Assembly
Parts Identification List
Refer to the separate Parts List Manual for serviceable parts, part numbers and quantities.
1 DIFFUSER
2 IMPELLER
3 LOWER SEAL ASSEMBLY
4 UPPER SEAL ASSEMBLY
5 IMPELLER NUT
6 SOCKET HEAD PIPE PLUG
7 SOCKET HEAD PIPE PLUG
8 BEARING CAP
9 HEX HEAD CAPSCREW
10 LOCKWASHER
11 LOWER MOTOR HOUSING O‐RING
12 STATOR KEY
13 MOTOR HOUSING
14 UPPER MOTOR HOUSING
15 UPPER BALL BEARING
16 MOTOR HOUSING O‐RING
17 IMPELLER ADJUSTING SHIM SET
18 RETAINING RING
19 SPRING HOLDER
20 HEX HEAD CAPSCREW
21 LOCKWASHER
22 FLAT WASHER
23 BUSHING
24 HOIST BAIL ASSEMBLY
25 DISCHARGE FLANGE GASKET
26 DISCHARGE FLANGE
27 PIPE PLUG
28 STUD
29 HEX NUT
30 NAME PLATE
31 DRIVE SCREW
32 STUD
33 DEFORM LOCKNUT
34 TERMINAL HOUSING
AND CABLE ASSEMBLY
35 STATOR ASSEMBLY
36 ROTOR & SHAFT ASSEMBLY
37 LOWER BALL BEARING
38 LOWER MOTOR HOUSING
39 PIPE PLUG
40 HEX HEAD CAPSCREW
41 DYNA SEAL WASHER
42 SEAL PLATE O‐RING
43 SEAL PLATE
44 MOTOR HOUSING O‐RING
45 IMPELLER WASHER
46 STRAINER SUPPORT
47 STRAINER
48 STUD
49 LOCKWASHER
50 HEX NUT
51 BASE PLATE
52 IMPELLER KEY
53 HEX HEAD CAPSCREW
54 LOCKWASHER

S SERIES PUMPS MR-04314
MAINTENANCE AND REPAIRPAGE C - 4
SECTION DRAWING
Figure C-2. Terminal Housing And Cable Assembly

MR-04314 S SERIES PUMPS
PAGE C - 5MAINTENANCE AND REPAIR
Terminal Housing And Cable Assembly Parts Identification List
Refer to the separate Parts List Manual for serviceable parts, part numbers and quantities.
ITEM
NO. PART NAME
1 TERMINAL GLAND
2 CABLE - 50 FT
3 CABLE GRIP
4 STUD
5 HEX NUT
6 GLAND BUSHING
7 TERMINAL WASHER
8 TERMINAL HOUSING
9 TERMINAL
10 HEAT SHRINK TUBE
11 ALLEN HEAD SETSCREW
12 TERMINAL COLLAR
13 DYNA SEAL WASHER
14 DYNA SEAL WASHER
15 TERMINAL POST
16 ALLEN HEAD SETSCREW
17 TERMINAL POST
18 ALLEN HEAD SETSCREW
19 DYNA SEAL WASHER
20 DYNA SEAL WASHER
21 TERMINAL PLATE GASKET
22 TERMINAL PLATE
23 TERMINAL PLATE GASKET
24 TERMINAL COLLAR
25 ALLEN HEAD SETSCREW
26 O‐RING
27 HEAT‐SHRINK TUBE
28 TERMINAL
29 RD HD MACHINE SCREW
30 T TYPE LOCKWASHER
31 DRIVE SCREW
32 INFORMATION PLATE
NOT SHOWN:
RTV SEALANT

S SERIES PUMPS MR-04314
MAINTENANCE AND REPAIRPAGE C - 6
PUMP END DISASSEMBLY
References are to Figure C-1 and Figure C-2.
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and de
cals attached to the pump.
The following maintenance and repair instructions
are keyed to the Pump Model sectional view (Fig
ure C-1) and the Terminal Housing sectional view
(Figure C-2), and the accompanying parts lists.
Refer to the Parts List manual for the part number
and quantity required.
Before attempting to service the pump or control,
terminate the power supply to the control box.
Close the discharge throttling valve, if so
equipped.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Make certain that the control
handle on the control box is in the off po
sition and locked out, or that the power
supply to the control box has been
otherwise cut off and locked out, before
attempting to open or service the pump
assembly. Tag electrical circuits to pre
vent accidental start‐up.
Use the hoisting bail to remove the pump from the
wet well or sump, and move it to a location where
the discharge line can be removed. It is not neces
sary to disconnect a flexible discharge hose before
removing the pump. If rigid discharge piping is
used, disconnect the piping before attempting to
move the pump.
Do not attempt to lift the pump by the
motor power cable or the piping. Attach
proper lifting equipment to the lifting
device fitted to the pump. If chains or
cable are wrapped around the pump to
lift it, make certain that they are posi
tioned so as not to damage the pump,
and so that the load will be balanced.
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
B 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 B, 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.
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.
PUMP END DISASSEMBLY
Strainer Removal
(Figure C-1)
To remove the strainer assembly (47), raise the
pump slightly, or lay it on its side and disengage
the hardware (49 and 50) securing the strainer as
sembly and base plate (51) to the diffuser (1).
Draining Oil From Seal Cavity
(Figure C-1)
If any further disassembly is to be performed on the
pump, the seal oil cavity must be drained.

MR-04314 S SERIES PUMPS
PAGE C - 7MAINTENANCE AND REPAIR
Let the pump cool before removing the
seal cavity drain plug. Pressure built up
within a hot pump could cause the oil to
spray out when the plug is removed. Re
move the plug slowly and permit pressure
to vent to atmosphere.
Lay the pump on its side with the pipe plug (6) fac
ing up. Clean any dirt from around the plug. Re
move the seal cavity drain plug (7), and install a
short 3/8‐inch NPT nipple in the hole. Tip the pump
and drain the seal oil into a clean container. In
spect the oil for water, dirt, or cloudy condition
which could indicate lower seal failure or poor gas
ket seal.
Positioning Pump For Disassembly
(Figure C-1)
It is recommended that the pump be positioned
upside‐down during disassembly. To hold the
pump in the inverted position, rest the pump se
curely on blocks. Be careful not to damage the ter
minal housing and cable assembly (34) while in
this position. Use adequate equipment and per
sonnel to safely handle the pump until it is secured.
If inverting the pump is not practical, lay the pump
on its side and secure it to prevent rolling.
Diffuser Removal
(Figure C-1)
To remove the diffuser (1), disengage the hardware
(53 and 54) securing the diffuser (2) to the seal
plate (43). Remove the diffuser and discard the
motor housing O‐ring (44). If the impeller (2) is
clogged, the debris can usually be removed with
out further disassembly.
Impeller Removal
(Figure C-1)
Temporarily install two of the capscrews (53).
Wedge a block of wood between the vanes of the
impeller (2) and the capscrews to prevent impeller
rotation. Remove the impeller nut (5) and washer
(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)
and pull the impeller from the rotor shaft. Use cau
tion when removing the impeller; tension on the
seal spring will be released. Retain the impeller key
(52). Inspect the impeller for wear or damage and
replace as required.
Remove the impeller adjusting shims (17). Tie and
tag the shims or measure and record their thick
ness for ease of reassembly.
If no further disassembly is required, proceed to
the appropriate areas in PUMP END REASSEMB
LY.
Lower Seal Removal
(Figures C-1 and C-3)
Carefully remove the seal spring. Lubricate the ro
tor shaft and work oil under the bellows assembly.
Use the hooked ends of two stiff wires to pull the
rotating portion of the seal off the shaft.
To remove the stationary portion of the seal, pry the
seal plate (43) and O‐ring (42) out of the lower mo
tor housing (38) and off the shaft. Remove and dis
card the seal plate O‐ring.
Place a clean cloth on a flat surface and place the
seal plate on the cloth with the impeller side down.
Use a drift pin or suitably sized dowel to press the
stationary seat and element out of the seal plate.
If no further disassembly is required, proceed to
the appropriate areas in PUMP END REASSEMB
LY.
Upper Seal Removal
(Figures C-1 and C-3)
Unless cracked or otherwise worn, it is not neces
sary to remove the lower motor housing (38) for ac
cess to the upper seal assembly (4).
If the lower motor housing must be re
moved, see the procedure under Motor

S SERIES PUMPS MR-04314
MAINTENANCE AND REPAIRPAGE C - 8
Disassembly in this section. Do not at
tempt to loosen the hardware (40 and 41)
securing the bearing cap (8) before refer
ring to this section; otherwise, the rotor
shaft and bearings could be damaged.
Remove the seal retaining ring (18) using snap ring
pliers. Use caution when removing the retaining
ring; tension on the seal spring will be released.
Remove the spring holder (19) and seal spring.
Lubricate the rotor shaft (36) and work oil under the
bellows. Use a pair of stiff wires with hooked ends
to pull the rotating portion of the seal off the shaft.
Slide the hooked ends of two wires along the shaft
and under the stationary seal seat. Hook the back
side of the seat and pull it from the lower motor
housing bore.
If no further disassembly is required, proceed to
the appropriate areas in PUMP END REASSEMB
LY.
NOTE
Do not disassemble the motor unless it is neces
sary and a clean, well‐equipped shop is available. If
the motor housing components are to be serviced,
see MOTOR DISASSEMBLY in this section. Do not
reassemble the end components at this time.
PUMP END REASSEMBLY
NOTE
Reuse of old O‐rings, gaskets, or shaft seal parts
will result in premature leakage or reduced pump
performance. It is strongly recommended that new
gaskets and shaft seal assemblies be used during
reassembly (see the parts lists for numbers).
Cleaning And Inspection Of Pump Parts
(Figure C-1)
With the pump inverted, stuff a clean tissue into the
stationary seal seat bore of the lower motor hous
ing (38) or wrap a small rag around the shaft to pre
vent foreign material from entering the motor cav
ity.
Carefully inspect any O‐rings or gaskets before re
moval and cleaning to determine if a proper seal
and compression existed prior to disassembly. If
sealing was faulty or questionable, the cause must
be determined and corrected before reassembly.
Replace any parts as required.
Thoroughly clean all reuseable parts with a soft
cloth soaked in cleaning solvent. Remove all O‐
rings and gaskets, and clean the sealing surfaces
of dirt or gasket material. Be careful not to scratch
gasket surfaces. Use a clean cloth lightly damp
ened with solvent to clean the lower motor housing
and seal plate. Do not allow the solvent to enter the
motor.
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.
Inspect the rotor shaft (36) for damaged threads,
scoring, or nicks. Remove nicks and burrs with a
fine file or emery cloth to restore original contours.
If the shaft is bent or severely damaged, the rotor
and shaft must be replaced as an assembly (see
MOTOR DISASSEMBLY).
Neither of the shaft seal assemblies (3 or 4) should
be reused because wear patterns on the finished
faces cannot be realigned during reassembly. This
could result in premature failure. If necessary to re
use an old seal in an emergency, carefully wash
all metallic parts in fresh cleaning solvent and allow
to dry thoroughly.
Handle the seal parts with extreme care to prevent
damage. Be careful not to contaminate the preci
sion finished faces; even fingerprints on the faces
can shorten seal life. If necessary, clean the faces
with a non‐oil based solvent and a clean, lint‐free
tissue. Wipe lightly in a circular pattern to avoid
scratching the faces.
Inspect the seal components for wear, scoring,
grooves, and other damage that might cause leak
age. If any components are worn, replace the com
plete seal; never mix old and new seal parts.

MR-04314 S SERIES PUMPS
PAGE C - 9MAINTENANCE AND REPAIR
Install the shaft seals as illustrated in Figure C-3.
STATIONARY
CUP SEAT
SPRING
RETAINER
SHAFT
SLEEVE
SPRING
IMPELLER
IMPELLER KEY
BELLOWS AND
RETAINING ASSY
ROTOR
SHAFT
ROTATING
ELEMENT
STATIONARY
ELEMENT
SEAL
RETAINING RING
SEAL PLATE
STATIONARY
SEAL SEAT
SPRING
IMPELLER
SHIMS
BELLOWS AND
RETAINING ASSY
ROTATING
ELEMENT
STATIONARY
ELEMENT LOWER MOTOR
HOUSING
RETAINING RING
Figure C-3. Upper And Lower Seal Assemblies
This seal is not designed for operation at
temperatures above 122_F (50_C). Do not
use at higher operating temperatures.
Upper Seal Installation
(Figures C-1 and C-3)
Do not unwrap a new seal assembly until time of
installation. Cleanliness of seal components is criti
cal, especially the seal faces.
Carefully remove the material stuffed into the seat
bore (or unwrap the shaft). Be sure no debris
stopped by the material falls into the seal cavity.
Clean the rotor shaft (36) and seal cavity area of the
lower motor housing (38). Be sure the area is dry
and free of lint and dirt. Check the seal bore for
burrs or nicks that might prevent a good seal. Re
move them with a fine file or emery cloth to restore
original contours. If the shaft is bent or damaged,
the complete rotor and shaft must be replaced as
an assembly. Apply a light coating of oil to the bore
of the lower motor housing.
Unpack the stationary seat. Apply a light coating of
oil to the stationary seat O‐ring. Keep the sealing
face dry.
NOTE
When pressing seal components onto the shaft,
use hand pressure only. A push tube cut from a
length of plastic pipe will aid in installing seal com
ponents. The I.D. of the push tube should be ap
proximately the same as the I.D. of the seal spring.
Position the seat in the lower motor housing bore
with the sealing face up and cover the seal face
with a clean tissue. Use your thumbs to press the
seat into the bore. Apply equal pressure on oppo
site sides until the seat is fully seated in the bore.
Remove the tissue and inspect the seal face to en
sure that it is clean and dry. If cleaning is neces
sary, use clean tissue to wipe lightly in a circular
pattern.

S SERIES PUMPS MR-04314
MAINTENANCE AND REPAIRPAGE C - 10
Unpack the rotating portion of the seal. Be certain
the seal face of the rotating element is free of grit or
surface damage. Because the rotating element
may not stay in the bellows retainer when turned
upside down, place a small amount of grease at
equal spaces on the back of the element and posi
tion it in the bellows retainer. The grease should
hold the element in position until the seal is in
stalled. Assemble the drive grooves of the rotating
element into the drive lugs of the bellows retainer.
Apply a light coating of oil to the seal seating sur
face on the shaft, the groove for the retaining ring
(18), and I.D. of the bellows. Apply a single drop of
light lubricating oil to the precision finished seal
face.
Position the rotating seal portion on the shaft with
seal face down. Apply firm steady pressure on the
bellows retainer until it slides down the shaft and
the seal faces contact. This step should be done in
one continuous motion to prevent the bellows from
sticking or rolling as it passes over the retaining
ring groove.
Slide the seal spring over the shaft and bellows re
tainer, and install the spring holder (19). Install the
seal retaining ring (18). See Figure C-3 for the
proper order of seal assembly.
Lower Seal Installation
(Figures C-1 and C-3)
Thoroughly clean the O‐ring surface and seal bore
of the seal plate (43). The seal bore must be free of
burrs and nicks which could damage the seal. In
spect the seal plate for cracks, distortion, or ero
sion and replace it if defective.
Position the seal plate on a clean flat surface with
the impeller side up.
Unpack the stationary seat and element. Subas
semble the stationary element in the stationary
seat. Apply a light coating of oil to the seal plate
bore and the O.D. of the seal seat and O‐ring. Keep
the sealing face dry.
Position the subassembly in the seal plate bore,
and cover it with a clean tissue. Use your thumbs to
press the seat into the bore. Apply equal pressure
on opposite sides of the seat until it is fully seated in
the bore. Remove the tissue and inspect the seal
face to ensure that it is clean and dry. If cleaning is
necessary, use clean tissue to wipe lightly in a cir
cular pattern.
NOTE
When pressing seal components onto the rotor
shaft, use hand pressure only. A push tube cut from
a length of plastic pipe will aid in installing seal
components. The I.D. of the push tube should be
approximately the same as the I.D. of the seal
spring.
Install the seal plate O‐ring (42) on the seal plate.
Carefully position the seal plate and stationary seal
components on the rotor shaft and press the seal
plate into the lower motor housing until fully
seated. Be careful not to damage the stationary
element already installed.
Unpack the rotating portion of the seal. Be certain
the seal face of the rotating element is free of grit or
surface damage. Because the rotating element
may not stay in the bellows retainer when turned
upside down, place a small amount of grease at
equal spaces on the back of the element and posi
tion it in the bellows retainer. The grease should
hold the element in position until the seal is in
stalled. Assemble the drive grooves of the rotating
element into the drive lugs of the bellows retainer.
Apply a light coating of oil on the shaft and the I.D.
of the bellows.
Slide the seal rotating portion onto the lubricated
shaft with the seal face down. Apply firm, steady
pressure on the bellows retainer until it slides down
the shaft and the seal faces contact.
Slide the seal spring over the shaft and bellows re
tainer. See Figure C-3 for proper order of seal as
sembly.
Impeller Installation
(Figure C-1)
Inspect the impeller (2) for cracks, broken vanes,
or wear from erosion, and replace it if damaged.
Clean the threads on the rotor shaft to remove any
old thread locking material. Be sure the impeller
bore and the shaft are free of oily film and com
pletely dry.