GORMAN-RUPP PUMPS S Series User manual

PUBLICATION NUMBER MR--04301
July 10, 1995
THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
eCopyright by the Gorman-Rupp Company
SSERIESPUMPS
S2A’s
All Materials And Voltages

MR--04301 SSERIESPUMPS
PAGE I -- 1
INTRODUCTION
INTRODUCTION
Thank You for purchasing a Gorman-Rupp S
Series Pump. Read this manual carefully to learn
howtosafelymaintainandserviceyourpump.Fail-
ure to do so could result in personal injury or dam-
age to the pump.
A set of three manuals accompanies your pump.
TheInstallation/OperationManualcontainsessen-
tial information on installing and operating the
pump, and on making electrical connections. The
Parts List Manualprovides a performance curve, a
pump model cross-section drawing, and parts list
foryourpump.
This Maintenance and Repair Manual provides
troubleshooting and maintenance instructions re-
quiredto properlydiagnose operationalproblems,
andtoservicethepumpcomponents.Pumpmotor
maintenance may be performed only by a Gor-
man-Rupp authorized Submersible repair facility,
orthefactory.Otherwise,thepumpwarrantywillbe
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
willalert personnel toknown procedures which re-
quire specialattention, to those which could dam-
age equipment, and to those which could be dan-
gerous topersonnel. However, this manualcannot
possibly anticipate and provide detailed precau-
tions for every situation that might occur during
maintenanceoftheunit.Therefore,itistherespon-
sibilityof the owner/maintenance personnel to en-
sure that only safe, established maintenance pro-
ceduresareused, andthat anyproceduresnotad-
dressedinthismanualareperformedonlyafteres-
tablishingthatneitherpersonalsafetynorpumpin-
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 --- 19...........................................................
VACUUM/PRESSURE TESTING PAGE C --- 20...............................................
LUBRICATION PAGE C --- 20...............................................................

MR--04301SSERIESPUMPS
PAGE I -- 2 INTRODUCTION
RECORDING MODEL AND
SERIAL NUMBERS
Pleaserecordthepumpmodel,serialnumber,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 anunautho-
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 resultin
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.
HazardsorunsafepracticeswhichCOULD
resultinminorpersonalinjuryorproductor
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.

SSERIESPUMPS MR--04301
PAGE A-- 1
SAFETY
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,thismanualcannotpossiblyantici-
pate and provide detailed instructions
and precautions for every situation that
might occur during maintenance of the
unit.Therefore,itis the responsibilityof
the owner/maintenance personnel to
ensurethatonlysafe, 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.
Thismanualcontainsessentialinforma-
tion on troubleshooting and maintain-
ing the pump.In additionto thismanual,
see the separate literature covering in-
stallation and operation, pump parts,
and any optional equipment shipped
with the pump.
Beforeattemptingtoopenorservicethe
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,orflammable 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 anycable tothe con-
trol box, be sure to ground the control
box. Refer tothe ControlBox manualfor
the suggested grounding methods.
The pump motor is designed to be oper-
ated through the control box furnished
withthepump.Thecontrolboxprovides
overload protection and power control.
Do not connect the pump motordirectly
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
electricalground.Besurethatthein-

MR--04301 SSERIESPUMPS
PAGE A -- 2 SAFETY
coming power matches the voltage and
phase of the pump and control before
connecting the power source. Do not
run the pump if the voltage is not within
the limits. If the overload unit is tripped
during pump operation, correct the
problem before restarting the pump.
The electrical power used to operate
this pump is high enough to cause inju-
ryordeath.Makecertainthat thecontrol
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.
Allelectricalconnections mustbe 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.
Afterthepumphasbeeninstalled,make
certain that the pump and all piping or
hoseconnections aresecure beforeop-
eration.
Approach the pump cautiously after it
hasbeenrunning.Althoughthemotoris
cooledbythe liquidbeing pumped,nor-
maloperating temperaturescanbehigh
enough to cause burns. The tempera-
ture will be especially high if operated
againsta closeddischarge valve.Never
operate against a closed discharge
valve for long periods of time.
Donotattempttoliftthepumpbythe
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--04301 SSERIESPUMPS
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, seeELECTRICAL TESTINGfollowing
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).

SSERIESPUMPS MR--04301
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 Loworhighvoltage,orexcessive
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,SectionB).
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.
Dischargelinecloggedorre-
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 DISASSEMBLY.
Check direction of rotation and cor-
rect by interchanging any two motor
leads at control box. (See Pump
Rotation,SectionC).

MR--04301 SSERIESPUMPS
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.
Damagedorunbalancedimpeller.
Discharge piping not properly sup-
ported.
Impellerjammedorloose.
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 arecaused
bydefectsinthemotor,powercableorcontrolbox,
performthefollowingcheckstohelpisolatethede-
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)
intheInstallationSectionofthismanualbe-
fore reconnecting any electrical compo-
nents which have been disconnected.
Test Equipment
A volt/amp/ohmmeter and megohmeter of ade-
quaterangeandqualitywillberequiredtoconduct
thefollowingelectricaltests.Thesuggestedequip-
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
yourpowercompanyandrequestthattheycorrect
the condition.
a. Useavoltmeter,amprobe,orequivalentme-
ter to read the voltage across terminals 1 &
2,2&3,and1&3inthecontrolbox.Allthree
measured voltages must be the same, as
accuratelyasthemeterwillread.Ifpossible,
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.Allthemeasuredvoltagesat eachcon-
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 fullload and at
no load. All three amperage readings must

SSERIESPUMPS MR--04301
TROUBLESHOOTINGPAGE B -- 4
be the same at each condition, as accurate-
ly as the meter will read. Nominalamperage
values are listed in Table 1, but these apply
onlywhentheactualvoltageat thesiteisthe
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
pumpmotorisrequiredtoisolatethedefect.
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
leadstoanytwoofthethreepowercable
leads(nottothegreengroundleadoryellow
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 cablefor 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 powercable lead atthe terminalposts.
NOTE
Whenshippedfromthefactory,theconnectionsbe-
tweenthepower cableleadsandthe terminalposts
were encapsulated in heat shrink tubing and
bonded totheterminal platetoprovideawatertight
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,
thereisnoneedto removethetubingorpottingma-
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 orpotting andallow adequatedry-
ing time before putting the pump back into service.
(See Power Cable Reassembly,SectionE).
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 readingindicates anopenorbrokencir-
cuit, there is an open circuit in the motor.
NOTE
Itisrecommendedthatapumpwithadefectivemo-
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 othertest lead toeach of thethree
power leads in turn.
b. The reading obtained will indicate resis-
tancevaluesinboththepowercableandthe
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.
Capacitors
Thestartcapacitorisdesignedtosplittheelectrical
phase during the initial power surge at motor star-

MR--04301 SSERIESPUMPS
TROUBLESHOOTING PAGE B -- 5
tup. The start capacitor is controlled by the start
relay at motor startup. When the motor reaches
load speed,the startrelay cuts outand permitsthe
run capacitor to maintain operation. Both the start
and run capacitors are located in the control box.
Before disconnecting the capacitor leads,
discharge the capacitors using a screw-
driver with an insulated handle, and place
the blade across the twoterminals of each
capacitor to short the terminals.
Zero-balance the ohmmeter set to read RX100K,
and test the capacitors as follows:
a. Disconnect the capacitor leads and remove
the resistor from the start capacitor.
b. Place a test lead against each of the termi-
nals ofthe start capacitor fora few seconds.
If the ohmmeter needle moves toward zero
thenslowlydriftsbacktotheleft, thecapaci-
tor is good. If the needle remains at infinity
(1) the capacitor is open; if the needle re-
mains at zero, the capacitor is shorted. In ei-
ther case, the capacitor must be replaced.
c. Test the run capacitor as in b. In addition,
test the metal run capacitor for shorts to
ground by touching on e test lead to the ca-
pacitor case and the other lead to each of
the capacitor terminals in turn. The ohmme-
ter should read infinity (1); if itdoes not, the
capacitor is grounded and must be re-
placed.
Start Relay
The start relay is located in the control box.
Disconnect the two wires from relay terminals 2.
Use a zero-balanced ohmmeter set to read
RX100K,andtouchoneleadtorelayterminal2and
the other to relay terminal 5. The resistance read-
ing should be between 1000 and 1500 ohms; ifthe
reading is not in this range, the start relay is defec-
tive and should be replaced.
NOTE
With the exception of the motor assembly, repair of
individual electrical components is not recom-
mended. Replace defective and/or malfunctioning
components.

SSERIESPUMPSMR--04301
MAINTENANCE AND REPAIR PAGE C -- 1
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.Ifslingsorchainsareusedto
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 thepump 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-
quiredto properlydiagnose operationalproblems,
andtoservicethepumpcomponents.Pumpmotor
maintenance may be performed only by a Gor-
man-Rupp authorized Submersible repair facility,
orthefactory.Otherwise,thepumpwarrantywillbe
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.Dischargehoseorpipingmustberemoved
before attempting to lift the pump.

MR--04301SSERIESPUMPS
PAGE C -- 2 MAINTENANCE AND REPAIR
SECTION DRAWING
1
3
42
7
6
5
8
9
11
10
14
13
12
16
15
17
18
19
22
21
20
25
24
23
26
27 28
29
30
31
32
33
34
35
36
37
38
39
40
414243444547, 4650, 49, 48
51
Seal Area Detail
Figure C---1. Typical S2A Series Pump Assembly

ITEM
NO. PART NAME ITEM NO. PART NAME
SSERIESPUMPSMR--04301
MAINTENANCE AND REPAIR PAGE C -- 3
Typical S2A 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 SEAL ASSEMBLY
4INTERMEDIATEGASKET
5 HEX HEAD CAPSCREW
6HEXNUT
7LOCKWASHER
8 DISCHARGE FLANGE GASKET
9 DISCHARGE FLANGE
10 STUD
11 HEX NUT
12 STUD
13 HEX NUT
14 LOCKWASHER
15 PIPE PLUG
16 ALLEN HEAD CAPSCREW
17 MOTOR HOUSING
18 UPPER BALL BEARING
19 BEARING SPRING WASHER
20 STUD
21 HEX NUT
22 LOCKWASHER
23 HEX HEAD CAPSCREW
24 LOCKWASHER
25 FLAT WASHER
26 BUSHING
27 HOISTING BAIL
28 TERMINAL HOUSING AND CABLE
ASSEMBLY
29 RELIEF VALVE ASSEMBLY
30 STATOR ASSEMBLY
31 ROTOR ASSEMBLY
32 MOTOR HOUSING GASKET
33 NAME PLATE
34 DRIVE SCREW
35 LOWER BALL BEARING
36 INTERMEDIATE
37 MOTOR HOUSING DRAIN PLUG
38 SEAL CAVITY DRAIN/FILL PLUG
39 DIFFUSER GASKET
40 IMPELLER ADJUSTING SHIM SET
41 BASE PLATE
42 IMPELLER WASHER
43 IMPELLER NUT
44 IMPELLER KEY
45 WEAR PLATE
46 HEX HEAD CAPSCREW
47 LOCKWASHER
48 STUD
49 HEX NUT
50 LOCKWASHER
51 STRAINER SCREEN

MR--04301SSERIESPUMPS
PAGE C -- 4 MAINTENANCE AND REPAIR
SECTION DRAWING
Figure C---2. Terminal Housing And Cable Assembly

SSERIESPUMPSMR--04301
MAINTENANCE AND REPAIR PAGE C -- 5
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
1TERMINAL
2 ALLEN HEAD SETSCREW
3 LOWER TERMINAL PLATE GASKET
4TERMINALPLATE
5 UPPER TERMINAL PLATE GASKET
6 ROUND HEAD MACHINE SCREW
7TTYPELOCKWASHER
8 INFORMATION PLATE
9 DRIVE SCREW
10 TERMINAL HOUSING
11 TERMINAL CAP
12 STUD
13 HEX NUT
14 CABLE ASSEMBLY
15 CABLE GRIP
16 GLAND BUSHING
17 HEAT SHRINK TUBE
18 RTV SEALANT
19 HEX NUT
20 DYNA---SEAL WASHER

MR--04301SSERIESPUMPS
PAGE C -- 6 MAINTENANCE AND REPAIR
PUMP END DISASSEMBLY
References are to Figure C---1 and Figure C---2.
Review all SAFETY information in Section A.
Followtheinstructionsonalltags,labelandde-
cals attached to the pump.
The following maintenance and repairinstructions
are keyed to the Pump Model sectional view (Fig-
ure C---1) and the TerminalHousing sectionalview
(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-
ryordeath.Makecertainthat thecontrol
handleonthecontrolboxisinthe offpo-
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 bailto remove the pump fromthe
wet well or sump, and move it to a location where
the discharge line can be removed. It is not neces-
sarytodisconnectaflexibledischargehosebefore
removing the pump. If rigid discharge piping is
used, disconnect the piping before attempting to
move the pump.
Donotattempttoliftthepumpbythe
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
performthe degreeof maintenancerequired. Ifthe
motor housing is to be opened, the work must be
done in a clean, well-equipped shop. All mainte-
nancefunctionsmustbedonebyqualifiedperson-
nel.
CheckthechartinTROUBLESHOOTING,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
andterminalhousing.Iftheproblemisdetermined
to be in the motor, proceed with PUMP END DIS-
ASSEMBLY, followed by MOTORDISASSEMBLY.
Otherwise, see Terminal Housing And Power Ca-
ble Disassembly.
Carefully inspect anyO-rings or gaskets before re-
moval and cleaning to determine if a proper seal
and compression existed prior to disassembly. If
sealing was faultyor questionable, the causemust
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 And Wear Plate Removal
(Figure C--1)
To remove the strainer assembly (51), raise the
pump slightly, or lay it on its side and disengage
thehardware(49and50)securingthestrainerand
base plate (41) to the intermediate (36).
To remove the wear plate (45), remove the hard-
ware(46and47)securingittothe diffuser(1).Ifthe
impeller (2) is clogged, the debris can usually be
removed without further disassembly.

SSERIESPUMPSMR--04301
MAINTENANCE AND REPAIR PAGE C -- 7
Draining Oil From Seal Cavity
(Figure C--1)
Ifanyfurtherdisassemblyistobeperformedonthe
pump, the seal oil cavity must be drained.
Let the pump cool before removing the
seal cavity drain plug. Pressure built up
within a hot pump could cause the oil to
spray out when the plug is removed. Re-
move the plug slowly and permit pressure
to vent to atmosphere.
Lay the pump on its side with the pipe plugs (37
and 38) facing up. Clean any dirt from around the
plugs. Remove the sealcavity drainplug (38), and
install a short 1/4-inch NPT nipple in the hole. Tip
the pump and drain the seal oil into a clean con-
tainer.Inspecttheoilforwater,dirt,orcloudycondi-
tion which could indicate lower seal failure or poor
gasket seal.
Draining Oil From Motor Cavity
(Figure C--1)
If motor problems are suspected, remove the mo-
tor cavity drain plug (37), and install a short nipple
in the hole. Tip the pump and drain the motor oil
into a clean container. Inspectthe oilfor darkcolor
which could indicate motor overheating, water or
dirt contamination. The presence of dirt or water
could indicate a breakdown in the waterproof in-
tegrity of the motor cavity, probably due to poor
gaskets or seals.
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 theter-
minal housing and cable assembly (28) while in
this position. Use adequate equipment and per-
sonneltosafelyhandlethepumpuntilitissecured.
If inverting the pump is not practical, lay the pump
on its side and secure it to prevent rolling.
Impeller Removal
(Figure C--1)
Wedge a piece of wood between the vanes of the
impeller (2). Remove the impeller nut (43) and
washer (42).
Remove the wood block and install the impeller
pullersuppliedwiththepump,andpulltheimpeller
off the shaft. Retain the impeller key (44).
Remove the impeller adjusting shim set (40). For
ease of reassembly, tie and tag the shims or mea-
sure and record their thickness.
Diffuser Removal
(Figure C--1)
Toremovethediffuser(1),disengagethehardware
(5,6and7)securing ittotheintermediate (36).Use
caution when removing the hardware; tension on
the sealspringwillbe released. Remove thediffus-
er. Remove and discard the intermediate and dif-
fuser gaskets (4 and 39).
Seal Removal
(Figures C--1 and C--3)
The lower seal base ring is secured to the diffuser
with a retaining ring. Place a clean cloth on a flat
surface and place the diffuser on the cloth with the
impeller side down. Remove the retaining ring us-
ing snap ring pliers. Press the base ring out of the
diffuser.
Remove the lower rotating seal element. Lubricate
therotorshaft(31)andworkoilunderthelowerbel-
lows assembly. Slide the lower bellows assembly
off the shaft. Carefully remove the seal spring.
Work oil under the upper bellows assembly and
slideitofftheshaft.Slidethehookedendsoftwo
stiffwiresalongtheshafttopulltheupperportionof
the stationary element. Hook the back side of the
element and pull it from the intermediate bore.
If no further disassembly is required, proceed to
theappropriateareasinPUMP END REASSEMB-
LY.

MR--04301SSERIESPUMPS
PAGE C -- 8 MAINTENANCE AND REPAIR
NOTE
Do not disassemble the motor unless it is neces-
saryandaclean,well-equippedshopisavailable.If
the motor housing components are to be serviced,
seeMOTOR DISASSEMBLY in this section. Donot
reassemblethepumpendcomponentsatthistime.
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)
Withthepumpinverted,stuffa cleantissueintothe
stationarysealseatboreoftheintermediate(36)or
wrap a small rag around the shaft to prevent for-
eign material from entering the motor cavity.
Carefully inspect anyO-rings or gaskets before re-
moval and cleaning to determine if a proper seal
and compression existed prior to disassembly. If
sealing was faultyor questionable, the causemust
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.
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 (31) for damaged threads,
scoring, or nicks. Remove nicks and burrs with a
fine file or hand honing stone to restore original
contours. If the shaft is bent or severely damaged,
the rotor and shaft must be replaced as an assem-
bly (see MOTOR DISASSEMBLY).
The shaft seal assembly (3) should not be reused
because wear patterns on the finished faces can-
not be realigned during reassembly. This could re-
sult in premature failure. If necessary to reuse an
old seal in an emergency,carefully wash all me-
tallicpartsinfreshcleaningsolventandallow todry
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, andother damage thatmight cause leak-
age.Ifanycomponentsareworn,replacethecom-
plete seal; never mix old and new seal parts.
Install the shaft seal as illustrated in Figure C---3.

SSERIESPUMPSMR--04301
MAINTENANCE AND REPAIR PAGE C -- 9
BELLOWS
STATIONARY
ELEMENT
SPRING
ROTATING
ELEMENT
ROTOR
SHAFT STATIONARY
SEAT
INTERMEDIATE
BELLOWS
O-RING
ROTATING
ELEMENT
RETAINING
RING
DIFFUSER
IMPELLER SHIMS
O-RING
SEAL RING
BASE
Figure C---3. 10214 Seal Assembly
This seal is not designed for operation at
temperaturesabove122_F(50_C).Donot
use at higher operating temperatures.
Seal Installation
(Figures C--1 and C--3)
Do not unwrap a new seal assembly until time of
installation.Cleanlinessofsealcomponents iscriti-
cal, especially the seal faces.
Cleantherotorshaft(31)andsealcavityareaofthe
intermediate (36). Be sure the area is dry and free
of lint and dirt. Check the seal bore for burrs or
nicks that might prevent a good seal. Remove
them with a fine file or emery cloth to restore origi-
nal contours. If the shaft is bent or damaged, the
complete rotor and shaft must be replaced as an
assembly. Apply a light coating of oil to the bore.
Carefully remove the material stuffed into the seat
bore (or unwrap the shaft). Be sure no debris
stopped by the material falls into the motor cavity.
NOTE
When pressing seal components onto the shaft,
use hand pressure only. A push tube cut from a
length of plastic pipe will aid in installing seal com-
ponents. The I.D. of the push tube should be ap-
proximately the same as the I.D. of the seal spring.
Unpack the upper seal stationary element and in-
stall the O-ring in the stationary seat, taking care
not to touch the sealing face. Applya lightcoating
of oil to the O-ring and the seal bore. Position this
subassembly in the intermediate bore with the
sealingfaceupandcoverthesealfacewithaclean
tissue.Useyourthumbstopresstheassemblyinto
the bore. Apply equal pressure on opposite sides
until the seat contacts the bore shoulder. Remove
thetissueandinspectthesealfacetoensurethatit
is clean and dry. If cleaning is necessary, use a
clean tissue to wipe lightly in a circular pattern.

MR--04301SSERIESPUMPS
PAGE C -- 10 MAINTENANCE AND REPAIR
Lightly oil the O.D. of the seal installation tool fur-
nished with the pump, and install it over the
threaded end of the shaft with the tapered end to-
ward the end of the shaft..
Unpack the rotating portion of the upper 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 backof the element
and position it in the bellows retainer. The grease
should hold the element in position until the seal is
installed. Assemble the drive grooves of the rotat-
ingelementintothedrivelugsofthebellowsretain-
er.
Slide the rotating portion of the seal over the seal
installation tool and onto the lubricated shaft as
shown in Figure C---3. Apply firm, steady pressure
on the seal retainer until it slides down the shaft
and the seal faces contact.
Slide the seal spring over the shaft and bellows re-
tainer.
Unpack the rotating portion of the lower seal. Be
certain the seal face of the rotating element is free
ofgritorsurfacedamage.Placeacleantissueover
thesealingfaceand slidethe rotatingportionofthe
seal over the seal installation tool and onto the lu-
bricated shaft as showninFigureC---3.Applyfirm,
steady pressure on the sealuntil it slides down the
shaft, past the shaft shoulder and the bellows re-
tainer seats against the seal spring.
NOTE
Thesealspringwillnotfullycompressuntilthelow-
er base ring and diffuser (1) are installed. (See Dif-
fuser Installation below).
Remove the installation tool and inspect the rotat-
ingsealface.Ifcleaningisnecessary,use cleantis-
suetowipe lightly in a circular pattern. See Figure
C---3 for the proper order of seal assembly.
Diffuser Installation
(Figure C--1)
Cleanandinspectthediffuser(1)forcracks,distor-
tion, and erosion. Replace if defective.
The lower seal base ring andstationary elementis
securedtothediffuser witharetainingring.Placea
clean cloth on a flat surface and place the diffuser
on the cloth with the impeller side up. Unpack the
lower seal base ring, and inspect the seal face to
ensure that it is clean and dry. If cleaning is neces-
sary, use a clean tissue towipe lightly in a circular
pattern.
Removethe retainingring andoilthe O.D. of theO-
ring. Place a clean tissue over the stationary seal
faceandcarefullypressthebaseringinthediffuser
untilfullyseated.Donotforcetheretainingringinto
position; cocking the ring may cause improper
mating ofthe seal faces. Secure the base ring with
the retaining ring.
Install theintermediateanddiffusergaskets(3and
39)
Coat the threads of the diffuser capscrews (5) with
“Never-Seez” or equivalent compound. Carefully
position the diffuser over the shaft and against the
intermediate (36). Be careful not to damage the
stationary seal face already installed. Install the
lockwashers(7)andtorquethenuts(6)to20ft.lbs.
(240 inch lbs. or 2,8 m. kg.)
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
oldthreadlockingmaterial.
Install the same thickness of impeller adjusting
shims (40) as previously removed. Install the im-
peller key (44) in the shaft keyway, align the impel-
ler keyway, and press the impeller onto the shaft
until it seats firmly against the adjusting shims.
After the impeller is installed, coat the threads of
the rotor shaft with ‘Loctite Threadlocker No. 242’
or equivalentcompound. Installthe impellerwash-
er (42) and nut (43). Place a block of wood be-
tween the vanes of the impeller toprevent shaft ro-
tation,and torquethe impellernut to20ft. lbs.(240
in. lbs.or 2,8 m. kg.).
Remove the block of wood and turn the impeller to
check for free rotation. Check the front clearance
after installing the wear plate (45).