GORMAN-RUPP PUMPS S4A1-E25 460/3 User manual

COM‐06098‐01
March 11, 2008
Rev. A 05‐15‐12
ACU
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
2008 The Gorman‐Rupp Company
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
SUBMERSIBLE PUMPS
MODELS
S4A1-E25 460/3
and
S4A1-E25 575/3

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:

TABLE OF CONTENTS
i
INTRODUCTION PAGE I - 1.................................................
SAFETY ‐ SECTION A PAGE A - 1............................................
INSTALLATION - SECTION B PAGE B - 1....................................
GENERAL INFORMATION PAGE B - 1..................................................
PUMP SEAL PAGE B - 1..............................................................
LUBRICATION PAGE B - 1.............................................................
PUMP INSTALLATION PAGE B - 1......................................................
Pump Motor Specifications PAGE B - 2..............................................
Pump Dimensions PAGE B - 2.....................................................
Lifting PAGE B - 2.................................................................
Positioning the Pump PAGE B - 3...................................................
Piping PAGE B - 3................................................................
ELECTRICAL CONNECTIONS PAGE B - 4...............................................
Field Wiring Connections (Incoming Power) PAGE B - 4...............................
Grounding Methods PAGE B - 5....................................................
Pump Power Cable Connections PAGE B - 6.........................................
Control Box Specifications PAGE B - 7..............................................
Motor Cable Grounding Test PAGE B - 7.............................................
Control Box Connections PAGE B - 7...............................................
Liquid Level Devices PAGE B - 7....................................................
WIRING DIAGRAMS PAGE B - 8.......................................................
OPERATION - SECTION C PAGE C - 1......................................
GENERAL INFORMATION PAGE C - 1..................................................
Pump Performance PAGE C - 1.....................................................
Control Box PAGE C - 1...........................................................
PUMP OPERATION PAGE C - 1........................................................
Liquid Temperature And Overheating PAGE C - 1.....................................
Impeller Rotation PAGE C - 2.......................................................
STARTING, STOPPING AND OPERATIONAL CHECKS PAGE C - 3.........................
Starting PAGE C - 3...............................................................
Stopping PAGE C - 3..............................................................
Operational Checks PAGE C - 3....................................................
COLD WEATHER PRESERVATION PAGE C - 4...........................................
LUBRICATION PAGE C - 4.............................................................
Draining Oil PAGE C - 5...........................................................
Condition of Oil Oil PAGE C - 5.....................................................
Adding Oil PAGE C - 5............................................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...............................................
PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................
STANDARD PERFORMANCE CURVE PAGE E - 1........................................

TABLE OF CONTENTS
(continued)
ii
PARTS LISTS:
Pump Assemblies PAGE E - 3......................................................
Terminal Housing and Cable Assemblies PAGE E - 5..................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 6.........................
PUMP END DISASSEMBLY PAGE E - 7.................................................
Strainer Removal PAGE E - 7.......................................................
Draining Oil From Seal Cavity PAGE E - 7............................................
Draining Oil From Motor Cavity PAGE E - 7..........................................
Positioning Pump For Disassembly PAGE E - 7.......................................
Strainer Plate and Suction Head Removal PAGE E - 7.................................
Impeller Removal PAGE E - 7......................................................
Lower Seal Removal PAGE E - 8....................................................
Upper Seal Removal PAGE E - 8...................................................
PUMP END REASSEMBLY PAGE E - 8..................................................
Cleaning and Inspection of Pump Parts PAGE E - 8...................................
Upper Seal Installation PAGE E - 9..................................................
Lower Seal Installation PAGE E - 10..................................................
Impeller Installation PAGE E - 11.....................................................
Suction Head and Strainer Plate Installation PAGE E - 11...............................
Strainer Screen and Base Plate Installation PAGE E - 12................................
MOTOR DISASSEMBLY PAGE E - 12....................................................
Terminal Housing and Power Cable Removal and Disassembly PAGE E - 12..............
Intermediate and Motor Housing Disassembly PAGE E - 13.............................
Rotor and Bearing Removal PAGE E - 13.............................................
Stator Removal PAGE E - 14........................................................
Relief Valve PAGE E - 14............................................................
Hoisting Bail PAGE E - 15...........................................................
MOTOR REASSEMBLY PAGE E - 15.....................................................
Stator Installation PAGE E - 15......................................................
Bearing Installation PAGE E - 16.....................................................
Rotor and Intermediate Reassembly PAGE E - 17......................................
Terminal Housing and Power Cable Reassembly and Installation PAGE E - 17.............
Sealing Terminal Housing Connections With Silicone Adhesive PAGE E - 18..............
Sealing Terminal Housing Connections With Potting Compound PAGE E - 19.............
Terminal Housing Installation PAGE E - 20............................................
FINAL ASSEMBLY PAGE E - 20.........................................................
VACUUM TESTING PAGE E - 21........................................................
LUBRICATION PAGE E - 22.............................................................
Seal Cavity PAGE E - 22............................................................
Motor Housing Cavity PAGE E - 22...................................................

OM-06098S SERIES PUMPS
PAGE I - 1INTRODUCTION
INTRODUCTION
Thank You for purchasing a Gorman‐Rupp S Se
ries Pump. Read this manual carefully to learn
how to safely install and operate your pump. Fail
ure to do so could result in personal injury or dam
age to the pump.
Because pump installations are seldom identical,
this manual cannot possibly provide detailed in
structions and precautions for every aspect of
each specific application. Therefore, it is the re
sponsibility of the owner/installer of the pump to
ensure that applications not addressed in this
manual are performed only after establishing that
neither operator safety nor pump integrity are com
promised by the installation. Pumps and related
equipment must be installed and operated ac
cording to all national, local and industry stan
dards.
The pump motor must be operated through the
control box furnished with the pump as standard
equipment. For control box information, consult
the separate control box manual accompanying
the unit.
Pump construction is aluminum, with ductile iron
wearing parts. The pump may be operated fully or
partially submerged. Neither the pump nor the
control box are explosion‐proof, and should not be
operated in a hazardous atmosphere.
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
Phone: [phone]
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: [phone]
RECORDING MODEL AND
SERIAL NUMBER
Please record the pump model and serial number
in the spaces provided on the inside front cover of
this manual. Your Gorman‐Rupp distributor needs
this information when you require parts or service.
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. Please note that should the equipment be
abused or modified to change its performance be
yond the original factory specifications, the war
ranty will become void and any claim will be de
nied.
The following are used to alert personnel to proce
dures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel:
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure re
quired and the injury which will result
from failure to follow the procedure.
Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.

OM-06098 S SERIES PUMPS
PAGE I - 2 INTRODUCTION
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.

OM-06098 S SERIES PUMPS
PAGE A - 1SAFETY
SAFETY - SECTION A
This information applies to the S Series
submersible motor driven pumps indi
cated on the front cover of this manual.
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and pre
cautions for each specific application.
Therefore, it is the owner/installer's re
sponsibility to ensure that applications
not addressed in this manual are per
formed only after establishing that nei
ther operator safety nor pump integrity
are compromised by the installation.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Lock out incoming power to the
control box to ensure that the
pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Close the discharge valve (if
used).
This pump is not designed to pump vol
atile, explosive, or flammable materials.
Do not attempt to pump any liquids for
which you pump is not approved, or
which may damage the pump or endan
ger personnel as a result of pump fail
ure. Consult the factory for specific ap
plication data.
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
qualified electrician to make all electri
cal connections. Make certain that the
pump and enclosure are properly
grounded; never use gas pipe as an
electrical ground. Be sure that the in
coming power matches the voltage and
phase of the pump and control before
connecting the power source. Do not
run the pump if the voltage is not within
the limits. If the overload unit is tripped
during pump operation, correct the
problem before restarting the pump.
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

S SERIES PUMPS OM-06098
PAGE A-2 SAFETY
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.
Obtain the services of a qualified elec
trician to troubleshoot, test and/or ser
vice the electrical components of this
pump.
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 remove plates, covers, gauges,
pipe plugs, or fittings from an over
heated pump. Vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Al
low the pump to completely cool before
servicing.
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.
Pumps and related equipment must be
installed and operated according to all na
tional, local and industry standards.

S SERIES PUMPS OM-06098
PAGE B - 1INSTALLATION
INSTALLATION - SECTION B
GENERAL INFORMATION
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this
section is intended only to summarize general rec
ommendations and practices required to inspect,
position, and arrange the pump and piping. If there
are any questions concerning your specific instal
lation, contact your Gorman‐Rupp distributor or
the Gorman‐Rupp Company.
Liquid level devices are available from Gorman‐
Rupp as optional equipment. For information on
installing and operating these items, refer to the lit
erature accompanying them.
Pump Model Designation
Following is a description of the model numbering
system for S Series pumps. These submersible
pumps are available in a range of sizes. Refer to the
following chart to identify the size of your specific
pump model.
S
Series
Discharge Size
Pump Hydraulics
Pump Construction
H.P.
Voltage/Phase
3 C 1 E 230/3- 6.2
Pump Model
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be
fore shipment from the factory. Before installation,
check for damage which may have occurred dur
ing shipment. Check as follows:
a. Inspect the pump assembly for cracks, dents,
damaged threads, and other obvious dam
age.
b. Check for loose attaching hardware. Since
gaskets tend to shrink after drying, check for
loose hardware at the mating surfaces.
c. Inspect the power cable for cuts or any other
obvious damage.
d. Check that amperes, phase, voltage and
hertz indicated on the name plate match the
ratings on the control box and incoming pow
er.
e. Carefully read all tags, decals, and markings
on the pump, and perform all duties indicated.
f. Check for oil leaks. If there is any indication of
an oil leak, see LUBRICATION at the end of
this manual.
PUMP SEAL
There are two shaft seals in the pump. The lower
seal prevents liquid from entering the intermediate
cavity at the impeller end. The upper seal prevents
oil leakage from the motor housing cavity and acts
as back‐up protection in the event of lower seal fail
ure.
LUBRICATION
These pumps utilize two lubrication cavities. The
motor housing cavity provides lubrication to the
motor assembly and bearings, while the intermedi
ate cavity provides lubrication to the pump seal.
The pumps are fully lubricated when shipped from
the factory. However, lubrication levels must be
checked before installing the pump (see LU
BRICATION in MAINTENANCE AND REPAIR -
SECTION E). An additional quart (0,9 liter) of oil is
provided to “top off” the oil level in the pump motor
cavity. If the oil level is abnormally low, determine
the cause before putting the pump into service.
Due to differences in pump design, the quantity of
oil and manner in which oil is to be added to the
seal cavity varies between pump models. Refer to
Table B‐2 for oil capacities and positions for filling
the seal cavity in each pump. Motor cavities requir
ing lubrication should always be positioned verti
cally for filling. Refer to LUBRICATION, Section C
for lubrication specifications and intervals.
PUMP INSTALLATION
When installing or servicing the pump
or controls, follow all requirements for
the installation of wiring or electrical

OM-06098 S SERIES PUMPS
PAGE B - 2 INSTALLATION
equipment as outlined in the National
Electric Code. Follow all safety require
ments. Failure to observe these require
ments could result in injury or death to
personnel.
Do not allow the free end of the power
cable to enter the liquid being pumped.
The free end of the cable must be kept dry
to prevent liquid from wicking through the
cable and into the motor.
NOTE
Refer to the performance curve in Maintenance
and Repair - Section E when determining the
most efficient piping installation. The recom
mended maximum submergence depth is 65
feet.
Pump Motor Specifications
See Table B‐1 for pump specifications.
Table B‐1. Pump Specifications
Dual
Voltage
Locked
Rotor
Amperes
Pump
HP/
KW
Motor
Speed
(RPM)
Full
Load
Amperes
No
Load
Amperes
Discharge
Size
(NPT)
Model Voltage/
Phase
S4A
460/3
575/3 NO 4 INCH25 HP 1750
32
26
8
6
121
94
Table B‐2. Additional Specifications
Pump
Model
Voltage/
Phase
460/3
575/3
S4A
Approximate
Weight - Lbs. (kg) Oil Capacity
Ounces (Liters)
Seal Cavity
Filling
Position
(H)orizontal
(V)ertical
Pump 50 Ft. Cable Seal
Cavity
Motor
Cavity
423 (192) 43 (20) 96 (2,8) 352 (10,4) V
Pump Dimensions
For the approximate physical dimensions of your
pump, refer to the pump specification data sheet
or contact your Gorman‐Rupp distributor or the
Gorman‐Rupp Company.
Lifting
Pump unit weights will vary depending on the
mounting and drive provided. Check the shipping
tag on the unit packaging for the actual weight, and
use lifting equipment with appropriate capacity.
Drain the pump and remove all customer‐installed
equipment such as suction and discharge hoses
or piping before attempting to lift existing, installed
units.
Refer to Table B-2 for the approximate maximum
weight for your 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.