GORMAN-RUPP SM SERIES Operating instructions

PUBLICATION NUMBER MR--05365
April 1, 2002
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
SM SERIES PUMPS
SM4G’S AND SM4J’S
All Materials And Voltages

MR--05365 SM SERIES PUMPS
PAGE I -- 1
INTRODUCTION
INTRODUCTION
Thank You for purchasing a Gorman-Rupp SM
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,andthatanyproceduresnotad-
dressedinthismanualareperformedonlyafteres-
tablishingthatneitherpersonalsafetynorpumpin-
tegrity are compromised by such practices.
If there are any questions regarding the pump
which are not covered in this manual orin 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 --- 2........................................................
Test Equipment PAGE B --- 3...........................................................
Voltage Imbalance PAGE B --- 3........................................................
Motor and Power Cable Continuity PAGE B --- 3..........................................
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.................................
TYPICALTERMINALHOUSING&CABLEASSEMBLY PAGEC---4.............................
TERMINAL HOUSING & 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 --- 15.......................................................
FINAL ASSEMBLY PAGE C --- 20...........................................................
VACUUM TESTING PAGE C --- 21..........................................................
LUBRICATION PAGE C --- 22...............................................................

MR--05365SM SERIES PUMPS
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 and approved by MSHA.
Please note that should the equipment be abused
ormodified tochange its performance beyondthe
originalfactory specifications, the warranty will be-
come 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 whichWILL 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.

SM SERIES PUMPSMR--05365
SAFETY PAGE A -- 1
SAFETY --- SECTION A
The following information applies
throughout this manual to Gorman-
Rupp SM Series submersible motor
driven 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.Closethedischargevalve(if
used).
This pump is not designed to pump vol-
atile,explosive,orflammablematerials.
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 is designed to be operated
through the control box furnished with
thepump.Thecontrolboxprovides
overload protection and power control.
Do not connect the pump motordirectly
to the incoming power lines.
When installing or servicing the pump
or controls, follow all requirements for
the installation of wiring or electrical
equipment as outlined by MSHA
SCHEDULE 2G. Follow all MSHA safety
requirements. Failure to observe these
requirements could result in injury or
death to personnel.

MR--05365SM SERIES PUMPS
PAGE A -- 2 SAFETY
The electrical power used to operate
this pump is high enough to cause inju-
ry or death. Obtain the services of a qu-
alified electrician to make all electrical
connections. Make certain that the
pump and enclosure are properly
grounded; never use gas pipe as an
electrical ground. Be sure that the in-
coming power matches the voltage and
phase of the pump and control before
connecting the power source. Do not
run the pump if the voltage is not within
the limits. 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.Makecertainthatthecontrol
handle on the control box is in the OFF
positionand lockedout,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.
Any control box used to operate the
pump must be approved by the MSHA
and the Gorman-Rupp Company for the
application.
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.
Allelectrical connections mustbe in ac-
cordance with MSHA Schedule 2G. If
there is a conflict between the instruc-
tions provided and MSHA specifica-
tions, MSHA specifications shall take
precedence. All electrical equipment
supplied with this pump was in confor-
mance with MSHA requirements in ef-
fect on the date of manufacture. Failure
to follow applicable specifications, or
substitution of electrical parts not
supplied or approved by the manufac-
turer, can result in severe injury or
death.
Afterthepumphasbeeninstalled,make
certain that the pump and all piping or
hoseconnections are secure beforeop-
eration.
Approach the pump cautiously after it
hasbeenrunning.Althoughthemotoris
cooledbytheliquidbeing pumped,nor-
maloperatingtemperaturescanbehigh
enough to cause burns. The tempera-
ture will be especially high if operated
againsta closeddischarge valve.Never

SM SERIES PUMPSMR--05365
SAFETY PAGE A -- 3
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--05365 SM 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.Closethedischargevalve(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 B-1 Troubleshooting Chart
TROUBLE CAUSE REMEDY
PUMP FAILS TO
START, CIRCUIT
BREAKER NOT
TRIPPED
Power source incompatible
with control box.
Novoltageatlinesideofcir-
cuit breaker.
Open circuit in motor wind-
ings or power cable.
Defective motor power cable.
Correct power source.
Check power source for blown fuse, open
overload unit, broken lead, or loose connec-
tion.
Check continuity.
Check for and replace defective unit.
CIRCUIT BREAKER
TRIPS Loworhighvoltage,orexces- sive voltage drop between
pump and control box.
Defective insulation in motor
windings.
Impeller jammed due to de-
bris or insufficient clearance.
Bearing(s) frozen.
Measure voltage at control box. Check that
wiring is correct type, size, and length. (See
Field Wiring Connections,OperationsAnd
Maintenance Manual.
Check insulation resistance; check continuity.
Disassemble pump and check impeller.
Disassemble pump and check bearing(s).

SM SERIES PUMPS MR--05365
TROUBLESHOOTINGPAGE B -- 2
Table B-1 Troubleshooting Chart (continued)
TROUBLE CAUSE REMEDY
MOTOR RUNS, BUT
PUMP FAILS TO DE-
LIVER RATED DIS-
CHARGE
Discharge head too high.
Low or incorrect voltage.
Discharge throttling valve par-
tially closed; check that valve
is installed improperly.
Dischargelinecloggedorre-
stricted; hose kinked.
Liquid being pumped too
thick.
Strainer screen or impeller
clogged.
Insufficient liquid in sump or
tank.
Worn impeller vanes; exces-
sive impeller clearance.
Pump running backwards.
Reduce discharge head, or install staging
adaptor and additional pump.
Measure control box voltage, both when
pump is running and when shut off.
Open discharge valve fully; check piping in-
stallation.
Check discharge lines; straighten hose.
Dilute liquid if possible.
Clear clog(s). Stop pump; back flow may
flush away debris.
Stop pump until liquid level rises.
Check impeller and clearance. See PUMP
END REASSEMBLY.
Check direction of rotation and correct by in-
terchanging any two motor leads at control
box. (See Pump Rotation,SectionC).
PUMP RUNS WITH
EXCESSIVE NOISE
OR VIBRATION
Pumping entrained air.
Damaged or unbalanced im-
peller.
Discharge piping not properly
supported.
Impellerjammedorloose.
Pump cavitation.
Motor shaft or bearings defec-
tive.
Check liquid level in sump; check position of
pump and liquid level sensing device(s).
Replace impeller.
Check piping installation.
Check impeller.
Reduce discharge head, or restrict flow on
low head applications.
Disassemble pump and check motor and
bearings.
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.

MR--05365 SM SERIES PUMPS
TROUBLESHOOTING PAGE B -- 3
Be certain to refer to the wiring diagram(s)
before reconnecting any electrical compo-
nents which have been disconnected.
Test Equipment
A volt/amp/ohmmeter and megohmeter of ade-
quaterangeandqualitywillberequiredtoconduct
thefollowingelectricaltests.Thesuggestedequip-
ment indicated below is commercially available, or
an equivalent substitute may be used.
Equipment Use
Ammeter/
Voltmeter To check AC Voltage and current (amperage)
Ohmmeter 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&3inthe controlbox. 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.Allthemeasured voltagesateachcon-
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
be the same at each condition, as accurate-
ly as the meter will read. Nominalamperage
values are listed in Table 1, but these apply
onlywhentheactualvoltageatthesiteisthe
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 cause a break in the
power cable or motor windings, orby a bad
connectionbetweenthemotorandthepow-
er 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
eachpowercableleadattheterminalposts.
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
testreadingindicatesanopenorbrokencir-
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 en-
ters.

SM SERIES PUMPS MR--05365
TROUBLESHOOTINGPAGE B -- 4
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.

SM SERIES PUMPSMR--05365
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 and 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 beper-
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. The approximate maximum weight for this
group of pumps is 541 lbs. (245 kg.) for the
SM4Gseriesand774 lbs.(351kg.)fortheSM4J
series, not includingthe cable.Discharge hose or
piping must be removed before attempting to lift
the pump.

MR--05365SM SERIES PUMPS
PAGE C -- 2 MAINTENANCE AND REPAIR
SECTION DRAWING
Figure C-1. Typical SM4G And SM4J Series Pump Assembly

ITEM
NO. PART NAME PART NAME
ITEM
NO.
SM SERIES PUMPSMR--05365
MAINTENANCE AND REPAIR PAGE C -- 3
Typical SM4G And SM4J Series Pump Assembly
Parts Identification List
Refer to the separate Parts List Manual for serviceable parts, part numbers and quantities.
1SUCTIONHEAD
2THREADEDROD
3HEXNUT
4LOCKWASHER
5 HEX HD CAPSCREW
6LOCKWASHER
7 DIFFUSER
8O-RING
9 IMPELLER
10 HEX NUT
11 SEAL PLATE
12 SOCKET HD PIPE PLUG
13 SOCKET HD PIPE PLUG
14 O-RING
15 HEX HD CAPSCREW
16 LOCKWASHER
17 O-RING
18 BEARING CAP
19 STATOR KEY
20 MOTOR HOUSING
21 UPPER MOTOR HOUSING
22 UPPER BALL BEARING
23 O-RING
24 IMPELLER SHIM SET
25 LOWER SEAL ASSY
26 SNAP RING
27 UPPER SEAL ASSY
28 SPRING HOLDER
29 HEX HD CAPSCREW
30 LOCKWASHER
31 FLAT WASHER
32 BUSHING
33 HOISTING BAIL ASSY
34 DISCH FLANGE GASKET
35 DISCHARGE FLANGE
36 STUD
37 HEX NUT
38 NAME PLATE
39 DRIVE SCREW
40 STUD
41 LOCKWASHER
42 HEX NUT
43 TERMINAL HSG & CABLE ASSY
44 STATOR ASSY
45 ROTOR & SHAFT ASSY
46 LOWER BALL BEARING
47 LOWER MOTOR HOUSING
48 HEX HD CAPSCREW
49 LOCKWASHER
50 SEAL PLATE O-RING
51 PUMP CASING O-RING
52 IMPELLER WASHER
53 STRAINER SUPPORT
54 STRAINER
55 STUD
56 LOCKWASHER
57 HEX NUT
58 BASE PLATE
59 IMPELLER KEY
60 DRIVE SCREW
61 MSHA APPROVAL PLATE

MR--05365SM SERIES PUMPS
PAGE C -- 4 MAINTENANCE AND REPAIR
SECTION DRAWING
Figure C-2. SM4G’s And SM4J’s Terminal Housing & Cable Assembly

SM SERIES PUMPSMR--05365
MAINTENANCE AND REPAIR PAGE C -- 5
SM4G’s And SM4J’s Terminal Housing & Cable Assembly
Refer to the separate Parts List Manual for serviceable parts, part numbers and quantities.
ITEM
NO. PART NAME
1 TERMINAL GLAND
2 50 FT. CABLE ASSEMBLY
3 CABLE CLAMP
4CABLEGRIP
5STUD
6HEXNUT
7LOCKWASHER
8GLANDBUSHING
9TERMINALWASHER
10 TERMINAL HOUSING
11 TERMINAL
12 HEAT SHRINK TUBE
13 ALLEN HEAD SETSCREW
14 TERMINAL COLLAR
15 DYNA SEAL WASHER
16 DYNA SEAL WASHER
17 TERMINAL POST
18 ALLEN HEAD SETSCREW
19 TERMINAL POST
20 ALLEN HEAD SETSCREW
21 DYNA SEAL WASHER
22 DYNA SEAL WASHER
23 LOWER TERMINAL PLATE GASKET
24 TERMINAL PLATE
25 UPPER TERMINAL PLATE GASKET
26 TERMINAL COLLAR
27 ALLEN HEAD SETSCREW
28 O-RING
29 HEAT-SHRINK TUBE
30 TERMINAL
31 ROUNDHEADMACHINESCREW
32 T TYPE LOCKWASHER
33 DRIVE SCREW
34 CERTIFICATION PLATE

MR--05365SM SERIES PUMPS
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.
Follow the instructions on all tags, labeland decals
attached to the pump.
All functions performed by the customer on the
pump or control must be done in accordance with
MSHA, schedule 2G regulations to ensure the ex-
plosion-proof integrity. No alterations of original
design may be made without the consent of the
Gorman-Rupp Company and MSHA.
The electrical power used to operate
this pump is high enough to cause inju-
ryordeath.Makecertainthatthecontrol
handleonthecontrolboxisintheoffpo-
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.
Do not open thecontrol boxin an explo-
siveatmosphere.Whensealed,thecon-
trolboxisexplosionprooftopreventthe
ignition of combustible gases. Opening
the box in an explosive atmosphere
could result in fire or explosion.
Before attempting to service the pump or control,
terminate the power supply to the control box.
Close the discharge throttling valve, if so
equipped.
Use the hoisting bailto 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-
sarytodisconnecta flexibledischargehosebefore
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, sealreplacement,
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.If theproblemisdetermined
to be in the motor, proceed with PUMP END DIS-
ASSEMBLY, followedby MOTORDISASSEMBLY.
Otherwise, seeTerminal 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.

SM SERIES PUMPSMR--05365
MAINTENANCE AND REPAIR PAGE C -- 7
PUMP END DISASSEMBLY
Strainer Removal
(Figure C-1)
Toremovethestrainer(54),raisethepumpslightly,
orlayitonitssideanddisengagethehardware(56
and 57) securing the base plate (58). Remove the
baseplate,strainer, andsupports(53).Iftheimpel-
ler (2) is clogged, the debris can usually be re-
moved without further disassembly.
Suction Head Removal
(Figure C-1)
To remove the suction head (1), disengage the
hardware (3 and 4). Pry thesuction headout of the
diffuser (7) and remove and discard the suction
head O-ring (8).
Draining Oil From Seal Cavity
(Figure C-2)
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.
With the pump in a vertical position, clean any dirt
fromaroundthepipeplug(12)andremovethe
plug. Remove the seal cavity drain plug (13) and
install a short 3/8 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.
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, screw a pipe in the
dischargeflange(35)andclampitinalargevise,or
removethedischargeflangeandsecuretheflange
studs to a bench or work stand. Be careful not to
damage the terminal housing and cable assembly
(43) while in this position. Use adequate equip-
ment and personnel tosafely handlethe pumpun-
tilitissecured.Ifinvertingthepumpisnotpractical,
lay the pump on its side and secure it to prevent
rolling.
Diffuser Removal
(Figure C-1)
Toremovethediffuser(7),removethesuction
head adjustment nuts (3) from the threaded rods
(2).Disengagethehardware(5and6)securingthe
diffuser to the seal plate (11). Remove thediffuser,
and remove and discard the pump casing O-ring
(51).
Impeller Removal
(Figure C-1)
Wedge a piece of wood between the vanes of the
impeller (2) and the threaded rod (2) to prevent
shaft rotation. Remove the impeller nut (10) and
washer (52).
Remove the wood block. Install the impeller puller
supplied with the pump,and pullthe impellerfrom
theshaft.Usecautionwhenremovingtheimpeller;
tension on the seal spring will be released. Retain
the impeller key (59).
Remove the impeller adjusting shim set (24). For
ease of reassembly, tie and tag the shims or mea-
sure and record their thickness.
Lower Seal Removal
(Figures C-1 and C-3)
Remove the seal spring. Lubricate the shaft, and
workoilup under therubber bellowsoftherotating

MR--05365SM SERIES PUMPS
PAGE C -- 8 MAINTENANCE AND REPAIR
portion of the seal. Carefully slide the rotating por-
tion of the seal assembly off the shaft.
Toremovethestationaryportionoftheseal,prythe
seal plate (42) out of the lower motor housing (47).
Remove and discard the seal plate O-ring (50).
Place a clean cloth on a flat surface and place the
sealplateontheclothwiththeimpellersidedown.
Use a drift pin or screwdriver to press on alternate
sides of the stationary seat until the stationary ele-
ment and seat are removed.
The rotating and stationary seal elements are pre-
cision finished and subject to wear. The complete
seal should be replaced with each overhaul toen-
suretrouble-free operation.However,iftheoldseal
must be reused, wrap the seal faces individuallyin
clean tissue paper to prevent damage to the seal-
ing surfaces.
If no further disassembly is required, proceed to
theappropriateareasinPUMP END REASSEMB-
LY.
Upper Seal Removal
(Figures C-1 And C-3)
Unless cracked, worn, or the O-ring (17) needs re-
placement, it is not necessary toremove the lower
motor housing (47) to remove the upper seal as-
sembly(4). If necessaryto removethe lowermotor
housing,however,seetheprocedureunderMotor
Disassembly in this section. Do not attempt to
loosen the hardware (48 and 49) securing the
bearing cap (18) before referring to this section;
otherwise, the rotor shaft and bearings could be
damaged.
Removethesealsmapring(26)usingsnapringpli-
ers.Usecautionwhenremovingthesnapring;ten-
sionofthesealspringwillbereleased.Removethe
seal spring holder (28) and spring. Lubricate the
shaft adjacent to the seal, and work oil up under
the rubber bellows. Position a screwdriver or other
suitable device on each side of the bellows retain-
ing flange, and pry thebellows upward untilthe ro-
tating portion is off the shaft.
Slide the hooked ends of two stiff wires along the
shaft and under the stationary seal seat. Hook the
back side of the seat, and pull the stationary seat
and O-ring from the lower motor housing.
Withthepumpinverted,stuffacleantissueintothe
seal bore of the lower motor housing (or wrap a
small rag around the shaft) to prevent contamina-
tion or foreign material from entering the motor
cavity.
NOTE
If the motor housing components are to be serv-
iced, see MOTOR DISASSEMBLY in this section.
Do not reassemble the pump end components at
this time.
If no further disassembly is required, proceed to
PUMP END REASSEMBLY.
PUMP END REASSEMBLY
NOTE
Reuse of old O-rings, gaskets, or shaft seal parts
will result in premature leakage or reduced pump
performance. It is strongly recommended that new
gaskets and shaft seal assemblies be used during
reassembly (see the parts lists for numbers).
Cleaning And Inspection Of Pump Parts
(Figure C-1)
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.
Thoroughlycleanallreusablepartswithasoftcloth
soaked in cleaning solvent. Use a clean cloth
lightly dampened with solvent to clean the lower
end of the motor housing, intermediate, and seal
plate. Do not allow the solvent to enter the motor.
Most cleaning solvents are toxic and
flammable. Use them only in a well ven-
tilated area free from excessive heat,

SM SERIES PUMPSMR--05365
MAINTENANCE AND REPAIR PAGE C -- 9
sparks, and flame. Read and follow all
precautions printed on solvent contain-
ers.
RemoveallO-rings,andcleanthesealingsurfaces
of dirt. Be careful not to scratch the surfaces.
Inspect the rotor shaft for damaged threads, scor-
ing, or nicks. Remove nicks and burrs with a fine
fileoremeryclothtorestoreoriginalcontours.Ifthe
shaft is bent or severely damaged, the rotor and
shaft must be replaced as an assembly (see MO-
TOR DISASSEMBLY).
Seal Installation
(Figures C-1 and C-3)
Neither of the shaft seal assemblies should be re-
used because wear patterns on the finished faces
cannot be realigned during assembly. This could
result inpremature failure.If necessary to reusean
oldsealinanemergency,carefullywashallmetal-
lic 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, andother damage thatmight cause leak-
age.Ifanycomponentsareworn,replacethecom-
plete seal; never mix old and new seal parts.
Ifanew sealistobeinstalled,donotunwrapituntil
time of installation. Cleanliness of seal compo-
nents is critical, especially the seal faces.
Cleantherotorshaftandsealcavityareaofthelow-
er motor housing. Be sure the area is dry and free
of lint and dirt. Do not permit cleaning solvent or
debris to fall into the motor cavity.
Install the shaft seals as illustrated in Figure C-3.
RETAINING
RING
STATIONARY
SEAT
ROTATING
ELEMENT
SPRING BELLOWS
STATIONARY
SEAT
STATIONARY
ELEMENT
ROTATING
ELEMENT
SPRING
BELLOWS
RETAINER
BELLOWS ADJUSTING
SHIMS
IMPELLER
ROTOR
AND
SHAFT
ASSY
IMPELLER
KEY
SEAL
PLATE
STATIONARY
SEAT O-RING
LOWER
MOTOR
HOUSING
SPRING HOLDER
BELLOWS
RETAINER
STATIONARY
SEAT O-RINGS
FigureC-3. UpperAndLowerSealAssemblies

MR--05365SM SERIES PUMPS
PAGE C -- 10 MAINTENANCE AND REPAIR
This seal is not designed for operation at
temperaturesabove160_F(71_C).Donot
use at higher operating temperatures.
Upper Seal Installation
(Figures C-1 and C-3)
If a new upper seal assembly is to be installed, do
not unwrap it until time of installation. Cleanliness
of seal components is critical, 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 motor cavity.
Clean the rotor shaft and seal cavity area of the
lower motor housing. Be sure the area is dry and
free of lint and dirt. Do not permit cleaning solvent
ordebristofallintothemotorcavity.Checktheseal
bore for burrs or nicks that might prevent a good
seal. Apply a light coating of oil to the bore.
Unpackthestationarysealseat. Applyalightcoat-
ing of oil to the stationary seat. Keep the sealing
face dry.
NOTE
When installing seal components, use hand pres-
sure only. A push tube cut from a length of plastic
pipe will aid in installing seal components.
Position the stationary seat in the bore with the
sealing face up, and cover it with a clean tissue.
Use your thumbs to press the seat into the bore.
Applyequalpressure onopposite sidesof the seat
untilit is fullyseated in the bore. Remove thetissue
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 circular pattern.
Unpack the rotating portion of the seal. Be certain
thesealface oftherotatingelement is freeof gritor
surfacedamage. Ifrequired,placeasmallamount
of grease at equal spaces on the back of the ele-
ment, and assemble the drive grooves of the rotat-
ingelementintothedrivelugsofthebellowsretain-
er. The grease should hold the element in position
until the seal is installed.
Apply a light coating of oil to the seal seating sur-
face on the shaft, the groove for the retaining ring
(26),andtheI.D.ofthebellows.Applyasingledrop
of lightlubricating oil to the precision-finished seal
face. Position therotating portion of the seal onthe
shaft with the seal face down. Apply firm, steady
pressureonthebellowsretainer untilitslidesdown
the shaft and the seal faces contact. This step
should be done in one continuous motion to pre-
ventthebellowsfromstickingor rollingas itpasses
over the retaining ring groove.
Position the seal spring over the shaft and against
the bellows retainer. Install the spring holder (28)
and secure the seal with the snap ring (26). See
Figure C-3 for proper order of seal assembly.
Lower Seal Installation
(Figures C-1 And C-3)
Thoroughly clean the sealing surfaces and seal
bore of the the seal plate (11). The seal bore must
befreeofburrs and nicks whichcould damagethe
seal.
NOTE
When installing seal components, use hand pres-
sure only. A push tube cut from a length of plastic
pipe will aid in installing seal components.
Unpack the stationary seat, and check that the O-
rings are properly installed. If required, press the
stationary element into the seat, making sure that
the grooves in the element engage the lugs on the
seat. Apply a light coating of oil to the stationary
seat. Keep the sealing face dry.
Positionthe sealplateon aflat surfacewith the im-
pellerside up. Position the seatin the bore withthe
sealing face up, and cover it with a clean tissue.
Use your thumbs to press the seal into the bore.
Applyequalpressureonoppositesidesoftheseal-
ing element until it is fully seated in the bore. Re-
movethetissueandinspectthesealfacetoensure
that itisclean anddry. If cleaningis necessary, use
clean tissue to wipe lightly in a circular pattern.
Lubricate the O-ring (50) with light oil, and install it
in the groove in the seal plate. Carefully position