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.