Gorman Rupp S4B1-E50 Manual OM-06099-01

OM‐06099‐01
March 14, 2008

Rev. C March 10, 2020
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
SUBMERSIBLE PUMPS
MODELS
S4B1-E50 460/3
and
S4B1-E50 575/3
GORMAN‐RUPP PUMPS
www.grpumps.com
2008 Gorman‐Rupp Pumps Printed in U.S.A.

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
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE I - 1
SAFETY ‐ SECTION A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE A - 1
INSTALLATION - SECTION B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 1

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 1
Pump Model Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 1
PREINSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
i
TABLE OF CONTENTS
(continued)
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 - 8
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 - 9
Upper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 10
Lower Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 11
Impeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 11
Suction Head and Strainer Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 12
Strainer Screen and Base Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 12
MOTOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 12
Terminal Housing and Power Cable Removal and Disassembly . . . . . . . . . . . . . . PAGE E - 13
Intermediate and Motor Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 14
Rotor and Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 14
Stator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 15
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 15
Hoisting Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 15
MOTOR REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 15
Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 16
Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 16
Rotor and Intermediate Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 18
Terminal Housing and Power Cable Reassembly and Installation . . . . . . . . . . . . . PAGE E - 18
Sealing Terminal Housing Connections With Silicone Adhesive . . . . . . . . . . . . . . PAGE E - 19
Sealing Terminal Housing Connections With Potting Compound . . . . . . . . . . . . . PAGE E - 20
Terminal Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 21
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 22
VACUUM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 22
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 23
Seal Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 23
Motor Housing Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE E - 24
ii
S SERIES PUMPS OM-06099
INTRODUCTION
Thank You for purchasing a Gorman‐Rupp S Se RECORDING MODEL AND

ries Pump. Read this manual carefully to learn SERIAL NUMBER
how to safely install and operate your pump. Fail
ure to do so could result in personal injury or dam
Please record the pump model and serial number
age to the pump.
in the spaces provided on the inside front cover of
this manual. Your Gorman‐Rupp distributor needs
Because pump installations are seldom identical,
this information when you require parts or service.
this manual cannot possibly provide detailed in
structions and precautions for every aspect of
each specific application. Therefore, it is the re
WARRANTY INFORMATION
sponsibility of the owner/installer of the pump to
ensure that applications not addressed in this The warranty provided with your pump is part of
manual are performed only after establishing that Gorman‐Rupp's support program for customers
neither operator safety nor pump integrity are com who operate and maintain their equipment as de
promised by the installation. Pumps and related scribed in this and the other accompanying litera
equipment must be installed and operated ac ture. Please note that should the equipment be
cording to all national, local and industry stan abused or modified to change its performance be
dards. yond the original factory specifications, the war
ranty will become void and any claim will be de
The pump motor must be operated through the nied.
control box furnished with the pump as standard
equipment. For control box information, consult The following are used to alert personnel to proce
the separate control box manual accompanying dures which require special attention, to those
the unit. which could damage equipment, and to those
which could be dangerous to personnel:
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

Immediate hazards which WILL result in
which are not covered in this manual or in other lit severe personal injury or death. These
erature accompanying the unit, please contact instructions describe the procedure re
your Gorman‐Rupp distributor or the Gorman‐ quired and the injury which will result
Rupp Company: from failure to follow the procedure.
The Gorman‐Rupp Company

P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: (419) 755-1011 Hazards or unsafe practices which
or: COULD result in severe personal injury
Gorman‐Rupp of Canada Limited or death. These instructions describe
70 Burwell Road the procedure required and the injury
St. Thomas, Ontario N5P 3R7 which could result from failure to follow
Phone: (519) 631-2870 the procedure.
INTRODUCTION PAGE I - 1
OM-06098 S SERIES PUMPS
damage which could result from failure to

follow the procedure.
Hazards or unsafe practices which COULD NOTE

result in minor personal injury or product or Instructions to aid in installation, operation, and
property damage. These instructions de maintenance or which clarify a procedure.
scribe the requirements and the possible
PAGE I - 2 INTRODUCTION
SAFETY - SECTION A
This information applies to the S Series
submersible motor driven pumps indi
cated on the front cover of this manual.
Before connecting any cable to the con
Because pump installations are seldom trol box, be sure to ground the control
identical, this manual cannot possibly box. Refer to the Control Box Manual for
provide detailed instructions and pre the suggested grounding methods.
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 The pump motor is designed to be oper
ther operator safety nor pump integrity ated through the control box furnished
are compromised by the installation. with the pump. The control box provides
overload protection and power control.
Do not connect the pump motor directly
to the incoming power lines.
Before attempting to open or service the

pump:
The electrical power used to operate
1. Familiarize yourself with this man this pump is high enough to cause inju
ual. ry or death. Obtain the services of a
2. Lock out incoming power to the qualified electrician to make all electri
control box to ensure that the cal connections. Make certain that the
pump will remain inoperative. pump and enclosure are properly
3. Allow the pump to completely cool grounded; never use gas pipe as an
if overheated. electrical ground. Be sure that the in
4. Close the discharge valve (if coming power matches the voltage and
used). 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.
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 The electrical power used to operate
ger personnel as a result of pump fail this pump is high enough to cause inju
ure. Consult the factory for specific ap ry or death. Make certain that the control
plication data. handle on the control box is in the OFF
SAFETY PAGE A - 1
position and locked out, or that the pow trician to troubleshoot, test and/or ser
er supply to the control box has been vice the electrical components of this
otherwise cut off and locked out, before pump.
attempting to open or service the pump
assembly. Tag electrical circuits to pre
vent accidental start‐up.
Approach the pump cautiously after it

has been running. Although the motor is
cooled by the liquid being pumped, nor
Never attempt to alter the length or re mal operating temperatures can be high
pair any power cable with a splice. The enough to cause burns. The tempera
pump motor and cable must be com ture will be especially high if operated
pletely waterproof. Injury or death may against a closed discharge valve. Never
result from alterations. operate against a closed discharge
valve for long periods of time.
All electrical connections must be in ac

cordance with The National Electric
Do not remove plates, covers, gauges,
Code and all local codes. If there is a
pipe plugs, or fittings from an over
conflict between the instructions pro
heated pump. Vapor pressure within the
vided and N.E.C. Specifications, N.E.C.
pump can cause parts being disen
Specifications shall take precedence.
gaged to be ejected with great force. Al
All electrical equipment supplied with
low the pump to completely cool before
this pump was in conformance with
servicing.
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
Do not attempt to lift the pump by the
sult in severe injury or death and void
motor power cable or the piping. Attach
warranty.
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
After the pump has been installed, make tioned so as not to damage the pump,
certain that the pump and all piping or and so that the load will be balanced.
hose connections are secure before op
eration.
Pumps and related equipment must be

installed and operated according to all na
Obtain the services of a qualified elec tional, local and industry standards.
PAGE A-2 SAFETY

INSTALLATION - SECTION B
GENERAL INFORMATION ratings on the control box and incoming pow
er.
Review all SAFETY information in Section A.
e. Carefully read all tags, decals, and markings
Since pump installations are seldom identical, this on the pump, and perform all duties indicated.
section is intended only to summarize general rec
ommendations and practices required to inspect, f. Check for oil leaks. If there is any indication of
position, and arrange the pump and piping. If there an oil leak, see LUBRICATION at the end of
are any questions concerning your specific instal this manual.
lation, contact your Gorman‐Rupp distributor or PUMP SEAL
the Gorman‐Rupp Company.
There are two shaft seals in the pump. The lower
Liquid level devices are available from Gorman‐ seal prevents liquid from entering the intermediate
Rupp as optional equipment. For information on cavity at the impeller end. The upper seal prevents
installing and operating these items, refer to the lit oil leakage from the motor housing cavity and acts
erature accompanying them. as back‐up protection in the event of lower seal fail
Pump Model Designation ure.
Following is a description of the model numbering LUBRICATION

system for S Series pumps. These submersible These pumps utilize two lubrication cavities. The
pumps are available in a range of sizes. Refer to the motor housing cavity provides lubrication to the
following chart to identify the size of your specific motor assembly and bearings, while the intermedi
pump model. ate cavity provides lubrication to the pump seal.
Pump Model The pumps are fully lubricated when shipped from
S 3 C 1 - E 6.2 230/3 the factory. However, lubrication levels must be
Voltage/Phase checked before installing the pump (see LU
H.P. BRICATION in MAINTENANCE AND REPAIR -
Pump Construction SECTION E). An additional quart (0,9 liter) of oil is
Pump Hydraulics provided to “top off” the oil level in the pump motor
Discharge Size
Series cavity. If the oil level is abnormally low, determine
the cause before putting the pump into service.
PREINSTALLATION INSPECTION
Due to differences in pump design, the quantity of
The pump assembly was inspected and tested be oil and manner in which oil is to be added to the
fore shipment from the factory. Before installation, seal cavity varies between pump models. Refer to
check for damage which may have occurred dur Table B‐2 for oil capacities and positions for filling
ing shipment. Check as follows: the seal cavity in each pump. Motor cavities requir
a. Inspect the pump assembly for cracks, dents, ing lubrication should always be positioned verti
damaged threads, and other obvious dam cally for filling. Refer to LUBRICATION, Section C
age. for lubrication specifications and intervals.
b. Check for loose attaching hardware. Since PUMP INSTALLATION

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. When installing or servicing the pump
d. Check that amperes, phase, voltage and or controls, follow all requirements for
hertz indicated on the name plate match the the installation of wiring or electrical
INSTALLATION PAGE B - 1
equipment as outlined in the National to prevent liquid from wicking through the
Electric Code. Follow all safety require cable and into the motor.
ments. Failure to observe these require NOTE
ments could result in injury or death to Refer to the performance curve in Maintenance
personnel. and Repair - Section E when determining the
most efficient piping installation. The recom
mended maximum submergence depth is 65
feet.
Do not allow the free end of the power

Pump Motor Specifications
cable to enter the liquid being pumped.
The free end of the cable must be kept dry See Table B‐1 for pump specifications.
Table B‐1. Pump Specifications
Model Voltage/ Dual Pump Motor Full No Locked Discharge

Phase Voltage HP/ Speed Load Load Rotor Size
KW (RPM) Amperes Amperes Amperes (NPT)
460/3 71 14 246
S4B NO 50 HP 1750 4 INCH
575/3 57 11 197
Table B‐2. Additional Specifications
Approximate Oil Capacity Seal Cavity

Weight - Lbs. (kg) Ounces (Liters) Filling
Pump Voltage/ Position
Model Phase Seal (H)orizontal
Pump Motor
50 Ft. Cable Cavity (V)ertical
Cavity
460/3
S4B 741 (336) 43 (20) 160 (4,7) 256 (7,6) V
575/3
Pump Dimensions Refer to Table B-2 for the approximate maximum

weight for your pump.
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 motor power cable or the piping. Attach
tag on the unit packaging for the actual weight, and proper lifting equipment to the lifting
use lifting equipment with appropriate capacity. device fitted to the pump. If chains or
Drain the pump and remove all customer‐installed cable are wrapped around the pump to
equipment such as suction and discharge hoses lift it, make certain that they are posi
or piping before attempting to lift existing, installed tioned so as not to damage the pump,
units. and so that the load will be balanced.
PAGE B - 2 INSTALLATION
Positioning the Pump The pump will operate if positioned on its side, but
this is not recommended because the motor
NOTE torque could cause the pump to roll during opera
Before installing and operating the pump, check tion.
the direction of impeller rotation to ensure that the
pump is properly wired at the control box. See IM The pump should be independently secured and
PELLER ROTATION, Section C. supported by the lifting device fitted on the pump.
If the application involves a lot of debris, protect the
pump from excessive wear and clogging by sus
The pump is designed to operate fully or partially
pending it in a perforated barrel or culvert pipe. If
submerged. The rotating parts are oil lubricated,
the bottom is heavily sludge‐covered, rest the
and the motor is cooled by a constant flow of liquid
pump on support blocks or suspend it from a raft
or air discharged through internal passages.
or similar device near the surface of the liquid. See
As a safeguard against rupture or explosion due to Figure B-1 for typical pump installations.
heat, models equipped with oil‐lubricated motors
are fitted with a pressure relief valve which will open All liquid entering the pump must pass through a
if vapor pressure within the pump motor reaches a strainer screen. Any spherical solids which pass
critical point. through the screen will pass through the pump.
BY BAIL IN PERFORATED CULVERT PIPE ON SUPPORTS
Figure B-1 Typical Pump Installations

Piping pump, allowing one pump to feed the other on high
discharge head applications.
No suction piping is required in a standard installa
tion.
To determine the size of the discharge connection,
These pumps are provided with a suction strainer see Table B-1, Pump Specifications. Either
to prevent large solids from clogging the impeller. hose or rigid pipe may be used. To facilitate mobil
If required, the strainer can be removed and the ity and maintenance, it is recommended that the
pump suction “staged” to the discharge of another discharge line be fitted with a quick disconnect fit
ting near the pump. The discharge line must be in sible to the operator, and located close enough to
dependently supported to avoid strain and vibra the pump to avoid excessive voltage drop due to
tion on the pump. cable length (see Pump Power Cable Connec
tion). After the box is installed, make certain the
Either hose or rigid pipe may be used to make dis
front cover latches properly.
charge connections. For maximum pumping ca
pacity, keep the line as short and straight as pos
sible. Elbows and fittings used in discharge lines
increase friction loss, minimize their use.
It is recommended that a check valve or throttling Failure to mount the control box vertically
valve be installed in the discharge line to control si on a level surface may affect operation of
phoning or back flow when the pump is shut off. the pump controls.
Field Wiring Connections (Incoming Power)
ELECTRICAL CONNECTIONS

Install and operate this pump in accor this pump is high enough to cause inju
dance with the National Electrical Code ry or death. Obtain the services of a
and all local codes. Have a qualified qualified electrician to make all electri
electrician perform all checks and con cal connections. Make certain that the
nections in this section. pump and enclosure are properly
Never attempt to alter the length of the grounded; never use gas pipe as an
pump motor cable or to repair it with a electrical ground. Be sure that the in
splice. The power cable and pump mo coming power matches the voltage and
tor must be kept completely waterproof. phase of the pump and control before
Serious damage to the pump and injury connecting the power source. Do not
or death to personnel can result from run the pump if the voltage is not within
any alteration to the cable. the limits.
Control Box Installation

to the incoming power lines. The pump
The pump is designed to be operated
through the control box furnished with motor is designed to operate through a
the pump. The control box provides Gorman‐Rupp approved control box
overload protection and power control. which provides overload protection and
power control; otherwise, the pump
to the incoming power lines. warranty will be voided. Make certain
that the pump and control box are prop
The control box is a rainproof enclosure with a pad
erly grounded. Install and operate the
lockable front cover. The enclosure is not de
control box in accordance with the Na
signed to be watertight, and should not be sub
tional Electric Code and all local codes.
merged. Refer to the control box manual for enclo
Failure to follow these could result in in
sure dimensions and parts.
jury or death to personnel.
Secure the control vertically on a level surface, Field wiring is not provided with the pump, and
above flood level. The box should be easily acces must be supplied by the user. The field wiring must
be of the proper size and type to ensure an ade Table B‐3. Pump Voltage Requirements
quate voltage supply to the pump. Voltage avail NOMINAL MINIMUM MAXIMUM
able at the motor must be within the range indi VOLTAGE PHASE VOLTAGE VOLTAGE
cated in Table B‐3. 460 3 420 500
575 3 520 630
To calculate the voltage available at the motor, pro
ceed as follows: Make certain all connections are tight and that
cable entry points are rainproof. Support the cable
weight, if required, to prevent excessive strain on
a. Measure the voltage across the incoming
cable clamps and cable.
lines (1 & 2 for single phase, 1 & 2, 2 & 3, and 1
Grounding Methods
& 3 for three phase) while the pump is oper
ating at full capacity. Refer to the literature Electrically ground the installation before connect
supplied with the control box for power supply ing the field wiring to the control box. Install a
grounding terminal to the enclosure and connect
connections.
it to a properly embedded electrode.
b. Next, subtract the motor cable voltage drop The material used for the electrode must be an ex
cellent conductor of electricity, such as copper. If
(see Table 4, Pump Power Cable Specifica
iron or steel is used, it must be galvanized or other
tions).
wise metal plated to resist corrosion. Do not coat
the electrode with any material of poor conductiv
c. Do not continue to operate the pump if this ity, such as paint or plastic.
voltage is not within the recommended limits.
The electrode must conform to the recommenda
Obtain the services of a qualified electrician to tions of N.E.C. ARTICLE 250. Follow all installation
determine the correct field wiring size and oth requirements of the N.E.C., and all applicable
er details to ensure an adequate voltage sup codes. See Figure B-3 for some suggested
ply to the pump. grounding methods.
a) PLATE ELECTRODE b) DRIVEN ELECTRODE c) BURIED ELECTRODE
SOIL SOIL SOIL
8 FEET ROCK
1/4 INCH (6,4 MM)
3/4 INCH (19,1 (2,4 M)
STEEL PLATE 2 SQ.
MM) NOMINAL
FEET (1858,1 SQ. CM) 3/4 INCH (19,1 MM)
DIAMETER
SURFACE AREA NOMINAL DIAMETER
(MINIMUM)
(MINIMUM) (MINIMUM) 8 FEET
(2,4 M) LONG
Figure B-3. Suggested Grounding Methods

a. Plate Electrode: An iron or steel plate, 1/4 b. Driven Electrode: A rod or pipe, 3/4 inch
inch (6,4 mm) thick, completely impeded in (19,1 mm) in diameter minimum, 8 feet (2,4 m)
the ground. The plate must present a surface long, completely driven into the ground.
area of at least 2 square feet (1858,1 sq. cm.).
c. Buried electrode: If rock or stone prevents this pump is high enough to cause inju
embedding the full 8 foot (2,4 m) length of the ry or death. Obtain the services of a
ground rod, bury it horizontally in a trench. qualified electrician to make all electri
Space the ground rod or plates at least 6 feet cal connections. Make certain that in
(1,8) from any other electrode or ground rod, coming power to the control box is in the
such as those used for signal circuits, radio OFF position and locked out, or that the
grounds, lightning rods, etc. power supply to the control box has
The earth surrounding the ground rod or plate
been otherwise cut off and locked out,
must contain enough moisture to make a before connecting power or accessory
good electrical connection. In dry or sandy cables.
areas, pour water around the rod, or consult The pump is provided with a 50 ft. (15,2 m) power
qualified personnel to devise a method of im cable (see Table B-4 for standard power cable
proving the connections. specifications). If a longer cable is required, an op
tional cable assembly must be ordered from the
factory. Splicing of the power cable is not recom
mended by the Gorman‐Rupp Company due to
safety and warranty considerations.
this pump is high enough to cause inju
ry or death. Make certain that the control
box is properly grounded after installa
tion. Never attempt to alter the length or re
Refer to the literature accompanying the control pair any power cable with a splice. The
box for field wiring connections. pump motor and cable must be com
Pump Power Cable Connections pletely waterproof. Injury or death may
result from alternations.

Table B‐4. Pump Power Cable Specifications
DC
Amp Resistance Voltage
Cable Conductor Rating (ohms) at Drop
A.W.G O.D. Dia. (See 25C (77F) per 100 ft.
Pump Voltage/ Cable Inches Inches Note Cable per 1000 ft. (30,5m) at
Model Phase Size (mm) (mm) Below) Type (305 m) Max. Load
460/3 6.39
S4B 6 1.01 (26) 0.21 (5) 79** GGC 0.45
575/3 5.13
NOTE: * Amp Rating at 30C (86F) Canada Use Type SOW Cable
** Amp Rating at 40C (104F)
When necessary to change or connect the pump and that the electrical data on the control matches
power cable to the control box, make certain the in the motor name plate data.
coming power is OFF and LOCKED OUT, Make
certain the control box is PROPERLY GROUNDED
Connect the pump power cable to the control box NOTE

as shown in the wiring diagrams in the control box For reference, internal motor wiring connections
manual. Use conduit or cable clamps to secure the are shown in Maintenance and Repair - Section
power cable to the control box. Make certain that E.
all connections are tight and that cable entry points
are rainproof. Liquid Level Devices
NOTE The standard pump is not furnished with a means
The power cable furnished with the pump includes to automatically regulate liquid level. However, the
three electrical conductors (white, red, and black), pump may be controlled to perform filling or dewa
two grounding conductors (green) and one ground tering functions by using either of the following op
check conductor (yellow). The yellow ground tional sensing devices (see Figure B-4):
check lead is used in conjunction with customer‐
supplied ground monitoring equipment. If this Diaphragm Type: two fixed‐position sen
equipment is not used, the yellow lead should be sors (upper and lower) each contain a dia
phragm which flexes with changes in liquid
used as a ground conductor.
level, thus activating an enclosed miniature
switch.
Control Box Specifications Bulb (Float) Type: a bulb raises or lowers
(floats) with the liquid level, thus activating
an enclosed miniature switch.
The liquid level circuitry may be prewired as a fac
Any control box used to operate the tory option, or easily added to the standard control
pump must be approved by the Gor box in the field by qualified personnel. The unit is
man‐Rupp Company for the application. complete except for the remote float switches. For
installation and operation, see the detailed instruc
Motor Cable Grounding Test
tions included with the optional package.
Do not connect the pump control cable

to the control box or incoming voltage Liquid level devices must be positioned far
enough apart to allow 10 minutes between
before verifying the pump ground;
starts. If the pump motor cycles more than
otherwise, personnel will be exposed to 6 starts per hour, it will over‐heat, resulting
serious injury or death. in damage to the motor windings or control
Using a volt‐ohm meter, connect one lead to the box components.
motor cable green/yellow ground lead. Connect
Other types of liquid level devices may also be
the other lead to an uninsulated point on the pump
used. Consult the factory for the liquid level device
body. The test circuit should close.
best suited for your application.
If the test circuit does not close, there is a defect in
the cable or motor which must be corrected.
Control Box Connections
This pump is shipped completely wired for the volt If the pump requires liquid level devices,
age shown on the name plate, and is ready for op install the liquid level devices and connect
eration through an approved control box. them to the control box in accordance with
Ground and wire the control box in accordance the instructions accompanying the de
with the instructions accompanying it. vices.
PUMP PUMP
CONTROL BOX CONTROL BOX
TO LEVEL CONTROL CIRCUIT TO LEVEL CONTROL CIRCUIT

IN MAIN CONTROL BOX IN MAIN CONTROL BOX
LIQUID LEVEL LIQUID LEVEL

RANGE RANGE
OFF OFF
DEWATERING DEWATERING
ON (FILLING) ON (FILLING)
BULB (FLOAT TYPE) DIAPHRAGM TYPE
Figure B-4. Liquid Level Devices

cluded with the option before making wir
ing connections.
WIRING DIAGRAMS
The internal wiring of the sensing devices Refer to the appropriate wiring diagram in the liter
are different for filling and dewatering func ature accompanying the control box when making
tions. Be sure to follow the instructions in electrical connections.
OPERATION - SECTION C
GENERAL INFORMATION

The pump motor and control box are not
designed to be explosion‐proof. Do not
operate in an explosive atmosphere.
Any control box used to operate the
This pump is designed to handle most pump must be approved by the Gor
non‐volatile, non‐flammable liquids. Do man‐Rupp Company for the application.
not attempt to pump any liquids for Improper location of a non‐explosion
which your pump is not approved, or proof control box could result in de
which may damage the pump or endan struction of equipment, injury or death
ger personnel as a result of pump fail to personnel.
ure. Consult the factory for specific ap
See the operating instructions furnished with the
plication data.
control box, and with other optional accessories
Follow the instructions on all tags, labels and de and controls, before attempting to start the pump.
cals attached to the pump.
PUMP OPERATION
Pump Performance
Liquid Temperature and Overheating.
Since operation of the pump motor is de

pendent upon the quality and performance Overheated pumps can cause severe
of the electrical controls, the pump warran burns and injury. If the pump becomes
ty is valid only when controls have been overheated:
specified or provided by The Gorman‐ 1. Stop the pump immediately.
Rupp Company. 2. Lock out the power to the control
Refer to the performance curve in Maintenance
panel to ensure that the pump will
and Repair - Section E for the specific perfor remain inoperative.
mance for your pump. 3. Allow the pump to completely cool
if overheated.
Control Box 4. Close the discharge valve (if
used).
A control box is provided to facilitate operation of
5. Refer to instructions in this manual
the pump. It contains controls for starting and stop before restarting the pump.
ping the pump, and provides overload protection Overheating can occur if the pump is misapplied;
for the pump motor. The pump control may be if it is started more than 6 times within one hour; if
equipped with an optional automatic liquid level the temperature of the liquid being pumped ex
sensing device, in which case those circuits are ceeds the temperature for which the pump was de
also contained within the control box. signed, if the control box fails to provide overload
OPERATION PAGE C - 1
or thermal protection, or if the pump is operated 4. Check the temperature before ser
against a closed discharge valve for an extended vicing.
period of time. 5. Vent the pump slowly and cau
tiously
6. Refer to instructions in this manual
before restarting the pump.
It is recommended that the pressure relief valve as
Do not start the pump more than 6 times sembly be replaced at each overhaul, or any time
per hour. If the motor does not cool be the pump motor overheats and activates the valve.
tween starts it will overheat, resulting in Never replace this valve with a substitute which
damage to the motor windings. has not been specified or provided by the Gorman‐
Rupp Company.
As a safeguard against rupture or explosion due to
heat, models equipped with oil‐lubricated motors Impeller Rotation
are fitted with a pressure relief valve which will open
if vapor pressure within the pump motor reaches a Check impeller rotation as follows before operation
critical point. Always terminate power to the pump to ensure that the impeller is rotating in the correct
and control before investigating pump or control direction.
box problems.
While checking impeller rotation, secure

Approach the pump cautiously after it the pump to prevent the power cable from
has been running. Although the motor is coiling.
cooled by the liquid being pumped, nor Suspend the pump from the lifting device fitted on
mal operating temperatures can be high the pump. Apply power briefly and note the direc
enough to cause burns. The tempera tion of pump kickback. As viewed from the top, the
ture will be especially high if operated pump should kick in a counterclockwise direc
against a closed discharge valve. Never tion; this will indicate that impeller rotation is cor
operate against a closed discharge rect.
valve for long periods of time.
If the pump kicks in a clockwise direction, impeller
If overheating does occur, stop the pump immedi rotation is incorrect. If the pump is powered by a
ately and allow it to cool before servicing it. Ap three‐phase motor, have a qualified electrician in
proach any overheated pump cautiously. terchange the control box connections of any two
pump motor power leads. Re‐check pump kick
back; it should now be in a counterclockwise direc
tion.
If rotation is incorrect on a single‐phase motor, con

Overheated pumps can cause severe tact the factory before installing the pump.
burns and injuries. If overheating of the
pump occurs:
1. Stop the pump immediately.
2. Ventilate the area.
3. Allow the pump to completely cool. The electrical power used to operate
PAGE C - 2 OPERATION
this pump is high enough to cause inju

ry or death. Make certain that incoming
power is off and locked out before inter
changing motor leads. Never start the pump more than 6 times per
hour. If the pump motor does not cool be
tween starts, it will over‐heat, resulting in
damage to the motor windings.
Stopping
Follow the instructions accompanying the control

DIRECTION OF
KICKBACK box for stopping the pump.
AT STARTUP
On pumps equipped with a motor ther

mal protector, the integral thermal over
load device will shut off the motor if the
temperature rises above design limits.
When the pump cools and the tempera
ture falls below these limits, the motor
will restart automatically. To avoid the
hazards of an unexpected motor start‐
up, do not attempt to handle or service
Figure C-1. Checking Pump Rotation the pump unless all power to the motor
has been shut off and locked out at the
control box; otherwise, serious person
STARTING, STOPPING, AND al injury could result.
OPERATIONAL CHECKS During motor shutoff by the thermal
overload device, control box circuits re
main live. Do not attempt to service any
Starting control box components unless incom
ing power has been shut off.
To stop the pump, turn the control handle OFF,
thereby opening the circuit breakers. This does
not terminate incoming power through the field
wiring connected to the control box.
Do not attempt to operate the pump until
After stopping the pump, be sure to perform all re
impeller rotation has been checked; im
quired maintenance and preservation procedures.
proper rotation will affect pump perform
ance and may damage the pump. Operational Checks
Follow the instructions accompanying the control To detect minor problems, check the pump for
box, start the pump, and run any recommended proper operation when it is first started, and at peri
checks. odic intervals during operation.
COLD WEATHER PRESERVATION
To avoid serious damage to the pump,

check for unusual noises or excessive vi
bration while the pump is running. If noise Do not attempt to thaw the pump by us
or vibration is excessive, stop operation ing a torch or other source of flame. This
and refer to the troubleshooting chart in the could damage gaskets, O‐rings or heat
maintenance and repair manual. the oil in the seal housing above critical
temperatures, causing the pump to rup
The suction inlet or impeller may become clogged
ture or explode.
with debris. In some cases, stopping the pump
momentarily may backflush this blockage. If back The pump will not freeze as long as the casing is
flushing does not clear the debris, remove the submerged in liquid. If the casing is not sub
pump from the sump or wet well and clear manu merged, or if the liquid begins to freeze, remove the
ally. pump from the sump or wet well and dry it thor
oughly. Run the pump for two or three minutes to
dry the inner walls.
If the pump does freeze while it is out of the liquid,

submerge it until thawed; if the liquid is near freez
Never introduce air or steam pressure
ing, the pump must be submerged for an extended
into the pump casing to remove a block period of time. Check thawing by starting the pump
age. This could result in personal injury and checking that the shaft rotates freely. If the
or damage to the equipment. If back pump remains frozen, allow additional thawing
flushing is absolutely necessary, limit time before attempting to restart.
liquid pressure input to 50% of the maxi
mum permissible operating pressure If submerging does not thaw the pump, move it
shown in the pump performance curve into a warm area until completely thawed.
(refer to the accompanying Parts List
Manual). LUBRICATION
Check the pump for overheating. Overheating can
occur if the pump is misapplied, required to start
repeatedly, if the control box fails to provide over
load or thermal protection, or if the pump is oper
ated against a closed discharge valve for an ex Do not remove plates, covers, gauges,
tended period of time. 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
Do not start the pump more than 6 times servicing.
per hour. If the motor does not cool be
On a new pump, check the oil level in both seal and
tween starts it will overheat, resulting in
motor cavities before initial startup, and drain and
damage to the motor windings.
replace the oil after the first 200 hours of operation.
Check the oil level(s) as indicated in the following Following this, check the oil level in the seal cavity
LUBRICATION section. after the first two weeks of operation, and every
month thereafter. Check the motor lubrication level Adding Oil

any time the pressure relief valve is activated, and
replace the oil annually. Refer to Table B-2 in INSTALLATION for oil ca
pacities and positions for filling the seal cavity in
Before installing or removing the lubrication your pump. Motor cavities requiring lubrication
plug(s), always clean the area around the plug(s) should always be positioned vertically for filling.
to prevent contamination.
The grade of lubricant used is critical to the opera
tion of this pump. Use premium quality submers
Draining Oil
ible pump oil as specified in the following table. Oil
must be stored in a clean, tightly closed container
Refer to the Parts List in Maintenance and Repair in a reasonably dry environment.
- Section E for drain plug location.
When lubricating the seal cavity, remove the lu
Remove the drain plug slowly to release any pres brication plug as indicated in Draining Oil, and
sure. Install a short pipe nipple in the hole. Place a position the pump as indicated in Table B-2. Add
clean container under the plug and, using a hoist, premium quality submersible pump oil through
tilt the pump at an angle of approximately 60. this plug hole. If the pump is to be positioned verti
cally or at an angle, fill the cavity to the bottom of
Repeat the procedure for the motor housing oil. the plug hole. If the pump is to be positioned hori
zontally, completely fill the cavity.
Condition Of Oil
Install and tighten the lubrication plug.
Check the condition of the oil drained from the When lubricating the motor cavity, add oil through
pump. Clear oil indicates that the pump seal(s) are the hole for the pressure relief valve. If the pump is
functioning properly. If the oil is milky or contains equipped with a motor lubricant level plug, remove
a small amount of water, it must be changed. this plug and fill the cavity until oil escapes through
the hole. If the pump is not equipped with a motor
If the oil contains a large amount of water, it must lubricant level plug, fill the cavity to the top of the
be changed, and the seal(s) must be checked be hole.
fore the pump is put back in operation (refer to the
Maintenance and Repair Manual). Reinstall the pressure relief valve.
Table C-1. Pump Oil Specifications
Specifications:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium high viscosity index, anti‐wear hydraulic oil
Viscosity @ 100F (38C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 to 155
Viscosity @ 210F (99C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 to 50
Dielectric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,000 (volts‐min)
Recommended supplier:
Gulf Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gulf Harmony HVI AW 26
Acceptable alternate suppliers:
Gulf Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gulf Harmony 32 AW
Texas Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rando HD 32 or HD AZ 32
Sun Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sunvis 816 or 916
BP (Also Boron) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Energol‐HLP 32
Shell Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tellus 32, Tellus T‐23 or T32
ARCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duro 32
Exxon (Also Esso) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuto H 32
Petro‐Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harmony HVI 22
TROUBLESHOOTING - SECTION D
NOTE
Many of the probable remedies listed in the TROU
BLESHOOTING CHART require use of electrical
test instruments; for specific procedures, see
ELECTRICAL TESTING at the end of the chart.
TROUBLESHOOTING CHART
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO Power source incompatible with con Correct power source.
START, OVER trol box.
LOAD UNIT NOT
No voltage at line side of circuit Check power source for blown fuse,
TRIPPED (MANU
AL MODE). breaker. open circuit breaker, broken lead or
loose connections.
Open circuit in motor windings or Check continuity.
power cable.
Defective motor power cable. Replace cable.
Defective motor. Check for and replace defective mo
tor components.
PUMP FAILS TO Liquid level device or control circuits Check wiring diagrams: cor
START, OVER improperly connected to main con rect or tighten connections.
LOAD UNIT NOT trol box.
TRIPPED (AUTO
MATIC MODE). Level sensing device(s) improperly Position device(s) at proper
positioned. level.
Level sensing device(s) fouled with Clean sensing device(s).
mud or foreign material.
Float type sensing device(s) tangled Check installation for free
or obstructed. movement of float.
Defective liquid level sensing de Repair or replace defective unit(s).
vice(s) or control panel.
OVERLOAD UNIT Low or high voltage, or excessive Measure voltage at control box.
TRIPS voltage drop between pump and Check that wiring is correct type,
control box. size, and length (see Field Wiring
Connection, Section B).
Defective insulation in motor wind Check insulation resistance; check

ings or power cable; defective wind continuity.
ings.
Impeller jammed due to debris or in Disassemble pump and check im
sufficient clearance. peller.
Bearing(s) frozen. Disassemble pump and check bear
ing(s).
TROUBLESHOOTING PAGE D - 1
TROUBLESHOOTING CHART (cont'd)

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
MOTOR RUNS, Discharge head too high. Reduce discharge head or install
BUT PUMP FAILS staging adaptor and additional
TO DELIVER pump.
RATED DIS Low or incorrect voltage. Measure control box voltage, both
CHARGE.
when pump is running and when
shut off.
Discharge throttling valve partially Open discharge valve fully; check
closed; check valve installed improp piping installation.
erly.
Discharge line clogged or restricted; Check discharge lines; straighten
hose kinked. hose.
Liquid being pumped too thick. Dilute liquid if possible.
Strainer screen or impeller clogged. Clear clog(s). Stop pump; back flow
may flush away debris.
Insufficient liquid in sump or tank. Stop pump until liquid level rises.
Worn impeller vanes; excessive im Check impeller and clearance (see
peller clearance. PUMP END REASSEMBLY in
Maintenance and Repair, Section
E).
Pump running backwards. Check direction of rotation. If incor
rect, interchange any two motor
leads at the control box (see Pump
Rotation, Section C).
PUMP RUNS Pumping entrained air. Check liquid level in sump; check
WITH EXCES position of pump and liquid level
SIVE NOISE OR sensing device(s).
VIBRATION
Damaged or unbalanced impeller. Replace impeller.
Discharge piping not properly sup Check piping installation.
ported.
Impeller jammed or loose. Check impeller.
Motor shaft or bearings defective. Disassemble pump and check mo
tor and bearings.
Pump is cavitating. Reduce discharge head or restrict
flow on low head applications.
PAGE D - 2 TROUBLESHOOTING
ELECTRICAL TESTING 3. The pump submerged and running under

full load.
Make the electrical checks which follow to deter
mine if pump malfunctions are being caused by The voltage measured under each condition
problems in the motor or in the motor cable. must be the same.
Test Equipment b. If voltage is balanced when the pump is off but

is imbalanced when the pump is running,
A volt/amp/ohmmeter and megohmmeter of ade thoroughly check the power source, all inter
quate range and quality are required to conduct connecting cables, and the pump motor to
the electrical tests which follow. isolate the defect.
c. Use an Amprobe or equivalent instrument to

Equipment Use measure the current draw (amperage) of
each phase while the pump is running under
Ammeter To check AC Voltage full load, and with no load. In each condition,
and current (amperage) the amperage readings for all three phases
must match as closely as can be measured.
Ohmeter To measure resistance Normal amperage values are listed in Table 1,
(ohms) to ground Section B; these values apply only when the
voltage at the site is the normal voltage listed.
Motor and Power Cable Continuity

Set the megohmmeter at R x 1 scale and zero‐ba
lance it. Test as follows:
a. Shut off incoming power to the control box,
Refer to the wiring diagram(s) accompany and disconnect the motor power cable leads.
ing the motor and control box before re Connect the megohmmeter test leads to any
connecting any electrical leads which have two power cable leads, and note the
been disconnected. Connections to the megohmmeter reading. A high resistance
wrong terminals may damage the motor reading indicates an open or broken circuit in
and/or control devices. the power cable or motor windings, or a bad
connection between the motor and cable.
Voltage Imbalance
Use a voltmeter to read each phase of the incom b. Repeat Step a. with each set of leads. The
ing 3 phase power. Each phase must balance with three readings shall be as close as can be
the other two as closely as can be measured with a measured.
commercial instrument. If the phases are out of
c. If readings indicate that continuity problems
balance, contact your power company. If the
exist in the motor or motor cable, the motor
phases are balanced, check out the motor as de
must be returned to the factory or to a U/L‐ap
scribed in the following steps:
proved facility.
a. Use a voltmeter, Amprobe, or equivalent in
strument to read the voltage of incoming
Insulation Resistance
power lines 1 and 2, 2 and 3, and 1 and 3 at the
control box. Voltage must match as closely as Set the megohmmeter at R x 100, and zero‐ba
can be measured. If possible, measure the lance it. Test as follows:
voltage at the control box with: a. Shut off incoming power to the control box,
and disconnect the motor power cable leads.
1. The pump shut off. Connect one megohmmeter test lead to the
2. The pump running in air. motor cable green/yellow ground lead. Touch
TROUBLESHOOTING PAGE D - 3
the other test lead to each of the motor cable should be rechecked regularly. If resistance
leads in turn. Note the readings. reads less than 1 megohm, insulation should
be checked more closely and frequently.
b. Readings will indicate resistance values in
both the power cable and motor windings.If
resistance reads infinity (1), insulation is c. If readings indicate that a ground exists, test
good. If resistance reads between infinity (1), the stator and motor power cable separately.
and 1 megohm, insulation is acceptable but Replace as required.
PAGE D - 4 TROUBLESHOOTING
PUMP MAINTENANCE AND REPAIR - SECTION E
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK
OPERATING PERFORMANCE.
STANDARD PERFORMANCE FOR PUMP MODELS S4B1-E50 460/3 AND S4B1-E50 575/3
Based on 70F (21C) clear water at sea level Contact the Gorman‐Rupp Company to verify per
with minimum suction lift. Since pump installations formance or part numbers.
are seldom identical, your performance may be dif
ferent due to such factors as viscosity, specific
gravity, elevation, temperature, and impeller trim.
Pump speed and operating condition

If your pump serial number is followed by an “N”, points must be within the continuous per
your pump is NOT a standard production model. formance range shown on the curve.
MAINTENANCE AND REPAIR PAGE E - 1

SECTION DRAWING
PARTS PAGE
Figure E-1. S4B1-E50 460/3 And S4B1-E50 575/3 Pump Assemblies
PAGE E - 2 MAINTENANCE AND REPAIR

S4B1-E50 460/3 And S4B1-E50 575/3 Pump Assemblies

Parts List
(From S/N 1396095 Up)
If your pump serial number is followed by an “N”, your pump is NOT a standard production model. Contact
the Gorman‐Rupp Company to verify part numbers.
ITEM PART NAME PART QTY ITEM PART NAME PART QTY
NO. NUMBER NO. NUMBER
1 DIFFUSER 10092A 11030 1 43 LOWER BALL BEARING 23431-461 1

2 IMPELLER 10091 11030 1 44 BEARING CAP 10087 10010 1
3 LOWER SEAL ASSY 12430 1 45 STUD C0811 17000 6
4 UPPER SEAL ASSY S1934 1 46 HEX NUT D08 17000 6
5 HEX HD CAPSCREW B1012 15991 6 47 LOCKWASHER J08 17000 6
6 HEX NUT D10 15991 6 48 HEX HD CAPSCREW B0608 15991 4
7 LOCKWASHER J10 15991 6 49 LOCKWASHER J06 15991 4
8 DIFFUSER GSKT 10092G 20000 1 50 INTERMEDIATE 10093 13040 1
9 ADJ SHIM SET 37J 17090 REF 51 STRAINER PLATE GSKT 10056G 20000 1
52 STRAINER PLATE 10054 13040 1
10 UPPER IMP WASHER 10047A 17000 1
11 SEAL DRAIN PLUG P06 17000 1 53 SUCT HEAD O‐RING 25151-463 1
12 SEAL FILL PLUG P06 17000 1 54 STRAINER SCREEN 10090 1
13 MOTOR DRAIN PLUG P06 17000 1 55 BASE PLATE 10036 13080 1
14 RETAINING RING S245 1 56 HEX HD CAPSCREW B1042 15991 6
15 BEARING CAP GSKT 10085G 20000 1 57 HEX NUT D10 15991 6
58 LOCKWASHER J10 15991 6
16 MOTOR HOUSING GSKT 10106G 20000 1
59 DIFFUSER STUD 10782A 17000 5
17 MOTOR HOUSING GSKT 10110G 20000 1 60 NYLON LOCKNUT BC08 17000 5
18 MOTOR HOUSING GSKT 10112G 20000 1 61 SUCT HEAD ASSY 42111-426 1
19 MOTOR HOUSING ASSY 42822-023 24130 1 62 IMPELLER WASHER 10773 17000 1
20 MOTOR OIL LEVEL PLUG P06 17000 1
63 IMPELLER JAM NUT AT14S 17000 1
21 HEX HD CAPSCREW B1006 15991 2
22 LOCKWASHER J10 15991 2 64 IMPELLER KEY N0406 17000 1
23 WASHER 21161-442 2 NOT SHOWN:
24 HOISTING BAIL 10094 1 CONTROL BOX
25 BAIL BUSHING 10095 15071 2 -460V 27515-505 1
-575V 27515-515 1
26 DISCH FLANGE GSKT 1676G 18000 1
HEATER PACK
27 DISCHARGE FLANGE 1756 10010 1
-460V 27521-211 1
28 DISCH FLANGE STUD C1010 15991 8
-575V 27521-210 1
29 HEX NUT D10 15991 8
1 QT SUB MOTOR OIL 9568 1
30 PIPE CAP V16 11999 1
MOTOR VOLTAGE TAG
31 STREET TEE ASSY 14138 1
-460V 6588BL 1
32 PRESS RELIEF VALVE 14139 1
-575V 6588BM 1
33 FILL TUBE ASSY 10040 24040 1
IMPELLER PULLER 5894 1
34 HEAVY PIPE NIPPLE THA1612 15079 1 OPTIONAL:
35 STUD C0607 15991 6
REPAIR GASKET SET 11000J 1
36 DEFORM LOCKNUT DD06 15991 6 HEAT‐SHRINK TERM KIT 48315-005 1
37 TERM HSG/CABLE ASSY 47367-059 1 ANODE PLATE ASSY 42116-002 1
38 UPPER BALL BEARING S1080 1 STAGING ADAPTOR KIT 48272-005 1
39 ROTOR/SHAFT ASSY 47112-081 1 LIQUID LEVEL DEVICES:
40 STATOR ASSY DIAPHRAGM TYPE GRP48-03 1
-460V 47113-083 1 GRP048 1
-575V 47113-084 1 FLOAT TYPE 27471-155 1
41 NAME PLATE 2613CY 17020 1 120V LIQUID LEVEL 27521-321 1
42 DRIVE SCREW BM#04-03 17000 6 CONTROL RELAY
INDICATES PARTS RECOMMENDED FOR STOCK

SECTION DRAWING
Figure E-2. Terminal Housing And Cable Assembly

Terminal Housing And Cable Assembly
Parts List
ITEM PART
NO. PART NAME NUMBER QTY
1 TERMINAL GLAND 11367 13040 1

2 POWER CABLE 10325S 1
3 CABLE GRIP 11227L 1
4 STUD C0808 17000 2
5 HEX NUT D08 17000 2
6 GLAND BUSHING 10758K 19100 1
7 TERMINAL WASHER 10659 15991 1
8 TERMINAL HOUSING 11366 13040 1
9 TERMINAL S1949 1
10 HEAT‐SHRINK TUBE 31413-014 19530 3
11 AL HD SETSCREW GA0501 1/2 14990 3
12 TERMINAL COLLAR 10144 14100 3
13 TERMINAL PLT ASSY 11163 24010 1
14 TERMINAL POST 38724-009 14100 3
15 AL HD SETSCREW GA0501 1/2 14990 3
16 DYNA SEAL WASHER S1586 3
17 TERMINAL S1550 1
18 RD HD MACH SCREW X0603 14990 2
19 T‐TYPE LOCKWASHER AK06 15991 2
20 DRIVE SCREW BM#04-03 17000 4
21 INFORMATION PLATE 38816-047 17990 1
NOT SHOWN:
RTV SEALANT 18771-106 1
INDICATES PARTS RECOMMENDED FOR STOCK

PUMP AND SEAL DISASSEMBLY AND used, disconnect the piping before attempting to
REASSEMBLY move the pump.

motor power cable or the piping. Attach
Do not attempt to service the pump as proper lifting equipment to the lifting
sembly unless all power to the motor device fitted to the pump. If chains or
has been shut off at the control box; cable are wrapped around the pump to
otherwise, injury or death could result. lift it, make certain that they are posi
tioned so as not to damage the pump,
Use a lifting device with sufficient ca and so that the load will be balanced.
pacity. If slings or chains are used to
Check the chart in TROUBLESHOOTING, Section
move the pump or components, make
D of this manual, to determine the nature of the
sure that the load is balanced; other
pump problem. If the problem is mechanical in na
wise serious personal injury or death
ture, such as worn pump parts, seal replacement,
could result. lubrication, etc., refer to PUMP END DISASSEM
The maintenance and repair instructions in this BLY for instructions.
manual are keyed to the sectional views, Figures
E-1 and E-2, and the corresponding parts lists. If the problem is electrical, complete disassembly
may not be required. Refer to Electrical Testing in
Select a suitable location, preferably indoors, to TROUBLESHOOTING, Section D, and have a
perform required maintenance. All work must be qualified electrician check the control box, cable
performed by qualified personnel. and terminal housing. If the problem is determined
to be in the motor, proceed with PUMP END DIS
ASSEMBLY, followed by MOTOR DISASSEMBLY.
Otherwise, see Terminal Housing And Power Ca
ble Disassembly.
All repairs to the pump motor must be per
formed by a Gorman‐Rupp authorized
Submersible repair facility or the factory.
Any repairs to the motor assembly per
formed by the customer or an unautho The electrical power used to operate
rized repair facility negates the warranty. this pump is high enough to cause inju
This section provides maintenance instructions re ry or death. Make certain that the control
quired to properly service the pump components. handle on the control box is in the off po
Pump motor maintenance may be performed only sition and locked out, or that the power
by a Gorman‐Rupp authorized Submersible repair supply to the control box has been
facility, or the factory. Otherwise, the pump warran otherwise cut off and locked out, before
ty will be negated, and damage to the pump, and attempting to open or service the pump
injury or death to personnel can result. Contact the assembly. Tag electrical circuits to pre
factory for the authorized repair facility closest to vent accidental start‐up.
you.
Carefully inspect any O‐rings or gaskets before re
Use the hoisting bail to remove the pump from the moval and cleaning to determine if a proper seal
wet well or sump, and move it to a location where and compression existed prior to disassembly. If
the discharge line can be removed. It is not neces sealing was faulty or questionable, the cause must
sary to disconnect a flexible discharge hose before be determined and corrected before reassembly.
removing the pump. If rigid discharge piping is All gaskets and most O‐rings must be replaced if

disturbed. Repair gaskets and O‐rings are listed in move the plug slowly and permit pressure
the Parts List. to vent to atmosphere.
Lay the pump on its side with the pipe plugs (12
and 13) facing up. Clean any dirt from around the
plugs. Remove the seal cavity drain plug (12), and
install a short 3/8‐inch NPT nipple in the hole. Tip
Use Only Genuine Gorman-Rupp re the pump and drain the seal oil into a clean con
placement parts. Failure to do so may cre tainer. Inspect the oil for water, dirt, or cloudy condi
ate a hazard and damage the pump or di tion which could indicate lower seal failure or poor
minish optimal pump performance. Any gasket seal.
such hazard, damage or diminished per
formance is not covered by the warranty. Draining Oil From Motor Cavity
NOTE (Figure E-1)

When appropriate recycling facilities are available,
the user should recycle components and fluids If motor problems are suspected, remove the mo
when doing any routine maintenance / repairs and tor cavity drain plug (13), and install a short nipple
also at the end of the pump’s useful life. All other in the hole. Tip the pump and drain the motor oil
components and fluids shall be disposed of ac into a clean container. Inspect the oil for dark color
cording to all applicable codes and regulations. 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
PUMP END DISASSEMBLY
gaskets or seals.
Strainer Removal Positioning Pump For Disassembly

(Figure E-1) (Figure E-1)
To remove the strainer screen and base plate (54 It is recommended that the pump be positioned
and 55), raise the pump slightly, or lay it on its side upside‐down during disassembly. To hold the
and disengage the hardware (56, 57 and 58) se pump in the inverted position, rest the pump se
curing the strainer and base plate to the diffuser curely on blocks. Be careful not to damage the
(1). If the impeller (2) is clogged, the debris can pressure relief valve (32) and the terminal housing
usually be removed without further disassembly. and cable assembly (37) while in this position. Use
adequate equipment and personnel to safely han
dle the pump until it is secured. If inverting the
Draining Oil From Seal Cavity
pump is not practical, lay the pump on its side and
(Figure E-1) secure it to prevent rolling.
If any further disassembly is to be performed on the Strainer Plate And Suction Head Removal
pump, the seal oil cavity must be drained.
(Figure E-1)
Remove the hardware (5, 6 and 7) securing the

strainer plate (52) to the intermediate (50). Remove
the strainer plate. Discard the strainer plate gasket
Let the pump cool before removing the (51) and the suction head O‐ring (53). Remove the
seal cavity drain plug. Pressure built up nylon locknuts (60) securing the suction head (61)
within a hot pump could cause the oil to to the diffuser (1). Pull the suction head off the dif
spray out when the plug is removed. Re fuser studs (59).

Impeller Removal Upper Seal Removal
(Figures E-1 and E-3)
(Figure E-1)
Unless cracked or otherwise worn, it is not neces
sary to remove the intermediate (50) for access to
Wedge a block of wood between the vanes of the the upper seal assembly (4).
impeller (2) and the suction head studs (59) to pre
vent impeller rotation. Remove the impeller nut (63) NOTE
and washer (62). Remove the wood block from be Do not attempt to loosen the hardware (48and 49)
tween the vanes of the impeller. securing the bearing cap (44) to the intermediate
(50) at this time (see MOTOR DISASSEMBLY). The
rotor shaft and bearings could be damaged.
Install the impeller puller (supplied with the pump)
and pull the impeller from the rotor shaft. Use cau
tion when removing the impeller; tension on the Remove the seal retaining ring (14) using snap ring
seal spring will be released. Retain the impeller key pliers. Use caution when removing the retaining
(64). Inspect the impeller for wear or damage and ring; tension on the seal spring will be released.
replace as required. Remove the spring retainer and seal spring.
Lubricate the rotor shaft (39) and work oil up under
Remove the impeller adjusting shims (9) and the the bellows. Use the hooked ends of two stiff wires
upper impeller washer (10). Tie and tag the shims to hook the retainer and pull the rotating portion of
for ease of reassembly. the seal off the shaft.
Slide the hooked ends of two wires along the shaft
If no further disassembly is required, proceed to and under the stationary seal seat. Hook the back
the appropriate areas in PUMP END REASSEMB side of the seat and pull it from the intermediate
LY. bore.
If no further disassembly is required, proceed to
the appropriate areas in PUMP END REASSEMB
Lower Seal Removal
LY.
(Figures E-1 and E-3) NOTE
Do not disassemble the motor unless it is neces
sary and a clean, well‐equipped shop is available. If
Carefully remove the seal spring. Lubricate the ro
the motor housing components are to be serviced,
tor shaft (39) and work oil under the bellows as
see MOTOR DISASSEMBLY in this section. Do not
sembly. Use the hooked ends of two stiff wires to
reassemble the end components at this time.
hook the retainer and pull the rotating portion of the
seal off the shaft.
PUMP END REASSEMBLY
To remove the stationary portion of the seal, use a
pair of screwdrivers to pry the diffuser (1) out of the NOTE
intermediate (50). Slide the diffuser off the shaft. Reuse of old O‐rings, gaskets, or shaft seal parts
Remove and discard the diffuser gasket (8). Place will result in premature leakage or reduced pump
a clean cloth on a flat surface and place the diffuser performance. It is strongly recommended that new
on the cloth with the impeller side down. Use a drift gaskets and shaft seal assemblies be used during
pin or screwdriver to press on alternate sides of the reassembly (see the parts list for numbers).
stationary seat until the stationary seat and O‐rings
are removed.
Cleaning And Inspection Of Pump Parts
(Figure E-1)
If no further disassembly is required, proceed to
the appropriate areas in PUMP END REASSEMB With the pump inverted, stuff a clean tissue into the
LY. stationary seal seat bore of the intermediate (50) or

wrap a small rag around the shaft to prevent for fine file or hand honing stone to restore original
eign material from entering the motor cavity. contours. If the shaft is bent or severely damaged,
the rotor and shaft must be replaced as an assem
Carefully inspect any O‐rings or gaskets before re bly (see MOTOR DISASSEMBLY).
moval and cleaning to determine if a proper seal
and compression existed prior to disassembly. If
Neither of the shaft seal assemblies (3 or 4) should
sealing was faulty or questionable, the cause must
be reused because wear patterns on the finished
be determined and corrected before reassembly.
faces cannot be realigned during reassembly. This
Replace any parts as required.
could result in premature failure. If necessary to re
Thoroughly clean all reuseable parts with a soft use an old seal in an emergency, carefully wash
cloth soaked in cleaning solvent. Remove all O‐ all metallic parts in fresh cleaning solvent and allow
rings and gaskets, and clean the sealing surfaces to dry thoroughly.
of dirt or gasket material. Be careful not to scratch
gasket surfaces. 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
Most cleaning solvents are toxic and
scratching the faces.
flammable. Use them only in a well ven
tilated area free from excessive heat,
Inspect the seal components for wear, scoring,
sparks, and flame. Read and follow all
grooves, and other damage that might cause leak
precautions printed on solvent contain age. If any components are worn, replace the com
ers. plete seal; never mix old and new seal parts.
Inspect the rotor shaft (39) for damaged threads,
scoring, or nicks. Remove nicks and burrs with a Install the shaft seals as illustrated in Figure E-3.

ROTOR
SHAFT STATIONARY
SEAL SEAT
ROTATING
ELEMENT STATIONARY
ELEMENT
SPRING
BELLOWS AND
RETAINING ASSY
SPRING
RETAINER
SEAL
RETAINING RING
STATIONARY
SEAL SEAT O‐RING
O‐RING STATIONARY
ELEMENT
DIFFUSER ROTATING
BELLOWS AND ELEMENT
RETAINING ASSY
SPRING
IMPELLER
WASHER
IMPELLER
SHIM SET
Figure E-3. Upper And Lower Seal Assemblies

Carefully remove the material stuffed into the seat
bore (or unwrap the shaft). Be sure no debris
stopped by the material falls into the seal cavity.
This seal is not designed for operation at NOTE

temperatures above 122 F (50 C). Do not When pressing seal components onto the shaft,
use at higher operating temperatures. 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
Upper Seal Installation
proximately the same as the I.D. of the seal spring.
(Figures E-1 and E-3)
Subassemble the stationary element in the station
Do not unwrap a new seal assembly until time of ary seat. Position this subassembly in the interme
installation. Cleanliness of seal components is criti diate bore with the sealing face up and cover the
cal, especially the seal faces. seal face with a clean tissue. Use your thumbs to
press the assembly into the bore. Apply equal
Clean the rotor shaft (39) and seal cavity area of the
pressure on opposite sides until the seat contacts
intermediate (50). Be sure the area is dry and free
the bore shoulder. Remove the tissue and inspect
of lint and dirt. Check the seal bore for burrs or
the seal face to ensure that it is clean and dry. If
nicks that might prevent a good seal. Remove
cleaning is necessary, use clean tissue to wipe
them with a fine file or emery cloth to restore origi
lightly in a circular pattern.
nal contours. If the shaft is bent or damaged, the
complete rotor and shaft must be replaced as an Unpack the rotating portion of the seal. Be certain
assembly. Apply a light coating of oil to the bore of the seal face of the rotating element is free of grit or
the intermediate. surface damage. Because the rotating element

may not stay in the bellows retainer when turned shaft, use hand pressure only. A push tube cut from
upside down, place a small amount of grease at a length of plastic pipe will aid in installing seal
equal spaces on the back of the element and posi components. The I.D. of the push tube should be
tion it in the bellows retainer. The grease should approximately the same as the I.D. of the seal
hold the element in position until the seal is in spring.
stalled. Assemble the drive grooves of the rotating
element into the drive lugs of the bellows retainer.
Secure the diffuser gasket (8) to the diffuser using
Apply a light coating of oil to the seal seating sur a light coating of `3M Gasket Adhesive No. 847' or
face on the shaft, the groove for the retaining ring equivalent compound.
(14), and I.D. of the bellows. Position the seal rotat
ing portion on the shaft with the seal face down. Carefully position the diffuser and stationary seal
Apply firm, steady pressure on the bellows retainer components on the rotor shaft, over the studs (59)
until it slides down the shaft and the seal faces con and against the intermediate (50). Be careful not
tact. This step should be done in one continuous to damage the stationary element already in
motion to prevent the bellows from sticking or roll stalled.
ing as it passes over the retaining ring groove.
Unpack the rotating portion of the seal. Be certain
the seal face of the rotating element is free of grit or
Slide the seal spring over the shaft and bellows re
surface damage. Because the rotating element
tainer, and install the spring retainer. Install the seal
may not stay in the bellows retainer when turned
retaining ring (14). See Figure E-3 for the proper
upside down, place a small amount of grease at
order of seal assembly.
equal spaces on the back of the element and posi
tion it in the bellows retainer. The grease should
Lower Seal Installation hold the element in position until the seal is in
(Figures E-1 and E-3) stalled. Assemble the drive grooves of the rotating
element into the drive lugs of the bellows retainer.
Thoroughly clean the gasket surfaces and seal Apply a light coating of oil on the shaft and the I.D.
bore of the diffuser (1). The seal bore must be free of the bellows.
of burrs and nicks which could damage the seal.
Slide the seal rotating portion onto the lubricated
Inspect the diffuser for cracks, distortion, or ero
shaft with the seal face down. Apply firm, steady
sion and replace it if defective.
pressure on the bellows retainer until it slides down
the shaft and the seal faces contact.
Position the diffuser on a clean flat surface with the
impeller side up. Slide the seal spring over the shaft and bellows re
tainer. See Figure E-3 for proper order of seal as
Unpack the stationary seat and element. Subas
sembly.
semble the stationary element in the stationary
seat. Apply a light coating of oil to the diffuser bore
and the O.D. of the seal seat and O‐ring. Keep the Impeller Installation
sealing face dry. (Figure E-1)
Position the subassembly in the diffuser bore, and Inspect the impeller (2) for cracks, broken vanes,
cover it with a clean tissue. Use your thumbs to or wear from erosion, and replace it if damaged.
press the seat into the bore. Apply equal pressure Clean the threads on the rotor shaft to remove any
on opposite sides of the seat until it is fully seated in old thread locking material. Be sure the impeller
the bore. Remove the tissue and inspect the seal bore and the shaft are free of oily film and com
face to ensure that it is clean and dry. If cleaning is pletely dry.
necessary, use clean tissue to wipe lightly in a cir
cular pattern. Install the upper impeller washer (10) with the in
side chamfer toward the shaft shoulder. Install the
NOTE adjusting shims (9) and the impeller key (64). Align
When pressing seal components onto the rotor the keyway of the impeller (2) and push the impel

ler onto the shaft until seated firmly against the up pump end disassembly, allowance must be made
per impeller washer and shim set. for bearing play when checking impeller clearance.
Final impeller clearance must be determined with
After the impeller is installed, coat the threads of the pump in a normal upright operating position.
the rotor shaft with `Loctite Threadlocker No. 242'
or equivalent compound. Install the impeller wash
er (62) and the impeller nut (63). Wedge a block of Clean the gasket surface between the intermedi
wood between the vanes of the impeller and torque ate (50) and the strainer plate (52) to ensure that
the nut to 175 ft. lbs. (2100 in. lbs. or 24,2 m. kg.). the old gasket and gasket cement is removed. In
spect the surface for major scratches. Secure the
Remove the block of wood and turn the impeller to strainer plate gasket (51) to the intermediate with a
check for free rotation. light coating of `3M Gasket Adhesive No. 847' or
equivalent compound.
NOTE
If the impeller (2) is not fully seated and binds Position the strainer plate (52) over the diffuser,
against the diffuser, the shaft and lower bearing aligning the bolt holes. Use a soft‐faced mallet to
have been driven out of position during impeller re tap the strainer plate into position.
moval. If this occurs, the lower bearing must be
Apply `Never‐Seez' or equivalent compound to the
pressed back into place (see MOTOR DISASSEM
threads of the capscrews (5). Install the hardware
BLY and MOTOR REASSEMBLY).
(5, 6 and 7) and torque evenly in a cross sequence
to 120 ft. lbs. (1440 in. lbs. or 16,6 m. kg.).
Suction Head And Strainer Plate Installation Strainer Screen And Base Plate Installation
(Figure E-1) (Figure E-1)
Inspect and thoroughly clean the suction head (61) Inspect the strainer screen (54) and base plate (55)
and its O‐ring groove. It must be clean and free of for cracks, distortion or erosion, and replace it if de
any flaws which could cut the O‐ring or prevent a fective.
good seal. Lightly oil the O‐ring (53) and install it in
the suction head. Carefully position the strainer screen on the strain
er plate (52) so that it seats against the strainer
Position the suction head on the diffuser studs plate shoulder. Install the base plate over the
(59). Using a soft faced mallet, “walk” the suction screen, aligning the bolt holes. Secure the com
head into the diffuser until fully seated. Be careful plete strainer assembly using the hardware (56, 57
not to damage the O‐ring (53). Apply `Never‐Seez' and 58). Make certain that the strainer seats prop
or equivalent compound to the threads of the studs erly against the shoulder of the strainer plate.
(59) and secure the suction head using the nylon
locknuts (60). Torque the locknuts evenly in a cross See FINAL ASSEMBLY and VACUUM TESTING
sequence to 60 ft. lbs. (720 in. lbs. or 8,3 m. kg.). followed by LUBRICATION before putting the
pump back into service.
For maximum pump efficiency, there should be a
clearance of .010 to .015 inch (0,25 to 0,38 mm) be MOTOR DISASSEMBLY
tween the suction head and the face of the impeller.
Use a feeler gauge to measure this clearance. If the Disassembly of the motor is rarely required except
clearance is not within the specific limits, remove to replace the motor rotor, stator or bearings. Do
the suction head and impeller. Add or remove ad not disassemble the motor unless it is necessary
justing shims (9) as required. Install the impeller and a clean, well‐equipped shop is available.
and suction head and recheck impeller clearance.
NOTE
NOTE It is recommended that a pump with a defective mo
If the intermediate and rotor assembly (50 and 39) tor be returned to Gorman‐Rupp, or to one of the
were not removed from the motor housing during Gorman‐Rupp authorized Submersible Repair

Centers. Separate the terminal housing and power cable
assembly (2) from the motor housing.
No further disassembly is required to test the stator

or power cable.
To disconnect the power cable (2), remove the nuts

The electrical power used to operate (5) securing the terminal gland (1) to the terminal
this pump is high enough to cause inju housing (8). Slide the gland back along the power
ry or death. Make certain that the control cable. Oil the bushing (6) and terminal housing
handle on the control box is in the off po bore and pull firmly on the cable. (Allow the oil to
sition and locked out, or that the power leak in around the bushing by agitating the cable in
supply to the control box has been the bore.) After the bushing has been loosened,
otherwise cut off and locked out, before the cable should pull out far enough to expose the
attempting to open or service the pump bushing. Apply oil on the cable jacket and slide the
assembly. Tag electrical circuits to pre bushing and washer (7) back along the cable.
vent accidental start‐up. Quite often, pressure exerted on the bushing will
deform the cable jacket. If such happens, addition
Carefully inspect any O‐rings or gaskets before re al oil and effort will be required to remove the bush
moval and cleaning to determine if a proper seal ing.
and compression existed prior to disassembly. If
sealing was faulty or questionable, the cause must NOTE
be determined and corrected before reassembly. If the rubber bushing cannot be removed from the
Replace any parts as required. terminal housing as indicated, it may be necessary
to cut the bushing into small pieces or cut the cable.
Terminal Housing And Power Cable
Removal And Disassembly
Push approximately 6 inches (152 mm) of the pow
(Figure E-1) er cable into the terminal housing so that the termi
nal plate comes free of the terminal housing. This
Total disassembly of the terminal housing and should permit access to the power cable connec
power cable (37) is not always required. Disassem tions in the terminal plate.
ble and replace only the parts proven defective by
inspection or testing (see Electrical Testing in NOTE
TROUBLESHOOTING). Do not remove the heat shrink tubing from the pow
er cable leads unless the power cable or terminals
The terminal housing and power cable assembly require replacement. If replacement is required,
may be serviced without disassembling the motor the connections between the power cable leads
housing or pump end or without draining the oil and the terminals must be sealed with heat shrink
from the motor cavity. However, the oil must be tubing before applying the silicone adhesive (see
drained before attempting to disassemble the mo Terminal Housing And Power Cable Reassemb
tor housing and components. ly).
Secure the pump in an upright position. Remove
the deform locknuts (36) securing the terminal To disconnect the power cable (2) from the termi
housing assembly (37) to the motor housing as nal housing, pull the terminal plate (13) away from
sembly (19). the terminal housing. When shipped from the fac
(Figure E-2) tory, the connections between the power cable
leads and the terminal collars (12) were encapsu
Carefully raise the terminal housing (8) from the lated in heat‐shrink tubing (10) and bonded to the
motor housing until the terminals (14) are accessi terminal plate with silicone adhesive (not shown).
ble. Loosen the allen head setscrews (15), and dis (In service, the adhesive may have been replaced
connect the motor leads from the terminal posts. by potting compound during previous repair.) If

damage is extensive and the terminal plate and ter Rotor And Bearing Removal
minals are to be replaced, simply cut the power
(Figure E-1)
cable leads above the terminal collars and heat‐
shrink tubing, and discard the terminal plate and Set the intermediate and rotor assembly on a clean
terminals. work area. Leave the lifting slings attached and re
duce the tension slightly. Remove the hardware
If damage is not extensive and it is necessary to re (48 and 49) securing the bearing cap to the inter
place the terminal plate (13) or terminal compo mediate. Steady the rotor and separate the inter
nents, carefully cut away the tubing and adhesive. mediate. If necessary, tap the impeller end of the
Disconnect the power cable leads from the termi rotor shaft with a soft faced mallet to loosen the
nal posts, and separate the terminal plate (13) from seal between the lower ball bearing (43) and the in
the terminal housing (8). Unscrew the terminal termediate bore.
posts (14), and remove the terminal collars (12),
posts and dyna seal washers (16) from the terminal
plate.
Remove the hardware (18 and 19) securing the To prevent damage during removal from
green and yellow ground leads to the terminal the shaft, it is recommended that bearings
housing. Reinstall the hardware. be cleaned and inspected in place. It is
strongly recommended that the bearings
See Terminal Housing/Power Cable Reassemb be replaced any time the shaft and rotor
ly if no further disassembly is required. assembly is removed.
Before removing the bearings from the rotor shaft,
clean and inspect the bearings in place as follows.
Intermediate And Motor Housing Disassembly
Clean the bearings thoroughly in fresh cleaning
(Figure E-1) solvent. Dry the bearings with filtered compressed
air and coat with light oil.
See PUMP END DISASSEMBLY, and remove all
pump end and seal components.
With the pump end disassembled and the motor

cavity drained of oil, secure the pump in an in
Most cleaning solvents are toxic and
verted position. Remove the hardware (46 and 47)
flammable. Use them only in a well ven
securing the intermediate (50) to the motor hous tilated area; free from excessive heat,
ing (19). Do not remove the hardware (48 and 49) sparks, and flame. Read and follow all
around the rotor shaft (39) at this time. precautions printed on solvent contain
ers.
Hook a three‐leg‐sling in the intermediate flange Rotate the bearings by hand to check for rough
holes and hoist the intermediate, rotor and shaft ness or binding and inspect the bearing balls. If ro
(39), bearing cap (44) and both ball bearings (38 tation is rough or the bearing balls discolored, re
and 43) from the motor housing as an assembly. If place the bearings.
necessary, tap around the parting surfaces with a
soft faced mallet to loosen the seal between the in The bearing tolerances provide a tight press fit
termediate and motor housing. Remove the motor onto the shaft and a snug slip fit into the motor
housing gaskets (16, 17 and 18). housing and bearing bore. Replace the shaft and
rotor (as an assembly), the motor housing or inter
mediate if the proper bearing fit is not achieved.
Cover the motor housing with a clean, lint free cloth
to avoid contamination by dirt or other foreign ma If replacement is required, use a bearing puller to
terial. remove the upper and lower ball bearings from the

rotor shaft. Remove the bearing cap (44) and gas ing tolerances and materials are closely
ket (15) from the rotor shaft. controlled by the manufacturer, and any
deviation can cause damage or operating
NOTE problems. Replace the stator, or return it to
It may be necessary to use the bearing cap (44) and one of The Gorman‐Rupp Authorized Sub
capscrews (48) in conjunction with a bearing puller
mersible Repair Centers or The Gorman‐
to remove the lower bearing.
Rupp factory, if defective.
Relief Valve
Stator Removal
(Figure E-1)
(Figure E-1)
It is recommended that the pressure relief valve
(32) be replaced at each overhaul, or at any time
Do not remove the stator (40) unless it is defective
the pump motor overheats and activates the valve.
(open windings, insulation resistance low, or stator
Never replace this valve with a substitute which has
core damaged). If the stator must be removed, re
not been specified or provided by the Gorman‐
move the terminal housing as indicated in Termi
Rupp Company.
nal Housing And Power Cable Disassembly.
It is not necessary to remove the heavy pipe nipple
Position an expandable tool, such as a split disc,
(34) to remove the pressure relief valve. If the nip
approximately 2 inches (51 mm) inside the stator,
ple is removed, apply `Loctite Retaining Com
and expand it tightly and squarely on the I.D. At
pound No. 680 or No. 620' or equivalent com
tach a lifting device to the lifting eye of the tool, and
pound on both ends of the nipple only.
raise the assembly approximately 1 inch (25 mm)
off the work surface. When installing the relief valve, use `Loctite Pipe
Sealant With Teflon No. 592' or equivalent com
The motor housing (19) must be heated with a pound on the threads. Position the valve out of the
torch to expand it enough for the stator to be re way, next to the terminal housing (8, Figure E-2)
moved. Apply heat evenly to the outside of the mo so there is enough room for the terminal housing to
tor housing; excessive heat is not required. Use a clear.
soft‐faced mallet to rap alternate edges of the mo
Hoisting Bail
tor housing, and “walk” the stator out. Continue
this process until the stator clears the motor hous (Figure E-1)
ing.
If the hoisting bail (24) requires replacement, re
move the hardware (21, 22 and 23) securing the
bail to the motor housing. Make sure the bushings
(25) are in place when installing the hoisting bail.
Take care not to damage the stator end MOTOR REASSEMBLY

turns during removal from the motor hous
ing.
After the stator has been removed, wrap it in clean,
dry rags or other suitable material until reassembly.
The stator must be kept clean and dry. When han Do not attempt to rewind the stator. Wind
dling the stator, do not set it on the end windings; ing tolerances and materials are closely
lay it on its side. controlled by the manufacturer, and any
deviation can cause damage or operating
problems. Replace the stator, or return it to
one of The Gorman‐Rupp Authorized Sub
mersible Repair Centers or The Gorman‐
Do not attempt to rewind the stator. Wind Rupp factory, if defective.

NOTE NOTE
Reuse of old O‐rings, gaskets, shaft seal parts will Remove any drops of varnish from the ends of the
result in premature leakage or reduce pump per stator before installation to ensure proper stack‐up
formance. It is strongly recommended that new height when assembled.
gaskets and shaft seal assemblies be used during
reassembly (see the parts list for numbers).
Position an expandable tool, such as a split disc,
approximately 2 inches (51 mm) down inside the
Stator Installation stator (opposite the lead wire end), and expand it
tightly and squarely on the I.D. Attach a lifting de
(Figure E-1) vice to the lifting eye of the tool, and carefully lift the
assembly. Take care not to damage the stator end
NOTE turns. Slip a sleeve over the stator leads, or tape
Stator installation involves heating the motor hous them together to protect them during installation.
ing. This process must be done quickly. Therefore it
is recommended that these steps be performed by NOTE
two people to promote efficient installation of the Stator installation involves heating the motor hous
stator. ing. This process must be done quickly to allow the
stator to slide into the motor housing before the
housing cools.
Clean all gasket and O‐ring surfaces of the motor
housing (19), completely removing any old gasket
and cement material. Inspect the sealing surfaces Heat the motor housing (19) with a torch to expand
for burrs, nicks and pits which could cause a poor it enough for the stator (40) to be installed; when
seal, and replace defective parts as required. heating the motor housing, make sure that the sta
tor is clear to avoid a fire hazard, or damage to the
Thoroughly clean the inside of the motor housing windings. Apply heat evenly to the outside of the
with fresh solvent. The interior must be dry and free housing; excessive heat is not required.
of dirt or lint.
When the motor housing is sufficiently heated, po
sition the stator so that the leads are in line with the
terminal opening. Carefully lower the stator into the
motor housing until fully seated against the hous
ing shoulder. Be careful not to damage the stator
Most cleaning solvents are toxic and leads insulation during reassembly. If the stator
flammable. Use them only in a well ven “cocks” in the motor housing, remove it and try
tilated area; free from excessive heat, again.
sparks, and flame. Read and follow all
After the stator is fully and squarely seated on the
precautions printed on solvent contain motor housing shoulder, remove the expandable
ers. disc tool. Untape or remove the protective sleeve
After the motor housing is thoroughly cleaned, po from the stator leads.
sition it on a flat surface with the discharge end
Cover the motor housing with a clean, lint‐free
down. Do not unwrap the stator (40) until the motor
cloth while the rotor is being assembled.
housing has been prepared for stator installation.
The stator must be kept clean and dry. When han
Bearing Installation
dling the stator, do not set it on the end windings;
lay it on its side and block it from rolling. (Figure E-1)
Test the new stator as indicated in Electrical Test Inspect the rotor shaft (39) for damaged threads,
ing in TROUBLESHOOTING, Section D, to ensure scoring in the seal area, and a nicked or damaged
that no damage has occurred during transit or han keyway. If the bearings were removed, inspect the
dling. bearing areas for scoring or galling. Remove nicks

and burrs with a fine file or emery cloth. Inspect the
rotor area for separated laminations. If the shaft is
bent or damaged, or if the laminations are sepa
rated, replace the shaft and rotor (a single assem
bly). Use caution when handling hot bear
ings to prevent burns.
If heating the bearing is not practical, use a suitably

sized sleeve, and an arbor (or hydraulic) press to
install the bearing on the shaft.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and rotor
assembly is removed. When installing the bearing onto the shaft,
never press or hit against the outer race,
The bearings may be heated to ease installation. balls, or ball cage. Press only on the inner
An induction heater, hot oil bath, electric oven, or
race.
hot plate may be used to heat the bearings. Bear
ings should never be heated with a direct flame or Clean the bearing cap (44) and position it over the
directly on a hot plate. lower bearing (43) before heating.
NOTE NOTE
If a hot oil bath is used to heat the bearings, both the Position the cap on the bearing so that when in
oil and the container must be absolutely clean. If stalled on the shaft, the bearing will be positioned
the oil has been previously used, it must be thor as indicated in Figure E-4.
oughly filtered.
Heat the lower bearing and cap to a uniform tem

Heat the upper bearing (38) to a uniform tempera perature no higher than 250F (120C). Slide the
ture no higher than 250F (120C). Slide the bear assembled cap and bearing onto the shaft until the
ing onto the shaft until it is fully seated against the bearing is fully seated against the shaft shoulder.
shaft shoulder. This should be done quickly, in one Do this quickly, in one continuous motion, to pre
continuous motion, to prevent the bearing from vent the bearing from cooling and sticking on the
cooling and sticking on the shaft. shaft.
INSTALLATION OF SKF 5200 AND 5300 SERIES BEARINGS
PART NUMBER MARKINGS ARE

LOCATED EITHER ON BEARING
O.D. (OFFSET FROM CENTER) OR
ON SIDE FACE OF BEARING. FOR
EITHER TYPE, POSITION BEAR
DIRECTION OF ING WITH TEXT AWAY FROM IM
THRUST PELLER.
NOTE:
THIS BEARING IS MANUFACTURED WITH TWO SEALS OR SHIELDS. WHEN INSTALLED ON THE SHAFT, THE MAN
UFACTURER'S PART NUMBER DESCRIPTION (LOCATED ON SIDE FACE OF BEARING OR BEARING O.D.) MUST BE
LOCATED WITH THE TEXT AWAY FROM THE IMPELLER.
Figure E-4. Bearing Installation

If heating the bearing is not practical, use a suitably Using a three‐leg sling and lifting eyes in the inter
sized sleeve and an arbor (or hydraulic) press to in mediate flange holes, carefully lower the intermedi
stall the cap and bearing on the shaft. ate over the shaft and lower bearing, guiding the
studs in the bearing cap through the holes in the
intermediate as it is lowered into place.
Apply `Never‐Seez' or equivalent compound to the

When installing the bearing onto the shaft, threads of the capscrews (48). Use two of the caps
crews and lockwashers (49) to draw the intermedi
never press or hit against the outer race,
ate and bearing cap together. Remove the studs
balls, or ball cage. Press only on the inner
temporarily installed in the bearing cap and install
race.
the remaining two capscrews and lockwashers;
After the bearings have been installed and allowed torque the capscrews evenly in a cross‐sequence
to cool, check to ensure that they have not moved to 20 ft. lbs. (240 in. lbs. or 2,8 m. kg.).
out of position in shrinking. If movement has oc
curred, use a suitably sized sleeve and a press to Refer to PUMP END REASSEMBLY, and reas
reposition the bearings. Make certain that they are semble the pump end components.
seated squarely against the shaft shoulders.
Secure the gasket (15) to the cap with a light coat Terminal Housing And Power Cable
ing of gasket adhesive. Reassembly And Installation
(Figure E-2)
Rotor And Intermediate Reassembly
(Figure E-1)
Use fresh solvent to clean all gasket and O‐ring

surfaces of the motor housing (19) and intermedi
ate (50), completely removing any old gasket and The electrical power used to operate
cement material. Inspect the sealing surfaces for this pump is high enough to cause inju
burrs, nicks and pits which could cause a poor ry or death. Make certain that the control
seal. Repair or replace as require. 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
Most cleaning solvents are toxic and assembly. Tag electrical circuits to pre
flammable. Use them only in a well ven vent accidental startup. Obtain the ser
tilated area free from excessive heat, vices of a qualified electrician, and refer
sparks, and flame. Read and follow all to the wiring diagram(s) in INSTALLA
precautions printed on solvent contain TION, Section B, to make electrical con
ers. nections.
Position the rotor (39), assembled bearings (38 Clean the exterior of the power cable with warm
and 43) and bearing cap (44) on a work surface water and mild detergent. Check for obvious physi
with the impeller end up, and use blocks to secure cal damage. Check the cable for continuity and in
it in this position. sulation resistance (see Electrical Testing in
TROUBLESHOOTING). Do not attempt repairs
To ease alignment of the bearing cap and inter except to cut off either end of the cable; splicing is
mediate, install two long studs, finger‐tight only, not recommended. Reinstall any wire tags or ter
180 apart in the bearing cap mounting holes. minals which may have been removed.

ing method is used, refer to the instructions in Seal
ing Terminal Plate Connections With Potting
Compound. Use only materials and heating equip
ment approved by Gorman‐Rupp for field repairs.
Never attempt to alter the length or re
pair any power cable with a splice. The
pump motor and cable must be com Before resealing the power and control cables, re
pletely waterproof. Injury or death may move all the old adhesive material (or potting com
result from alterations. pound) from the leads, terminal collars, and termi
nal plate. Inspect all parts for damage, and replace
Use oil to lightly lubricate the outside of the pump as required. If the rubber bonding material on the
power cable (2), and the bores of the terminal terminal plate (13) is severely worn or cracked, the
housing (8), terminal gland (1) and gland bushing terminal plate must be replaced. If the bonding ma
(6) for ease of assembly. Slide the terminal gland, terial has been noticeably compressed, it should
cable grip (3), gland bushing (6), terminal washer be supplemented with two gaskets contained in
(7) and terminal housing (8) on the cable, allowing the overhaul gasket kit (see Options listed in the
approximately 3 ft. (1 m) of cable to extend beyond Parts List manual).
the terminal housing. Temporarily tape the green
and yellow ground wires to the cable. NOTE
Clean the cable leads and terminal plate in the ar
Sealing Terminal Housing Connections eas to be sealed with cleaning solvent. Incomplete
With Silicone Adhesive sealing will occur if the surfaces are dirt, oil or
grease coated.
(Figure E-2)
Assemble the terminal posts (14), dyna seal wash

ers (16 ), and terminal collars (12) to the terminal
plate as shown in Figure E-2.
Do not attempt to operate this pump un NOTE

less the power cable leads are properly Both the power cable and motor conductor leads
sealed in the terminal housing. Mois should be tinned prior to reassembly.
ture entering the terminal housing
could cause a short circuit, resulting in
Slide a length of heat‐shrink tubing (10) up over
pump damage and possible serious in
each of the power cable leads. Insert the leads in
jury or death to personnel.
the terminal collars and secure them using the al
When shipped from the factory, the cable leads len head setscrews (11). Slide the tubing down
and terminal collars (12) were encapsulated in each lead until the terminals are covered, and the
heat‐shrink tubing (10), and bonded to the terminal tubing contacts the terminal plate. The tubing
plate (13) with silicone adhesive to provide a water‐ must extend up the leads far enough to ensure a
tight seal. If this insulating material has been dam good seal.
aged or removed during maintenance, it must be
Carefully heat each tube with a commercially avail
replaced using materials and equipment approved
able hot air gun capable of producing 750F
by Gorman‐Rupp (see the parts list for repair kits).
(399C), and shrink the tubes around the cable
NOTE leads and terminal collars.
Heat‐shrink tubing must be used to seal the power
and control cable leads to the terminals before
bonding the leads to the terminal plate. If silicone
adhesive is not available in the field, a commercially
available potting kit may be used to bond the con Use only Dow‐Corning 737 Silicone Adhe
nections to the terminal plate. If this alternate seal sive (see the Parts List Manual for the part

number) or potting compound for sealing
terminal housing connections. Use of un
approved sealing products will void the
pump warranty. All air pockets, voids or gaps in the sili
NOTE cone sealant must be removed to en
Do not use a mold or reservoir with the silicone sure a water‐tight seal in the terminal
adhesive. housing. Otherwise, moisture entering
the terminal housing could cause a
See Figure E-6 and check terminal locations. Ap short circuit, resulting in pump damage
ply a 1/4 to 3/8 in. (6,4 to 9,7 mm) thick layer (maxi and possible serious injury or death to
mum) of silicone adhesive around each of the ter personnel.
minal posts as shown in Figure E-5. Remove any
Allow the adhesive to cure for at least one hour be
adhesive from gasketed surfaces.
fore securing the terminal housing to the motor
housing.
Silicone Sealant
Figure E-5. Silicone Adhesive Sealing
1 YELLOW - CONNECT TERMINAL TO GROUND

INSIDE TERMINAL HOUSING
WHITE
(T1) 2 GREEN - TOGETHER IN ONE TERMINAL.
CONNECT TERMINAL TO
GROUND INSIDE TERMINAL
HOUSING
RED
(T3)
BLACK
(T2)
Figure E-6. Terminal Housing Wiring Connections

Sealing Terminal Housing Connections production. A commercially available potting kit
With Potting Compound (Products Research Corp., part number
PR‐1201‐Q Class 1 potting compound, Chemseal
(Figure E-2) potting compound, part number GS3100, or equiv
alent) may also be used to seal the connections.
Potting compound and silicone adhesive have the
same electrical properties when correctly applied. Clean and assemble all terminal components as
Silicone adhesive is used at the factory to facilitate indicated in Sealing Terminal Plate With Silicone

Adhesive. Use medium grit sandpaper to prepare When potting has been completed, leave the ter
the surface of the terminal plate in the area where minal plate assembly undisturbed until the potting
the potting mold will be installed. material has cured. Complete curing usually takes
about 24 hours. Curing time can be shortened by
using a heat lamp, but be careful not to melt the
NOTE
potting or potting mold, or burn the cable. When
Clean the cable lead and terminal plate in the areas
the potting material is no longer “tacky” to the
to be potted with cleaning solvent before potting.
touch, it has cured.
Potting compound will not adhere properly to oil or
grease coated surfaces.
Terminal Housing Installation
(Figure E-2)
Trim the potting mold so it is just long enough to
cover the terminal collars. Slide the potting mold After the terminal plate has been sealed, slide the
up over the leads of the power cable and control terminal housing down the cable. Untape the
cable. ground lead(s) and secure them to the terminal
housing with the hardware (18 and 19). Be sure
the lead(s) make good contact with the housing.
Secure each cable lead as described in the pre
vious section. Slide the potting mold down over the Pull gently on the cable to remove any excess
terminal collars and onto the terminal plate. Hang length from within the terminal housing. The termi
the cable in a vertical position with the terminal nal plate should fit loosely against the terminal
plate horizontal. The cable leads and terminals housing.
should be centered in the potting mold. Use quick‐
setting cement, such as `3‐M Weather Seal' to se Lubricate the upper bore of the terminal housing,
cure the potting mold to the terminal plate. and slide the gland washer (7), bushing (6) and
cable grip (3) into place. Slide the terminal gland
(1) into place and install the nuts (5). Do not fully
tighten the nuts at this time.
Attach the appropriate motor lead (T1, T2, T3) to

Most potting base compounds contain each terminal post (14) using the allen head set
toluene; use adequate ventilation and screws (15).
avoid prolonged breathing of vapors. Position the terminal housing and terminal plate
Most potting accelerators contain lead; against the upper motor housing. If required, ro
avoid ingestion or prolonged contact tate the terminal housing and twist the motor leads
with the skin. Read and follow all warn to remove excess slack.
ings and recommendations accompa
(Figure E-1)
nying the potting kit.
Coat the threads of the motor housing studs (35)
See the instructions with the potting kit regarding
with `Never‐Seez' or equivalent compound, and
application life and setting and curing time. Mix the
secure the terminal housing assembly to the motor
base compound and accelerator and fill the mold
housing with the hardware (36); torque the nuts
until the electrical connections are completely in
evenly in a cross sequence to 20 ft. lbs. (240 in. lbs.
sulated. Tamp the potting material to eliminate air
or 2,8 m. kg.). Tighten the nuts (5, Figure E-2)
bubbles and ensure the material has completely
drawing the terminal gland (1) down into the termi
covered the area around the terminal posts.
nal bore to the dimenstion shown in Figure E-2.
Do not overtighten and damage the terminal gland
NOTE or hardware.
The potting compound must completely cover the
terminal collar and lead connections. NOTE
A .09 to .15 in. (3,05 mm) gap is required between

the terminal gland flange and the terminal housing Use a manometer with a range of 30 to 0 to 30 inch
when the nuts (5, Figure E-2) are fully tightened. es of mercury to perform the test. Do not use a vac
uum gauge. Vacuum gauges are not sensitive
enough to detect minor leaks.
See FINAL ASSEMBLY and VACUUM TESTING
followed by LUBRICATION.
It is recommended that a vacuum pump be used to
draw the vacuum on the cavities. If a vacuum pump
FINAL ASSEMBLY is not available, a compressor/venturi system may
(Figure E-1) be used. If the compressor/venturi cannot draw
the higher vacuum level shown in Table E-1, draw
If the discharge flange (27) was removed from the the motor cavity vacuum down as far as the system
motor housing, replace the discharge flange gas will allow, then draw the seal cavity down so the dif
ket (26). Apply `Never‐Seez' or equivalent com ferential between the two cavities is the same as
pound on the flange studs (28), and secure the the differential between the vacuum readings
flange with the nuts (29). shown in the table.
If the hoisting bail (24) was removed, install the bail

Install full‐closing ball‐type shutoff valves with
bushings (25) and secure the bail to the motor
quick‐disconnect fittings in the pipe plug holes in
housing with the hardware (21, 22 and 23).
both the motor and seal cavities. Test the motor
cavity for its full duration first, then use the shutoff
VACUUM TESTING valve to maintain the motor cavity vacuum while
testing the seal cavity. The motor cavity vacuum
To ensure the water‐tight integrity of the pump, it is must be higher than the vacuum in the seal cavity
recommended that the motor and seal cavities be to prevent separation of the seal faces or unseating
vacuum tested any time the seal(s) and/or motor the stationary seal seat between the seal and mo
are serviced. tor cavities.
Drain all of the oil from both the seal and motor
cavities before performing the test. Oil within the Figure E-7 shows a simple schematic for setting
cavities will be drawn into the system, resulting in up either a vacuum pump or a venturi/compressor
damage to the vacuum pump or manometer. test system.
Vacuum Pump Manometer Quick Disconnect
Fitting
Tee
Full-Closing
Ball-Type
Venturi Shutoff Valve Submersible
Pump
ÎÎÎ
ÎÎÎ
Quick Disconnect
Air Compressor Fitting
Figure E-7. Vacuum Test System

Table E-1 shows the vacuum to be drawn on each the test indicates a leak which must be identified
cavity, and the duration to maintain each vacuum and corrected before putting the pump back into
reading. Any change in vacuum reading during service.

Table E-1. Vacuum Test Data
Pump Motor Cavity Duration Seal Cavity Duration

Model Vacuum (Minutes) Vacuum (Minutes)
(In. Hg.) (In. Hg.)
S4B 30 6 20 2
LUBRICATION mally low, or the color milky or dark, refer to Drain

ing Oil From Seal Cavity in this section for instruc
tions and troubleshooting tips. If the oil is clear, ap
Seal Cavity
ply `Loctite Pipe Sealant With Teflon No. 592.' or
equivalent to the threads of the pipe plug, before
Check the oil level in the seal cavity before initial
reinstalling the plug.
startup, after the first two weeks of operation, and
every month thereafter.
To fill the seal cavity, remove the pipe plug (12) and
add the recommended grade of submersible
pump oil. Apply `Loctite Pipe Sealant With Teflon
No. 592.' or equivalent to the threads of the pipe
plug, before reinstalling the plug.
Check the oil level only when the pump
is cool. If the oil level plug is removed See Table E‐2 for quantity of lubricant when lubri
when the pump is hot, pressure in the cating a dry (overhauled) pump. See Table E‐3 for
seal cavity can cause hot oil to be lubricant specifications.
ejected as the plug is removed.
The grade of lubricant used is critical to the opera
To check the seal cavity oil, lay the pump on its side tion of this pump. Use premium quality hydraulic oil
and remove the seal cavity plug (11) in the interme as specified in the following table. Oil must be
diate. Tip the pump and drain off a small amount of stored in a clean, tightly closed container in a rea
oil into a transparent cup. If the oil level is abnor sonably dry environment.
Table E-2. Oil Quantity
Pump Model Seal Cavity Motor Cavity
S4B 160 ounces (2,8 liters) 256 ounces (10,4 liters)

Table E‐3. Pump Oil Specifications
Specifications:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium high viscosity index, anti‐wear hydraulic oil
Viscosity (SSU @ 104F [40C]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 to 155
Viscosity (SSU @ 210F [100C]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 to 50
Dielectric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,000 (volts‐min)
Recommended supplier:
Gulf Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gulf Harmony AW Hydraulic Fluid MG 32
Acceptable alternate suppliers:
Gulf Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gulf Harmony 32 AW
Texas Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rando HD 32 or HD AZ 32
Sun Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sunvis 816 or 916
BP (Also Boron) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Energol‐HLP 32
Shell Oil Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tellus 32, Tellus T‐23 or T32
ARCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duro 32
Exxon (Also Esso) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuto H 32
Petro‐Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harmony HVI 22
Motor Housing Cavity
With the pump in an upright position, remove the

pipe cap (30) on the top of the pump. See Table E‐2
and add the recommended grade of lubricant
(Table E‐3) to the motor cavity. Maintain the oil at
Never attempt to fill the motor cavity
this level. Apply `Loctite Pipe Sealant With Teflon through the drain plug (13) opening or the
No. 592' or equivalent sealant to the threads of the oil level plug (20). A volume of air must be
street tee assembly (31). Reinstall and tighten the trapped above the motor to permit thermal
cap. expansion of the motor oil.

For Warranty Information, Please Visit
www.grpumps.com/warranty
or call:
U.S.: 419-755-1280
Canada: 519-631-2870
International: +1-419-755-1352
GORMAN‐RUPP PUMPS

Gorman Rupp S4B1-E50 Manual OM-06099-01

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OM‐06099‐01

March 14, 2008

2008 Gorman‐Rupp Pumps Printed in U.S.A.

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

Please record your pump model and serial number in the

SAFETY ‐ SECTION A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE A - 1

INSTALLATION - SECTION B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 1

OPERATION - SECTION C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE C - 1

TROUBLESHOOTING - SECTION D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE D - 1

PUMP MAINTENANCE AND REPAIR ‐ SECTION E . . . . . . . . . . . . . . . . . PAGE E - 1

Thank You for purchasing a Gorman‐Rupp S Se­ RECORDING MODEL AND

If there are any questions regarding the pump

The Gorman‐Rupp Company

damage which could result from failure to

Hazards or unsafe practices which COULD NOTE

Before attempting to open or service the

Approach the pump cautiously after it

All electrical connections must be in ac­

Pumps and related equipment must be

PAGE A-2 SAFETY

Following is a description of the model numbering LUBRICATION

b. Check for loose attaching hardware. Since PUMP INSTALLATION

Do not allow the free end of the power

Table B‐1. Pump Specifications

Model Voltage/ Dual Pump Motor Full No Locked Discharge

Table B‐2. Additional Specifications

Approximate Oil Capacity Seal Cavity

Pump Dimensions Refer to Table B-2 for the approximate maximum

BY BAIL IN PERFORATED CULVERT PIPE ON SUPPORTS

Figure B-1 Typical Pump Installations

The electrical power used to operate

Do not connect the pump motor directly

a) PLATE ELECTRODE b) DRIVEN ELECTRODE c) BURIED ELECTRODE

SOIL SOIL SOIL

Figure B-3. Suggested Grounding Methods

The electrical power used to operate

Connect the pump power cable to the control box NOTE

Do not connect the pump control cable

TO LEVEL CONTROL CIRCUIT TO LEVEL CONTROL CIRCUIT

LIQUID LEVEL LIQUID LEVEL

BULB (FLOAT TYPE) DIAPHRAGM TYPE

Figure B-4. Liquid Level Devices

Review all SAFETY information in Section A.

Since operation of the pump motor is de­

While checking impeller rotation, secure

If rotation is incorrect on a single‐phase motor, con­

this pump is high enough to cause inju­

Follow the instructions accompanying the control

On pumps equipped with a motor ther­

COLD WEATHER PRESERVATION

To avoid serious damage to the pump,

If the pump does freeze while it is out of the liquid,

month thereafter. Check the motor lubrication level Adding Oil

Table C-1. Pump Oil Specifications

Defective insulation in motor wind­ Check insulation resistance; check

TROUBLESHOOTING CHART (cont'd)

ELECTRICAL TESTING 3. The pump submerged and running under

Test Equipment b. If voltage is balanced when the pump is off but

c. Use an Amprobe or equivalent instrument to

Motor and Power Cable Continuity

Thank You for purchasing a Gorman‐Rupp S Se RECORDING MODEL AND

All electrical connections must be in ac

Since operation of the pump motor is de

If rotation is incorrect on a single‐phase motor, con

this pump is high enough to cause inju

On pumps equipped with a motor ther

Defective insulation in motor wind Check insulation resistance; check

Heat the lower bearing and cap to a uniform tem

Assemble the terminal posts (14), dyna seal wash

Do not attempt to operate this pump un NOTE

LUBRICATION mally low, or the color milky or dark, refer to Drain