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GORMAN-RUPP PUMPS JDV4H60-E19 230/3 Installation, Operation And Maintenance Manual

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D
OM−03501−02
June 14, 2007
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
SUBMERSIBLE PUMPS
MODELS
JDV4H60−E19 230/3
JDV4H60−E19 460/3
THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO
www.grpumps.com
D
GORMAN-RUPP OF CANADA LIMITED
ST. THOMAS, ONTARIO, CANADA
Printed in U.S.A.
e
Copyright by the Gorman-Rupp Company

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Summary of Contents for GORMAN-RUPP PUMPS JDV4H60-E19 230/3

  • Page 1 OM−03501−02 June 14, 2007 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST SUBMERSIBLE PUMPS MODELS JDV4H60−E19 230/3 JDV4H60−E19 460/3 THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO www.grpumps.com GORMAN-RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A. Copyright by the Gorman-Rupp Company...
  • Page 2 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:...

  • Page 3: Table Of Contents

    OM−03500 JDV4A−B−C TABLE OF CONTENTS INTRODUCTION ......PAGE I−1 SAFETY − SECTION A ..... PAGE A−1 INSTALLATION −...
  • Page 4 JDV4A−B−C OM−03500 Insulation Resistance ......PAGE D−3 MAINTENANCE & REPAIR − SECTION E .

  • Page 5: Introduction

    JDV SERIES OM−03501 INTRODUCTION Thank You for purchasing a Gorman-Rupp pump. The following are used to alert personnel to proce- Read this manual carefully to learn how to safely dures which require special attention, to those install and operate your pump. Failure to do so which could damage equipment, and to those could result in personal injury or damage to the which could be dangerous to personnel:...

  • Page 6: Safety − Section A

    JDV SERIES OM−03501 SAFETY − SECTION A This information is specific to the Gorman-Rupp J Series Submersible pumps listed on the cover and in MAINTENANCE AND REPAIR − SECTION E. They apply throughout this manual to the in- 230/460 volt models are dual-voltage; structions contained in the pages which follow.
  • Page 7 OM−03501 JDV SERIES the pump to lift it, make certain that they take necessary precautions during are positioned so as not to damage the maintenance and repair to prevent per- pump, and so that the load will be bal- sonal contamination which could result anced.

  • Page 8: Installation − Section B

    JDV SERIES OM−03501 INSTALLATION − SECTION B Review all SAFETY information in Section A. d. Check that amperes, phase, voltage, and Hertz indicated on the motor name plate match the ratings on the control box. This section is intended only to summarize recom- mended installation practices for this pump.
  • Page 9 OM−03501 JDV SERIES FIGURE B−1. PUMP DIMENSIONS PAGE B − 2 INSTALLATION...

  • Page 10: Pump Motor Specifications

    JDV SERIES OM−03501 Pump Motor Specifications (104_F) ambient, plus 115_C (239_F) temperature rise. The motor furnished with this pump is a 60 Hz., Squirrel Cage, Induction Start, G-R Frame Size No. 4; Class F Insulation Rated 155_C (311_F), 40_C See Table B−1 for motor specifications. TABLE B-1.

  • Page 11: Field Wiring Connections (Incoming Power)

    OM−03501 JDV SERIES Piping able at the motor must be within the range indi- cated in Table B-2. NOTE Refer to PERFORMANCE CURVES in OPERA- TABLE B-2. MOTOR VOLTAGE LIMITS TION − SECTION C when determining the most ef- NOMINAL PHASE MINIMUM MAXIMUM...

  • Page 12: Conductor Identification

    JDV SERIES OM−03501 Connect second test lead to an uninsulated point Ground the control box in accordance with the in- on the pump body. The test circuit should close. structions accompanying it. Refer to FIGURE B−2, and connect the pump mo- If the test circuit does not close there is a defect in tor cable to the control box.

  • Page 13: Liquid Level Devices

    OM−03501 JDV SERIES The internal wiring of the sensing devices are different for filling and dewatering func- tions. Be sure to follow the instructions in- cluded with the option before making con- nections. Diaphragm Type: two fixed-position sen- sors (upper and lower) each contain a dia- phragm which flexes with changes in liquid level, thus activating an enclosed miniature switch.
  • Page 14 JDV SERIES OM−03501 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 DEWATERING DEWATERING ON (FILLING) ON (FILLING) FIGURE B−4. LIQUID LEVEL DEVICES INSTALLATION PAGE B −...
  • Page 15 OM−03501 JDV SERIES FIGURE B−5. INTERNAL MOTOR WIRING PAGE B − 8 INSTALLATION...

  • Page 16: Operation − Section C

    JDV SERIES OM−03501 OPERATION − SECTION C PERFORMANCE CURVE NOTE The curve applies to standard production models. In the performance curve which follows, perform- If your pump serial number is followed by an N", ance is based on 70_F (21_C) clear water at sea your pump is not a standard production model.

  • Page 17: Control Box And Optional Controls

    OM−03501 JDV SERIES Review all SAFETY information in Section A. closed discharge valve for an extended period of time. Follow the instructions on all tags, labels and decals attached to the pump. Impeller Rotation CONTROL BOX AND OPTIONAL CONTROLS Refer to Figure C−1, and check impeller rotation as follows before installing the pump on rails or in a wet well.

  • Page 18: Starting, Stopping, And Operational Checks

    JDV SERIES OM−03501 STARTING, STOPPING, AND OPERATIONAL After stopping the pump, be sure to perform all re- CHECKS quired maintenance and preservation procedures. Operational Checks Starting To detect minor problems, check the pump for proper operation when it is first started and at peri- odic intervals.
  • Page 19 OM−03501 JDV SERIES merged, or if the liquid begins to freeze, remove the If submerging does not thaw the pump, move it pump from the wet well and dry it thoroughly. Run into a warm area until completely thawed. the pump for two or three minutes to dry the inner walls.

  • Page 20: Troubleshooting − Section D

    JDV SERIES OM−03501 TROUBLESHOOTING − SECTION D Review all SAFETY information in Section A. 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...

  • Page 21: Troubleshooting Chart Page

    OM−03501 JDV SERIES TROUBLESHOOTING CHART TROUBLE POSSIBLE CAUSE PROBABLE REMEDY (CONT.) LIQUID BEING PUMPED TOO THICK. DILUTE LIQUID IF POSSIBLE. MOTOR RUNS, BUT DOES NOT IMPELLER WORN OR DAMAGED. REPLACE. DELIVER RATED INSUFFICIENT LIQUID IN WET WELL. STOP PUMP UNTIL LIQUID LEVEL RISES. DISCHARGE.

  • Page 22: Voltage Imbalance

    JDV SERIES OM−03501 Section B; these values apply only when the Equipment voltage at the site is the normal voltage listed. Ammeter To check AC Voltage Motor and Power Cable Continuity and current (amperage) Set the megohmmeter at R x 1 scale and zero- Ohmeter To measure resistance balance it.

  • Page 23: Maintenance & Repair − Section E

    JDV SERIES OM−03501 MAINTENANCE AND REPAIR − SECTION E MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING EFFICIENCY. PUMP MODELS THE FOLLOWING PUMP MODELS, FROM SERIAL NO. 1219284 UP , ARE COVERED IN THIS SECTION. JDV4H60−E19 230/3 JDV4H60−E19 460/3 IF YOUR PUMP SERIAL NUMBER IS FOLLOWED BY AN N", YOUR PUMP IS NOT A STANDARD...
  • Page 24 OM−03501 JDV SERIES PARTS PAGE SECTIONAL DRAWING FIGURE E−1. PUMP MODEL ASSEMBLY PAGE E − 2 MAINTENANCE AND REPAIR...
  • Page 25 JDV SERIES OM−03501 PARTS LIST − FIGURE E−1 ITEM PART NAME PART NUMBER MOTOR ASSEMBLY (230V) 26825−110 MOTOR ASSEMBLY (460V) 26825−167 IMPELLER 26826−802 SHAFT KEY 26824−173 IMPELLER SCREW 26824−379 VOLUTE CASING 26823−712 SCREW 26824−384 FLANGE 26823−975 SCREW 26824−424 STAND 26823−951 SCREW 26824−418 NAME PLATE...
  • Page 26 OM−03501 JDV SERIES SECTIONAL DRAWING FIGURE E−2. MOTOR ASSEMBLIES PAGE E − 4 MAINTENANCE AND REPAIR...

  • Page 27: Motor Assemblies

    JDV SERIES OM−03501 MOTOR ASSEMBLIES PARTS LIST ITEM PART NAME PART NUMBER : ROTOR AND SHAFT 26825−238 : UPPER BALL BEARING 26823−732 RETAINING RING 26824−217 WASHER 26824−302 COVER 26823−681 : LOWER BALL BEARING S1034 SUPPORT RING 26824−302 RETAINING RING 26824−217 LOWER BEARING HOUSING 26823−623 RETAINING RING...

  • Page 28: Pump End Disassembly

    OM−03501 JDV SERIES PUMP AND MOTOR DISASSEMBLY AND REASSEMBLY Review all SAFETY information in Section A. assembly, be careful not to mar the surface or tapered end of the shaft. Do not attempt to service the pump end When servicing the pump, always protect and/or motor assemblies unless all the free ends of the cables from exposure power to the motor has been shut off at...
  • Page 29 JDV SERIES OM−03501 the volute casing until the impeller screw (10) has NOTE been loosened. To loosen the impeller, insert a Use caution in Step 2; tension on the seal spring will wood block or metal bar through the discharge be released.

  • Page 30: Motor Disassembly

    OM−03501 JDV SERIES 3. Install the seal clamp (261) in the step in the seal housing, and secure with the locking ring (264). 4. Lubricate the O-ring in the I.D. of the rotating The threads of the impeller screw (10) and portion of the seal.
  • Page 31 JDV SERIES OM−03501 1. See FIGURE E−2, and remove the screws screws (254) and separate the seal housing (233) securing the lifting handle (231) to the mo- (257) from the lower bearing housing (213). tor cover (230), and remove the handle. Remove the O-rings (251 and 403).

  • Page 32: Inspection And Cleaning

    OM−03501 JDV SERIES 6. To remove the bearing cover (206), remove the deform the cable, and they will have to be trimmed if upper retaining ring (204). they are moved. Motor Top Cover Removal and Disassembly 6. To remove the motor cable (234), remove the cable clamp screws (237) and pull the cable, NOTE cable inlet (236), cable clamp (238) and rubber...

  • Page 33: Cleaning Seal Assembly

    JDV SERIES OM−03501 4. Cover the bearings with clean cloth to keep ex- 2. Inspect all mating surfaces and the rotor/shaft ternal surfaces free of all dirt and foreign mate- assembly for nicks or burrs, and restore to rial; failure to do so could damage the bear- original contours with a honing stone or fine ings or their mating surfaces.
  • Page 34 OM−03501 JDV SERIES Motor Top Cover Reassembly and Installation with the top of the cover. Secure the cable inlet and installed components with the screws (237). 1. Clean the exterior of the motor cable (234) with warm water and mild detergent, and inspect 7.
  • Page 35 JDV SERIES OM−03501 heat bearings by direct flame. An induction heater, hot oil bath or electric oven may be used. If a hot oil bath is used to heat the bearings, both the oil and the container must be absolutely clean, and The switch is extremely sensitive to atmo- if the oil has been previously used, it must be thor- spheric moisture and contamination from...

  • Page 36: Pump End Reassembly

    OM−03501 JDV SERIES the end of this section. Do not fully pack the sary to clean, use a clean tissue and wipe in a bearings; allow some room for expansion of concentric pattern. grease when the bearings are in operation. 3.

  • Page 37: Seal Testing

    JDV SERIES OM−03501 lute, and secure it with the screws (13, Figure ture switch (224) to trip. Test 1: Upper Seal Integrity 2. Remove the screws (233) securing the lifting handle (231) to the motor and remove the han- dle. 3.

  • Page 38: Lubrication

    OM−03501 JDV SERIES 8. Disassemble the seal housing (257) and bear- Draining Oil ing housing (213), and find and correct the 1. Lay the pump flat on a work surface with the cause of the leak. upper of the two screw plugs (268) in the seal housing (257) facing up.
  • Page 39 JDV SERIES OM−03501 2. Fill the upper bearing with approximately 5.4 oz. (160 cm ) of grease. 3. Fill the lower bearing with approximately 8.1 oz. (240 cm ) of grease. MAINTENANCE AND REPAIR PAGE E − 17...
  • Page 40 For U.S. and International Warranty Information, Please Visit www.grpumps.com/warranty or call: U.S.: 419−755−1280 International: +1−419−755−1352 For Canadian Warranty Information, Please Visit www.grcanada.com/warranty or call: 519−631−2870 THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO GORMAN-RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA...

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Jdv4h60-e19 460/3

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