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GORMAN-RUPP PUMPS JDV4A60-E2.7 200/3 Installation, Operation And Maintenance Manual

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D
OM−03500−OM06
December 14, 2006
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
SUBMERSIBLE PUMPS
MODELS
JDV4A60−E2.7 200/3 JDV4A60−E2.7 230/3 JDV4A60−E2.7 460/3
JDV4B60−E2.7 200/3 JDV4B60−E2.7 230/3 JDV4B60−E2.7 460/3
JDV4C60−E2.7 200/3 JDV4C60−E2.7 230/3 JDV4C60−E2.7 460/3
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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  • Page 1 OM−03500−OM06 December 14, 2006 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST SUBMERSIBLE PUMPS MODELS JDV4A60−E2.7 200/3 JDV4A60−E2.7 230/3 JDV4A60−E2.7 460/3 JDV4B60−E2.7 200/3 JDV4B60−E2.7 230/3 JDV4B60−E2.7 460/3 JDV4C60−E2.7 200/3 JDV4C60−E2.7 230/3 JDV4C60−E2.7 460/3 THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO www.grpumps.com GORMAN-RUPP OF CANADA LIMITED ST.
  • 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−03500 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−03500 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−03500 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−03500 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−03500 JDV SERIES FIGURE B−1. PUMP DIMENSIONS PAGE B − 2 INSTALLATION...

  • Page 10: Lifting

    JDV SERIES OM−03500 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. 1; Class F Insulation Rated 155_C (311_F), 40_C See Table B−1 for motor specifications. TABLE B-1.

  • Page 11: Piping

    OM−03500 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−03500 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 OM−03500 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−03500 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 FIGURE B−5.
  • Page 15 OM−03500 JDV SERIES FIGURE B−6. INTERNAL MOTOR WIRING PAGE B − 8 INSTALLATION...

  • Page 16: Operation − Section C

    JDV SERIES OM−03500 OPERATION − SECTION C PERFORMANCE CURVES NOTE The curves apply to standard production models. If In the performance curves which follow, perform- 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 OM−03500 JDV SERIES PERFORMANCE CURVE − JDV4B60−E2.7 200/230/460/3 PAGE C − 2 OPERATION...
  • Page 18 JDV SERIES OM−03500 PERFORMANCE CURVE − JDV4C60−E2.7 200/230/460/3 OPERATION PAGE C − 3...

  • Page 19: Control Box And Optional Controls

    OM−03500 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 Refer to Figure C−1, and check impeller rotation CONTROL BOX AND OPTIONAL CONTROLS as follows before installing the pump on rails or in a wet well.

  • Page 20: Starting, Stopping, And Operational Checks . Page

    JDV SERIES OM−03500 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 21 OM−03500 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 22: Troubleshooting − Section D

    JDV SERIES OM−03500 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 23: Troubleshooting Chart Page

    OM−03500 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 24: Insulation Resistance

    JDV SERIES OM−03500 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 25: Maintenance & Repair − Section E

    JDV SERIES OM−03500 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. 1314740 UP , ARE COVERED IN THIS SECTION. JDV4A60−E2.7 200/3 JDV4A60−E2.7 230/3 JDV4A60−E2.7 460/3 JDV4B60−E2.7 200/3 JDV4B60−E2.7 230/3 JDV4B60−E2.7 460/3 JDV4C60−E2.7 200/3 JDV4C60−E2.7 230/3 JDV4C60−E2.7 460/3...
  • Page 26 OM−03500 JDV SERIES PARTS PAGE SECTIONAL DRAWING FIGURE E−1. PUMP MODEL ASSEMBLY PAGE E − 2 MAINTENANCE AND REPAIR...
  • Page 27 JDV SERIES OM−03500 PARTS LIST − FIGURE E−1 ITEM PART NAME PART NUMBER MOTOR ASSEMBLY (200V) 26825−161 MOTOR ASSEMBLY (230V) 26825−130 MOTOR ASSEMBLY (460V) 26825−129 IMPELLER (JDV4A60) 26823−947 IMPELLER (JDV4B60) 26823−946 IMPELLER (JDV4C60) 26823−945 SHAFT KEY 26824−180 NOT REQUIRED IMPELLER SCREW 26824−378 VOLUTE CASING 26823−762...
  • Page 28 OM−03500 JDV SERIES SECTIONAL DRAWING FIGURE E−2. MOTOR ASSEMBLIES PAGE E − 4 MAINTENANCE AND REPAIR...

  • Page 29: Motor Assemblies

    JDV SERIES OM−03500 MOTOR ASSEMBLIES PARTS LIST ITEM PART NAME PART NUMBER : ROTOR AND SHAFT 26825−246 : UPPER BALL BEARING 26823−725 RETAINING RING 26824−230 : LOWER BALL BEARING 26823−738 SUPPORT RING 26824−326 RETAINING RING 26824−229 LOWER BEARING HOUSING 26826−621 MOISTURE SWITCH 26823−301 SCREW...

  • Page 30: Pump End Disassembly

    OM−03500 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. PUMP END DISASSEMBLY References are to FIGURE E−1. Do not attempt to service the pump end and/or motor assembly unless all power NOTE to the motor has been shut off at the con-...

  • Page 31: Removing Seal Assembly

    JDV SERIES OM−03500 2. To remove the impeller, apply pressure to the Remove the seal stationary element and re- back of the impeller and strike it sharply with a taining seat from the retaining cup. soft-faced mallet. Repeat as necessary until 4.

  • Page 32: Removing Rotor And Shaft Assembly

    OM−03500 JDV SERIES motor cable (234) from the motor cover (230), or 2. Remove the retaining ring (209), and support move or remove the components in the cable inlet ring (208) from the shaft. (236). When these components are installed, they NOTE deform the cable, and it will have to be trimmed if they are moved.

  • Page 33: Other Reusable Parts (Except Seal Assembly)

    JDV SERIES OM−03500 rial; failure to do so could damage the bear- Installing Bearings ings or their mating surfaces. NOTE The bearings in this pump are permanently lubri- Other Reusable Parts (Except Seal Assembly) cated. 1. Thoroughly clean all reusable parts. 2.

  • Page 34: Installing Shaft And Rotor Assembly

    OM−03500 JDV SERIES (120_C), and slide the bearings onto the shaft in 3. After the motor is fully assembled, lubricate the one continuous motion to prevent cooling and motor as indicated in LUBRICATION at the sticking. end of SECTION E. Installing Motor Cover 2.

  • Page 35: Pump End Reassembly

    JDV SERIES OM−03500 seal bottoms in the cover, and that the cable clamp (238) and cable inlet (236) are flush with the top of the cover. Secure the cable inlet and installed components with the screws (237). The switch is extremely sensitive to atmo- spheric moisture and contamination from 8.
  • Page 36 OM−03500 JDV SERIES NOTE when installing these components. It is recom- mended that the pump be inverted during seal in- Use hand pressure only to install seal components. stallation. A push tube cut from plastic pipe approximately the same O.D. as the stationary seat is a useful aid O-RING BEARING STATIONARY...

  • Page 37: Seal Testing

    JDV SERIES OM−03500 shaft and against the motor housing. Tap the Test 2: seal housing lightly with a soft-faced mallet un- 1. Install air hoses as in Test 1. til it is fully seated in the motor housing. NOTE See SEAL TESTING before assembling the remain- ing pump end components.

  • Page 38: Installing Impeller

    OM−03500 JDV SERIES The lower screw plugs will be used in LUBRI- LUBRICATION CATION. All references are to FIGURE E−2. Installing Impeller References are to FIGURE E−1. The upper screw plug (268) in the motor 1. Check the impeller (5) for broken vanes, housing is used for testing only;...
  • Page 39 JDV SERIES OM−03500 the motor housing (302) facing up; slowly 30 motor oil through the top plug hole until it open the plug to release any pressure in the escapes from the lower plug hole. seal housing (257). 2. Remove the second (lower) screw plug along 3.
  • 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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