AEM Mody Pumps G 530 T Guide

MODELS: G 530 T, G 554 T
OPERATING INSTRUCTIONS, INSTALLATION & MAINTENANCE
MANUAL INCLUDING SPARE PARTS LIST
Mody Pumps Inc.
2166 Zeus Court
Bakersfield, CA 93308
Tel.: [phone] FAX.: [phone]
EMAIL: [e-mail]
http://www.modypump.com
ISO 9001 Certified

L
LI IF FE E I IS S P PR RE EC CI IO OU US S - - T TH HI IN NK K S SA AF FE ET TY Y
1. Most accidents can be avoided by using COMMON SENSE.
2. Please read the operation and maintenance instruction manual supplied with the
pump. If you did not receive one, please call your local distributor before pump
installation.
3. Do not wear loose apparel that may become entangled in the impeller or other
moving parts.
4. Always use appropriate safety equipment, such as safety glasses, when working on
the pump or piping.
5. Pumps build up heat and pressure during operation-allow time for pumps to cool
before handling or servicing.
6. Only qualified service personnel should install, operate and repair pump.
7. Keep clear of suction and discharge openings. DO NOT insert fingers in pump with
power connected.
8. Do not pump flammable or hazardous materials (gasoline, acids, alkalis, etc.)
9. Do not block or restrict discharge hose, as it may whip or burst catastrophically
under pressure.
10. Make sure lifting handles/hooks are securely fastened each time before lifting.
11. Do not lift pump by the power cord under any circumstances.
12. Do not exceed manufacturer's recommendation for optimum performance, as this
could cause the motor/pump to overheat and lead to premature wear or failure.
13. Secure the pump in its operating position so it does not tip over, fall or slide.
14. Keep away from impeller when power is connected.
15. Submersible Pumps are not approved for use in swimming pools, recreational water
installations, decorative fountains or any installation where human contact with the
pumped fluid is common.
16. Do not operate pump without adequate protection and safety devices in place.
17. Always replace safety devices that have been removed during service or repair.
18. To reduce risk of electrical shock, pump must be properly grounded in accordance
with the National Electric Code and all applicable state and local codes and
ordinances.
19. To reduce risk of electrical shock, always disconnect the pump from the power
source before handling or servicing.
20. Any wiring of pumps should be performed by a qualified electrician.
21. Never operate a pump with a power cord that has frayed or brittle insulation.
22. Cable should be protected at all times to avoid punctures, cuts, and
abrasions - inspect frequently.
23. Never handle connected - "hot" power cords with wet hands.
24. Never operate a pump with a plug-in type power cord without a ground fault circuit
interrupter, adequate overload and short circuit protection.
IMPORTANT !!! MODY Pumps Inc. is not responsible for losses, injury, or death resulting
from a failure to observe these safety precautions, misuse or abuse of pumps or
equipment.
Mody Pumps Inc.: 2166 Zeus Court, Bakersfield, CA 93308 Tel.: [phone] Fax: [phone]

INTRODUCTION
THE “mody” MOTOR DRIVEN PORTABLE SUBMERSIBLE PUMPS HAVE BEEN DEVELOPED DUE TO
A LONG FELT NEED OF HAVING A TRULY MAINTENANCE FREE PUMPSET FOR VARIOUS
APPLICATIONS. THE PUMP IS A LIGHTWEIGHT, COMPACT UNIT ENABLING IT TO BE USED IN
MOST SEA-CRAFT AND DIFFICULT LAND INSTALLATIONS. THE UNIT CONSISTS OF A
VERTICAL CENTRIFUGAL PUMP WITH AN IN-BUILT SQUIRREL CAGE, INDUCTION ELECTRIC
MOTOR WHICH IS AVAILABLE FOR VARIOUS ELECTRIC SUPPLY CONFIGURATIONS. THE PUMPED
WATER IS USED AS A COOLING MEDIUM WHICH COOLS THE ELECTRIC MOTOR. THE PUMPSET
CAN ALSO BE USED IN ANY POSITION THUS MAKING IT IDEAL FOR DEWATERING IN
DIFFICULT LOCATIONS.
THE SERVICE LIFE OF A SUBMERSIBLE PUMP DEPENDS MAINLY ON TWO THINGS: THE
DEPENDABILITY OF THE SEALING SYSTEM AND THE WEAR RESISTANCE OF THE PUMP WEAR
PARTS.
ALL “mody” SUBMERSIBLE SUMP PUMPS INCORPORATE A UNIQUE SEALING SYSTEM. THE
CONSTRUCTION CONSISTS OF TWO MECHANICAL SEALS, ARRANGED IN TANDEM, IMMERSED IN
AN OIL BATH. THE COMPLETE PACKAGE IS A PRESSURE COMPENSATED SEALING DEVICE
WHICH ENSURES A MINIMAL PRESSURE DIFFERENTIAL ACROSS THE SEAL FACES,
IRRESPECTIVE OF THE DEPTH SETTING OF THE PUMP OR THE HEAD AGAINST WHICH THE
PUMP IS OPERATING.
IN “mody” SUBMERSIBLE SUMP PUMPS, ALL WEAR PARTS ARE RUBBER LINED/COVERED AND
ARE READILY REPLACEABLE AS NEEDED. BOTH WEAR AND ELECTRICITY CONSUMPTION ARE
STILL FURTHER REDUCED WHEN THE PUMPS ARE FITTED WITH BUILT-IN LEVEL CONTROLS
FOR AUTOMATIC STARTING AND STOPPING. IT IS HOWEVER RECOMMENDED THAT
IRRESPECTIVE OF TYPE OF PUMP, ADEQUATE MOTOR PROTECTION SWITCHGEAR SHOULD BE
USED AT THE INSTALLATION. WE STRONGLY RECOMMEND THE USE OF SUITABLE CONTROL
PANELS WHICH ARE AVAILABLE FROM US INCORPORATING ALL REQUIRED PROTECTION
DEVICES.
IT IS IN THE INTEREST OF THE USER THAT HE GO THROUGH THIS MANUAL IN DETAIL
PRIOR TO USING THE PUMP. THE MANUAL WILL HELP HIM UNDERSTAND THE CONSTRUCTIONAL
FEATURES AND TO OBTAIN TROUBLE FREE SERVICE FROM THE PUMP.
PLEASE NOTE THAT ALL PART NOS. REFERRED TO IN DISMANTLING AND RE-ASSEMBLY ARE
PERTAINING TO MODEL G 554T. NUMBERS FOR MODEL G 530T ARE INDICATED IN THE
DRAWINGS. THE CONSTRUCTION IS IDENTICAL.
PURPOSE:
THE PUMP HAS BASICALLY BEEN DESIGNED AS A DEWATERING UNIT TO PUMP OUT FLOODED
INSTALLATIONS OR ANY CONDITIONS THAT NEED DEWATERING OF UNWANTED FLUIDS. THE
PUMP HAS BEEN DESIGNED TO HANDLE WATER CONTAMINATED WITH OIL AS WELL AS
ABRASIVE PARTICLES NORMALLY ASSOCIATED WITH RAW WATER. THE MAXIMUM SIZE OF
PARTICLES THAT CAN BE HANDLED IS APPROX. 0.4”. THE MAXIMUM SPECIFIC GRAVITY OF
THE PUMPED FLUID SHOULD NOT EXCEED 1.1.

OVERALL DIMENSIONS AND WEIGHT.
G 530T G 554T
OVERALL HEIGHT 28”(APPROX.)/711MM 31”(APPROX.)/790MM
MAX. DIAMETER 10.75”/275MM 10.75”/275MM
MAX. WEIGHT(EXCL. CABLE) 121 lbs./55KG 135 lbs./61KG
MAINTENANCE SERVICES REQUIRED.
THE FOLLOWING CHECKS TO BE DONE AT INTERVALS INDICATED BELOW:
1. CONDITION OF SEALS TO BE CHECKED AT EVERY 2500 HRS. OF OPERATION BY
ASCERTAINING THE CONDITION OF OIL IN THE SEAL CHAMBER.
2. MONTHLY RUNNING OF PUMP FOR AT LEAST 5/10 MINUTES AND CHECKING OF AMPERES
DRAWN AND INSULATION RESISTANCE. (MIN. INSULATION RESISTANCE 1 MEG. OHM AND
MAX. CURRENT DRAWN AS PER NAME PLATE)
SAFETY PRECAUTIONS.
1. ENSURE THAT THE INSULATION RESISTANCE OF THE MOTOR IS AT LEAST 1 MEG. OHM
BEFORE ENERGIZING THE UNIT.
2. CHECK THAT THE AVAILABLE POWER SUPPLY (VOLTAGE, PHASE, FREQUENCY) MATCHES
WITH THE DETAILS ON THE PUMP NAMEPLATE.
3. ENSURE THAT THE GROUND WIRE IN THE 4 CORE CABLE SUPPLIED WITH THE PUMP IS
SECURELY EARTHED.
4. ENSURE HOSE CONNECTION IS CORRECTLY AND SECURELY FITTED
5. ENSURE DELIVERY HOSE IS FREE FROM KINKS AND SHARP BENDS.
6. DO NOT LIFT OR PULL THE PUMP UNDER ANY CIRCUMSTANCES BY MEANS OF THE CABLE.
THE PUMP MUST BE LOWERED/LIFTED FROM THE SPACE TO BE PUMPED BY USING A LIFTING
ROPE ATTACHED TO THE HANDLE/EYEBOLT PROVIDED IN THE PUMP.
7. AT THE STARTING MOMENT THE PUMP SHALL MAKE A KICK WHICH IS OPPOSITE TO THE
DIRECTION OF ROTATION OF THE IMPELLER. ENSURE THE KICK IS IN THE CORRECT
DIRECTION (SEE THE ARROW CAST ON THE CONTACTOR COVER OF THE PUMP).SHIFT ANY TWO
PHASES IN THE MALE PLUG IF THE KICK IS WRONG.
8. DRY RUNNING OF THE PUMP IS NOT DESIRABLE. HOWEVER THE PUMP WILL NOT BE
DAMAGED OR SUFFER ANY ILL EFFECTS IF IT IS RUN DRY FOR SHORT PERIODS (UPTO
APPROX. 30 MINUTES).
9. THE MAXIMUM PUMP SUBMERGENCE RECOMMENDED IS 50 FEET.
10. THE SPECIFIC GRAVITY OF PUMPED FLUID SHOULD NOT EXCEED 1.1 UNDER ANY
CIRCUMSTANCES. PUMP IS DESIGNED TO OPERATE IN FLUIDS WITH pH from 5 – 8.
11. IF PUMP IS NOT USED AND LYING IN STORAGE FOR MORE THAN 30 DAYS PLEASE
ENSURE THAT THE SEAL FACES ARE NOT GAUGE LOCKED – ROTATE THE IMPELLER/KICK
START THE UNIT ONCE A MONTH. REFER TO INSTRUCTIONS ON DISASSEMBLY/REASSEMBLY OF
MECH. SEALS IN THE EVENT THE FACES HAVE LOCKED.

12. FULL LOAD AMPS AT 460V IS 14AMPS (G554), 11.5AMPS (G530) & AT 400V IS
16 AMPS (G554), 12.5AMPS (G530)
13. ENSURE CORRECT RATING H.R.C. BACK UP PROTECTION FUSES ARE INSTALLED IN
POWER CIRCUIT BEFORE STARTING THE PUMP.(REFER TABLE BELOW).
MAINS VOLTAGE AT SITE HRC FUSE RECOMMENDED
220 VOLTS / 3 PHASE 40 AMPERES
380 VOLTS / 3 PHASE 25 AMPERES
415 VOLTS / 3 PHASE 22 AMPERES
460 VOLTS / 3 PHASE 20 AMPERES
FAULT FINDING IN THE UNIT.
TROUBLE GUIDE CAUSE REMEDY
1.FUSES BLOWN. 1.REPLACE FUSES
2.CABLE DAMAGED 2.SHORTEN/REPLACE CABLE
PUMP DOES NOT START. 3.NO POWER. 3.CHECK POWER SUPPLY.
4.BLOCKED IMPELLER. 4.CLEAN BOTTOM PARTS.
6.STATOR WINDING BURNT. 6.REPLACE STATOR/REWIND
1.BLOCKED IMPELLER. 1.CLEAN BOTTOM PARTS.
2.IMPELLER ROT.WRONG 2.SHIFT TWO PHASE CONN.
PUMP STARTS BUT STOPS.3.CONNECTED FOR WRONG 3.CHECK & RECONNECT.
VOLTAGE.
4.VOLTAGE LOW/HIGH 4.CONTACT POWER CO.
5.CLOGGED STRAINER 5.CLEAN STRAINER
6.PUMP RUNNING DRY 6.SWITCH OFF POWER
7.WATER TOO WARM 7.SWITCH OFF POWER
(ABOVE 60 DEGREES C)
1.IMPELLER ROT.BACKWARD. 1.SHIFT TWO PHASE CONN.
2.PUMP WORN DOWN. 2.REPLACE WEAR PARTS
PUMP GIVES TOO LITTLE 3.LONG HOSE AND DIAMETER 3.CHECK PRESSURE LOSSES
OUTPUT TOO SMALL.
4.PRESSURE HEAD TOO HIGH 4.USE PUMPS IN TANDEM.
5.DISCHARGE HOSE TORN 5.USE NEW HOSE
6.LEAKING/CRACKED OUTLET 6.REPL.OUTLET/GASKET.

TECHNICAL DESCRIPTION.
THE MODY SUBMERSIBLE PUMP IS IN ITSELF A COMPLETE PUMPING STATION. BESIDES A
POWER SUPPLY AND A DISCHARGE HOSE NO EXTRA EQUIPMENT IS REQUIRED. THE
COMPLETE PUMPSET IS IN A MODULAR CONSTRUCTION ENSURING GOOD AND SIMPLE
SERVICEABILITY. THE MAJOR DESIGN FEATURES ARE AS UNDER:
THE MOTOR
A RUGGED ALUMINUM DIE CAST/COPPER ROTOR DYNAMICALLY BALANCED TO GRADE 2.5
ACCURACY OF ISO 942.A STAINLESS STEEL SHAFT RUNNING IN TWO BALL BEARINGS.
INSULATION CLASS "H" (180 DEGREES CELSIUS). END WINDINGS DULY EPOXY COATED TO
PREVENT DETERIORATION OF INSULATION EVEN IN EXTREMELY HUMID CONDITIONS. WINDING
WIRE IS DUAL COATED SUITABLE FOR "H" CLASS INSULATION.

THE SEAL CHAMBER
THE HEART OF THE MODY PUMP. TANDEM MECHANICAL, TUNGSTEN CARBIDE V/S TUNGSTEN
CARBIDE SEAL FACES (LOWER SEAL) AND TUNGSTEN CARBIDE V/S TUNGSTEN CARBIDE
(UPPER SEAL), SECONDARY SEALS OF HNBR RUBBER AND METAL PARTS IN STAINLESS
STEEL, RUNNING IN AN OIL BATH, ENCLOSED IN A PRESSURE COMPENSATING RUBBER OIL
BAG - CREATES THE ULTIMATE SEAL SOLUTION. THE DESIGN OPTIMIZES SEAL LIFE AND
ALLOWS FOR SIX MONTHLY (2500 HOURS) SERVICE INTERVALS.
BEARINGS.
SINGLE ROW DEEP GROOVE BALL BEARINGS SEALED FOR LIFE WITH A SPECIAL HIGH
TEMPERATURE BEARING GREASE REQUIRING NO PERIODIC MAINTENANCE WHATSOEVER.
THE HYDRAULIC ELEMENTS.
THE STAINLESS STEEL IMPELLER RUNNING AGAINST A RUBBER LINED DIFFUSER AND WEAR
PLATE, CONSTITUTE THE HYDRAULIC ELEMENTS OF THE PUMP. THE IMPELLER/DIFFUSER CAN
BE ADJUSTED TO MAINTAIN MAXIMUM OUTPUT AFTER USAGE WITHOUT PARTS REPLACEMENT.
IT IS IMPORTANT, HOWEVER, TO MAINTAIN CLEARANCES BETWEEN THE WEAR PARTS.
CABLE GLAND ASSEMBLY. (REFER DRG.)
THE PUMP IS SUPPLIED WITH 50 FEET CABLE AS STANDARD. THE CABLE IS A 4 CORE EPR
SHEATHED AND INSULATED CABLE CONFORMING TO INTERNATIONAL STANDARDS. THE CABLE
IS WATERPROOF AND CAN BE COMPLETELY SUBMERGED IN WATER. THE CABLE IS TERMINATED
IN THE PUMP AT THE CABLE GLAND. THE GLAND ASSEMBLY SEALS THE CABLE ON THE
OUTSIDE SHEATH AS WELL AS A WATER DAM ARRANGEMENT IS PROVIDED WHICH SEALS THE
INDIVIDUAL CORES OF THE CABLE. THIS FEATURE IS UNIQUE AND IS ESSENTIAL TO
PREVENT WATER SEEPING THROUGH THE CORES OF THE CABLE INTO THE MOTOR CHAMBER IN
THE EVENT OF A CUT CABLE. THE CABLE IS ALSO SHEATHED FOR THE FIRST ONE METER BY
MEANS OF A CABLE GRIP MADE OF STAINLESS STEEL. THIS IS ESSENTIAL TO ENSURE THAT
THERE IS NO UNDUE STRAIN ON THE CABLE IF THE PUMP IS PULLED OR LOWERED
INADVERTENTLY BY MEANS OF THE CABLE. COMPLETE DETAILS OF THE CABLE GLAND
ASSEMBLY ARE SHOWN IN THE DRAWING.
GALVANIC CORROSION PROTECTION (FOR SEA-WATER DUTY PUMPS ONLY)
THE PARTS OF THE "MODY" SUBMERSIBLE PUMP THAT ARE IN CONTACT WITH SEA- WATER
ARE PRIMARILY OF STAINLESS STEEL AND ALUMINUM. AS SEA-WATER IS AN ELECTROLYTE
THE PROBLEM OF GALVANIC CORROSION EXISTS DUE TO THE DIFFERENT ELECTRIC
POTENTIALS OF THE MATERIALS IN FLOWING SEA-WATER. TO PREVENT THIS, THE PUMPS
ARE EQUIPPED WITH ZINC ANODES FIXED ON THE OUTER CASING AND DIFFUSER. ZINC,
BEING THIS LESS "NOBLE" METAL (MORE NEGATIVE POTENTIAL) GETS CORRODED THUS
PREVENTING CORROSION OF ALUMINUM AND STEEL. IT IS HOWEVER NECESSARY TO INSPECT
THE CONDITION OF THE REPLACEABLE ANODES PERIODICALLY AND REPLACE WHENEVER
NECESSARY. (INSPECTION ONCE IN A YEAR IS ENOUGH.)
NON REPAIRABLE ITEMS
1. ALL "O" RINGS TO BE REPLACED WHENEVER PARTS ARE DISMANTLED.
2. SEAL ELASTOMER PARTS SHOULD NEVER BE RE-USED AFTER DIS-ASSEMBLY.
3. DO NOT REFILL BEARING GREASE. ALWAYS REPLACE COMPLETE NEW BEARING WITH
SPECIAL HIGH TEMPERATURE GREASE.

ELECTRICAL INFORMATION.
MOTORS ARE DESIGNED TO OPERATE ON SINGLE VOLTAGE AND FREQUENCY. MAX. DEVIATION
IN VOLTAGE ALLOWED IS + - 6 % AND FREQUENCY +- 3%. CHECK NAME PLATE FOR
OPERATING VOLTAGE AND FREQUENCY.
DISMANTLING AND OVERHAULING.
GENERAL OVERHAUL AND OIL CHECK.(REF. DRGS. NO. DW/136/00 SHEETS 1 &
2)
1. ALWAYS REPLACE O-RINGS WITH NEW ONES WHENEVER DISMANTLING AND RE-ASSEMBLING
A PUMP. NEVER RE-USE OLD O-RINGS.
2. REMOVE BASE PLATE (75),STRAINER (74),NUT (18), HEX HD. BOLTS (76), DIFFUSER
HOLDER (71),AND DIFFUSER (70).THE DRAWING SHOWS THESE DETAILS. CHECK BY HAND
THAT THE ROTOR SHAFT IS NOT BLOCKED.
3. PLACE THE PUMP ON THE BOTTOM STUDS (62). TAP THE OUTER CASING (69) WITH
NYLON TIPPED HAMMERS TILL IT LOOSENS FROM THE TOP BRACKET (22). SEPARATE THE
OUTER CASING FROM THE TOP BRACKET BY EMPLOYING TWO SCREW DRIVERS AS LEVERS AND
PUSH THE OUTER CASING DOWNWARDS TILL IT STANDS ON THE FLOOR. LIFT THE UNIT BY
THE EYE BOLTS (31) CLEAR OFF THE OUTER CASING.
4. THE SEAL CHAMBER CONTAINS APPROX. 1.5 LITTERS OF OIL. THE LEVEL AND
CONDITION OF THE OIL SHOULD BE CHECKED EVERY SIX MONTHS. UNSCREW THE OIL PLUGS
(45) AND POUR OUT SOME OIL. NOTE THAT THE OIL GETS A SLIGHTLY DARKER SHADE, BUT
THIS IS NORMAL AND IS NO CAUSE FOR WORRY. IF THE OIL IS EMULSIFIED BY WATER,
THE SEALS HAVE WORN OUT AND MUST BE REMOVED FROM THE ROTOR FOR FURTHER ACTION.
5. LAY DOWN THE PUMP AND REMOVE THE REMAINING PARTS. UNSCREW NUT (67) AND
REMOVE LOCK WASHER (66)(USE IMPELLER SPANNER (T7005)TO HOLD IMPELLER WHILE
UNSCREWING NUTS) AND SLIDE OFF IMPELLER(65) FROM SHAFT. THEN REMOVE TRIMMING
SPACERS (63). UNSCREW THE FOUR PHILLIPS HEAD SCREWS (60) AND REMOVE THE SAND
GUARD (59) FROM THE SEAL HOUSING (49).
6. UNSCREW NUTS (72) AND FOUR STUDS (62) AND REMOVE WEAR PLATE (61). THIS CAN
BE EASILY DONE BY INSERTING TWO SCREWDRIVERS BETWEEN WEAR PLATE AND LOWER
BRACKET (43) AND PRYING THE WEAR PLATE LOOSE. ALL THE PUMP PARTS HAVE BEEN
DISMANTLED. REPLACE WORN PARTS.
7. THE OIL DIAPHRAGM (54) IS NOW IN VIEW. UNSCREW BOTH THE OIL PLUGS (45) AND
DRAIN OUT THE OIL FROM THE OIL CHAMBER. LOOSEN SCREWS AND NUTS (55/56) FROM THE
BIG OIL CLAMP (58) AND REMOVE CLAMP. TURN OIL DIAPHRAGM INSIDE OUT AND REMOVE
SMALL OIL CLAMP IN THE SAME FASHION. REMOVE OIL DIAPHRAGM. SLIDE OFF OUTER
RETAINING SNAP RING/CIRCLIP (48) FROM ROTOR SHAFT AND REMOVE LOWER MECHANICAL
SEAL FROM ROTOR SHAFT. BE VERY CAREFUL IN HANDLING THE TUNGSTEN CARBIDE SEAL
FACE. LEAVE STATIONARY TUNGSTEN CARBIDE SEAT IN THE SEAL HOUSING (49). UNSCREW
FOUR NUTS (52) AND PULL OUT SEAL HOUSING (49). THE STATIONARY TC SEAL FACE WILL
COME OUT WITH THE SEAL HOUSING. HANDLE THE FACE CAREFULLY. THE UPPER MECHANICAL
SEAL IS NOW IN VIEW. REMOVE THE UPPER SEAL IN THE SAME WAY AS THE LOWER SEAL.

8. REMOVE THE FOUR NOS. DEEP SEATED CAP SCREWS (44) THAT HOLD THE LOWER BEARING
BRACKET AGAINST THE INNER CASING. BY MEANS OF TWO NOS. SCREW DRIVERS REMOVE THE
LOWER BEARING BRACKET FROM THE STATOR CASING (25). THE COMPLETE ROTOR (38) WITH
BEARING (41), BEARING COVER (40) AND TUNGSTEN CARBIDE SEAT WILL COME OUT WITH
THE LOWER BEARING BRACKET. REMOVE BOLTS (38) AND REMOVE BEARING COVER. PULL OUT
ROTOR WITH BEARING FROM LOWER BEARING BRACKET. (IF THIS IS DIFFICULT USE A HAND
PRESS TO REMOVE ROTOR FROM BEARING BRACKET. ENSURE NO DAMAGE TO THE TUNGSTEN
CARBIDE SEAT IN BEARING BRACKET). THE TC SEAT WITH CUP SEAL HOLDER CAN NOW BE
PUSHED OUT FROM THE BEARING SIDE BY GENTLY TAPPING THE SAME. (USE FINGERS OR A
NYLON TIPPED LIGHT HAMMER ONLY).
9. CHECK BOTH UPPER AND LOWER BEARINGS (36 & 41) FOR ANY RADIAL OR AXIAL PLAY
OR ANY ABNORMAL NOISE WHILE SPINNING THE SAME. CHECK FOR ANY LEAKAGE OF GREASE
THROUGH THE SHIELD OF THE BEARING. IF BEARING SEEMS WORN OUT OR ANY GREASE
LEAKAGE IS OBSERVED, REPLACE BEARING. (DO NOT USE ANY STANDARD BEARING PROCURED
FROM THE MARKET. THE PUMPS USE A SPECIAL BEARING WHICH IS PRE-FILLED WITH A
SPECIAL HIGH TEMPERATURE GREASE WHICH ARE AVAILABLE FROM US READILY).
10. REMOVE THE CABLE GLAND ASSEMBLY (2) BY TAKING OFF THE HEX NUTS (6). USING
TWO SCREWDRIVERS GENTLY PLY OUT THE CABLE GLAND BASE (12). EXAMINE THE CABLE
LEAD GROMMET (11) AND THE CABLE GROMMET (9). REMOVE THE WIRE NUTS (15,16) AND
UNSCREW THE EARTHING SCREW (17).
11. THE TOP BRACKET (22) IS HELD IN POSITION BY FOUR BOLTS (33) ON THE STATOR
CASING. UNSCREW THE BOLTS AND REMOVE THE STATOR CASING WITH THE HELP OF PULLER
FOR STATOR (T8003). ALTERNATIVELY TWO SCREW DRIVERS MAY BE USED TO PRY THE TOP
BRACKET FROM THE STATOR.
12 THE STATOR IS SHRINK-FITTED IN THE INNER CASING. THE STATOR CAN NOW BE
CHECKED FOR ANY ELECTRICAL FAULTS. MEASURE LINE TO LINE RESISTANCE AND PERFORM
A MEG OHM TEST. IF THE STATOR IS WET BAKE FOR THREE HOURS AT 250F AND PERFORM A
HIGH POT TEST.
RE-ASSEMBLY OF THE PUMPSET.
THE PUMP CAN BE RE-ASSEMBLED AS PER PROCEDURE GIVEN BELOW. PLEASE HOWEVER NOTE
THE FOLLOWING:
A) ALWAYS REPLACE NEW O-RINGS AND DISCARD OLD ONES.
B) REPLACE NEW LOCK WASHER WHEN RE-ASSEMBLING.
1. THE CHECKED/REPAIRED STATOR IS KEPT UPRIGHT AND THE TOP BRACKET IS FIT USING
THE FOUR BOLTS (33).
2. SLIDE BEARING COVER (40) ON ROTOR SHAFT.
3. FIT BEARINGS (IF REMOVED OR REPLACED) ON ROTOR SHAFT (USE EITHER A HAND
PRESS OR SHRINK THE SAME -- DO NOT HAMMER THE BEARINGS ON THE SHAFT-- YOU MAY
BEND THE SHAFT AND ALSO DAMAGE THE BEARINGS) AND FIT CIRCLIPS ON TOP AND BOTTOM
GROOVES ON SHAFT.(IF THE BEARINGS ARE SHRINK FITTED ON THE SHAFT, HEAT THE
BEARINGS IN OIL TO A MAXIMUM TEMPERATURE OF 120 DEGREES CELSIUS AS A HIGHER
TEMPERATURE WILL LIQUEFY THE GREASE IN THE BEARING AND RENDER THE SAME
UNUSABLE).
4. SLIDE LOWER BEARING BRACKET (43) ON TO LOWER BEARING AND ALIGN FOUR NOS.
HOLES ON BEARING COVER WITH THE TAPPED HOLES ON LOWER BEARING BRACKET. FIT THE
BOLTS (39) AND TIGHTEN BEARING COVER.

5. FIT COMPLETE ROTOR ASSEMBLY IN STATOR HOUSING GUIDING UPPER BEARING IN TOP
BRACKET BEARING SEAT. TIGHTEN FOUR CAP SCREWS (44). FIT UPPER TC SEAT IN LOWER
BEARING BRACKET (LIGHTLY OIL THE RUBBER SEAT CUP --ENSURE THE SEAT SITS SQUARE
IN THE BRACKET) AND SLIDE ON UPPER SEAL ASSEMBLY ON ROTOR SHAFT. (USE SEAL
ASSEMBLY MANDREL(T9006) TO ASSIST IN SLIDING BELLOWS ON TO THE SHAFT). LIGHTLY
OIL THE ROTOR SHAFT BEFORE PUSHING BELLOWS ON SHAFT. USE EXTREME CARE SO THAT
THE SEAL FACES ARE NOT DAMAGED. SLIDE ON CIRCLIP (48) AND FIT IN GROOVE ON
SHAFT.
6. PRESS HOME BY HAND LOWER TUNGSTEN CARBIDE SEAT INTO SEAL HOUSING (49).
LIGHTLY OIL RUBBER SEAT CUP BEFORE PRESSING IN CAVITY. THE SEAT MUST SIT SQUARE
IN THE HOUSING.
7. FIT SEAL HOUSING (49) INTO LOWER BRACKET AND TIGHTEN NUTS (51).
8. SLIDE ON LOWER SEAL ASSEMBLY ON SHAFT. APPLY LIGHT COAT OF OIL ON SHAFT
BEFORE SLIDING BELLOWS ON THE SAME. (USE SAME SEAL MANDREL AS USED FOR THE
UPPER SEAL TO SLIDE BELLOWS ON SHAFT). FIT RETAINER SPRING AS FOR THE UPPER
SEAL ASSEMBLY
9. FIT SAND GUARD (59) INTO SEAL HOUSING AND SCREW THE FOUR PHILLIPS HEAD
SCREWS INTO THE SEAL HOUSING. (49)
10. TURN OIL BAG INSIDE OUT AND FIT OIL BAG "VEE" SECTION INTO GROOVE IN SEAL
HOUSING (48). USING SMALL OIL BAG CLAMPS AND SCREWS & NUTS CLAMP THE OIL BAG TO
THE SEAL HOLDER. TURN OIL BAG TO CLAMP THE LARGER SIDE "VEE" SECTION TO THE
GROOVE IN THE LOWER BEARING BRACKET IN THE SAME WAY.
11. FIT ONE DRAIN PLUG WITH "O" RING IN LOWER BEARING BRACKET AND FILL OIL IN
THE OIL BAG. PERIODICALLY PRESS THE OIL BAG TO LET AIR ESCAPE SO THAT FILLING
IS PROPER AND NO AIR IS ENTRAPPED IN THE OIL BAG. (A SMALL AMOUNT OF AIR IN THE
OIL BAG WILL NOT BE DETRIMENTAL IN ANY WAY). REPLACE PLUG WITH "O" RING.
12. SLIDE ON WEAR PLATE AGAINST LOWER BEARING BRACKET AND TIGHTEN THE SAME. FIT
KEY (64) ON THE SHAFT AND SLIDE ON IMPELLER. CLEARANCES BETWEEN IMPELLER AND
WEAR PLATE CAN BE ADJUSTED BY MEANS OF THE TRIMMING SPACERS (63). TIGHTEN NUT
(67) AND SEE THAT ROTOR SHAFT IS FREE.
13. FIT OUTER CASING ON TOP BRACKET WITH "O" RING. FIT DIFFUSER AND ADJUST
CLEARANCES. SLIDE ON DIFFUSER WASHERS (72) AND FIT DIFFUSER HOLDER (71) AGAINST
THE OUTER CASING (69). TIGHTEN BY MEANS OF NUTS (18). FIX STRAINER, BASE PLATE
AND TIGHTEN BOLTS (77)
OIL SPECIFICATIONS
A) H.P. ENKLO OIL 46/48
B) SHELL TELLUS 29.
C) CHEVRON SUPERLA FDA APPROVED WHITE # 10
USE NON-CONDUCTING, NON-FOAMING, NON-DETERGENT OIL ONLY

PARTS CATALOG
1. COMPONENTS LIST : AS PER DRAWING NO. DW/136/00 (SHEET 1 & 2).
2. SPECIAL TOOLS :
S.NO. TOOL PART NO. DESCRIPTION QUANTITY
1. T7005 IMPELLER SPANNER 1
2. T5204 CIRCLIP PLIERS 8" 1
3. T2104 ALLEN KEY 6 MM 1
4. T9006 SEAL ASSEMBLY MANDREL 1
5. T4102 BEARING PULLER 4" 1
6. T4104 BEARING PULLER 8" 1
7. T8003 PULLER FOR STATOR 1
3: STANDARD MAINTENANCE TOOLS
1. T1109 D/E SPANNER SIZE 19-22 MM 1
2. T1102 D/E SPANNER SIZE 6--7 MM 1
3. T1107 D/E SPANNER SIZE 13-17 MM 1
4. T1104 D/E SPANNER SIZE 10-13 MM 1
5. T1108 D/E SPANNER SIZE 25-28 MM 1
6. T3104 SCREW DRIVER 8” 1
7. T1208 RING SPANNER 19-22 MM 1
DRAWINGS :
1. SECTIONAL ASSEMBLY(DW/136/00)(SHEET 1)
2. SEALING ARRANGEMENT WITH MATERIAL PARTS LIST (DW/136/00)(SHEET 2)
R: RECOMMENDED SPARES FOR TWO YEARS OPERATION
SR.NO DESCRIPTION PART NO. RECOMMENDED QTY.
1. MECHANICAL SEAL 535-022-00 1 NO.
2. MECHANICAL SEAL 535-022-00 1 NO.
3. "O" RING SET 375-003-66 2 SETS.
4. CABLE GROMMET 260-029-66 2 NOS.
5. CABLE LEAD GROMMET 260-031-66 2 NOS.
6. UPPER BEARING 020-005-07 1 NO.
7. LOWER BEARING 020-011-07 1 NO.
8. STRAINER 640-013-11 1 NO.
9. IMPELLER (G530T) 60HZ 300-039-22 1 NO.
10. IMPELLER (G530T) 50HZ 300-038-22 1 NO.
11. IMPELLER (G554T) 60HZ 300-042-22 1 NO.
12. IMPELLER (G554T) 50HZ 300-041-22 1 NO.
13. DIFFUSER (NEW) 175-017-80 1 NO.
14. WEAR PLATE 715-004-80 1 NO.
15. LOCK WASHER 695-004-21 2 NOS.

PUMP MODEL G530T/E VER - 1.5
D.NO. PART # DESCRIPTION QTY
1 065-016-79 CABLE AWG 10/4 SOOW 50'
2 660-093-00 CABLE GLAND & GRIP 1
3 085-022-21 CABLE CLAMP 1
4 525-022-21 PH.PAN HD.SCREW 2
5 662-002-66 CABLE SUPPORT 1
6 370-006-21 HEX NUT 2
7 700-004-21 WASHER 2
8 380-010-66 "O" RING 1
9 260-029-66 CABLE GROMMET 1
10 600-057-40 CABLE GLAND SPACER 1
11 260-081-66 CABLE LEAD GROMMET 1
12 235-009-21 CABLE GLAND BASE 6 HOLE 1
13 380-007-66 "O" RING 1
14 380-005-66 "O" RING 1
15 365-027-00 WIRE NUT CONNECTOR 3
16 365-025-00 WIRE NUT CONNECTOR 2
17 525-007-40 EARTHING SCREW 1
18 370-008-21 HEX NUT 10
19 650-020-21 STUD 2
20a 405-025-21 OUTLET 4" HOSE 1
20b 405-102-21 OUTLET 4" BSP 1
20c 405-048-21 OUTLET 4' NPT 1
21 220-005-66 GASKET (OUTLET) 1
22 035-012-30 TOP BRACKET 1
23 380-013-66 "O" RING 1
24 380-028-66 "O" RING 2
25 625-007-33 STATOR CASING 1
26 010-006-26 ZINC ANODE 2
27 520-008-21 CAP SCREW 6
28 619-021-00 BARE STATOR 1
29 350-022-21 NAME PLATE 1
30 465-006-11 RIVET 6
31 270-005-21 LIFTING HOOK 2
32 650-013-21 STUD 2
33 045-018-21 HEX HD.BOLT 4
34 700-006-21 WASHER 8
35 635-009-21 ROTATION ARROW 1
36 080-004-08 CIRCLIP 1
37 020-005-07 UPPER BEARING 1
38 480-026-00 ROTOR COMPLETE 1
39 045-004-21 HEX HD.BOLT 4
40 037-003-30 BEARING COVER 1
41 020-011-07 LOWER BEARING 1
42 080-006-08 CIRCLIP 1
43 035-013-30 LOWER BEARING BRACKET 1
44 520-003-21 SOCKET HEAD SCREW 4
45 520-002-21 OIL PLUG 2
46 380-001-66 "O" RING 2

PUMP MODEL G530T/E VER - 1.5
D.NO. PART # DESCRIPTION QTY
47 535-022-00 MECHANICAL SEAL 2
48 080-005-21 CIRCLIP 2
49 545-008-21 SEAL HOUSING 1
50 650-003-21 STUD 4
51 700-002-21 WASHER 4
52 370-005-21 HEX NUT 4
53 600-034-21 CAP FOR CIRCLIP 1
54 150-004-66 OIL DIAPHRAGM 1
55 525-022-21 PH.PAN HD.SCREW 4
56 370-002-21 HEX NUT 8
57 085-007-21 OIL BAG CLAMP SMALL 2
58 085-008-21 OIL BAG CLAMP BIG 2
59 515-008-21 SAND GUARD 1
60 525-025-21 PH.PAN HD.SCREW 4
61 715-004-80 WEAR PLATE 1
62 650-022-21 STUD ASSEMBLY 4
63 600-020-21 TRIMMING SPACER 8
64 320-006-21 KEY 1
65a 300-038-22 IMPELLER (50HZ) 1
65b 300-039-22 IMPELLER (60HZ) 1
66 695-004-21 LOCK WASHER 1
67 365-038-21 DOME NUT 1
68 380-036-66 "O" RING 1
69 400-018-31 OUTER CASING 1
70 175-017-80 DIFFUSER 1
71 160-001-30 DIFFUSER HOLDER 1
72 710-020-22 DIFFUSER WASHER 4
73 010-007-26 ZINC ANODE 2
74 640-013-21 STRAINER 1
75 030-006-30 BASE PLATE 1
76 705-001-21 SPRING WASHER 4
77 045-016-21 HEX HD.BOLT 4
78 375-011-66 "O" RING SET 1

PUMP MODEL G554T/E VER - 1.5 10/6/2008
D.NO. PART # DESCRIPTION QTY
1 065-016-79 CABLE AWG 10/4 SOOW 50'
2 660-093-00 CABLE GLAND & GRIP 1
3 085-022-21 CABLE CLAMP 1
4 525-022-21 PH.PAN HD.SCREW 2
5 662-002-45 CABLE SUPPORT 1
6 370-006-21 HEX NUT 2
7 700-004-21 WASHER 2
8 380-010-66 "O" RING 1
9 260-029-66 CABLE GROMMET 1
10 600-057-40 CABLE GLAND SPACER 1
11 260-081-66 CABLE LEAD GROMMET NEW 1
12 235-009-21 CABLE GLAND BASE 6 HOLE 1
13 380-007-66 "O" RING 1
14 380-005-66 "O" RING 1
15 365-027-00 WIRE NUT CONNECTOR 3
16 365-025-00 WIRE NUT CONNECTOR 2
17 525-007-40 EARTHING SCREW 1
18 370-008-21 HEX NUT 10
19 650-020-21 STUD 2
20A 405-025-21 OUTLET 4" HOSE 1
20B 405-102-21 OUTLET 4" BSP 1
20C 405-048-21 OUTLET 4' NPT 1
21 220-005-66 GASKET (OUTLET) 1
22 035-012-30 TOP BRACKET 1
23 380-013-66 "O" RING 1
24 380-028-66 "O" RING 2
25 625-037-33 STATOR CASING 1
26 010-006-26 ZINC ANODE 2
27 520-008-21 CAP SCREW 6
28 619-023-00 BARE STATOR 1
29 350-022-21 NAME PLATE 1
30 465-006-11 RIVET 6
31 270-005-21 LIFTING HOOK 2
32 650-013-21 STUD 2
33 045-018-21 HEX HD.BOLT 4
34 700-006-21 WASHER 8
35 635-009-21 ROTATION ARROW 1
36 080-004-08 CIRCLIP 1
37 020-005-07 UPPER BEARING 1
38 480-061-00 ROTOR COMPLETE 1
39 045-004-21 HEX HD.BOLT 4
40 037-003-30 BEARING COVER 1
41 020-011-07 LOWER BEARING 1
42 080-006-08 CIRCLIP 1
43 035-013-30 LOWER BEARING BRACKET 1
44 520-003-21 SOCKET HEAD SCREW 4
45 520-002-21 OIL PLUG 2
46 380-001-66 "O" RING 2

PUMP MODEL G554T/E VER - 1.5
D.NO. PART # DESCRIPTION QTY
47 535-022-00 MECHANICAL SEAL 2
48 080-005-21 CIRCLIP 2
49 545-008-21 SEAL HOUSING 1
50 650-003-21 STUD 4
51 700-002-21 WASHER 4
52 370-005-21 HEX NUT 4
53 600-034-21 CAP FOR CIRCLIP 1
54 150-004-66 OIL DIAPHRAGM 1
55 525-022-21 PH.PAN HD.SCREW 4
56 370-002-21 HEX NUT 8
57 085-007-21 OIL BAG CLAMP SMALL 2
58 085-008-21 OIL BAG CLAMP BIG 2
59 515-008-21 SAND GUARD 1
60 525-025-21 PH.PAN HD.SCREW 4
61 715-004-80 WEAR PLATE 1
62 650-022-21 STUD 4
63 600-020-21 TRIMMING SPACER 8
64 320-006-21 KEY 1
65A 300-041-22 IMPELLER (50HZ) 1
65B 300-042-22 IMPELLER (60HZ) 1
66 695-004-21 LOCK WASHER 1
67 365-038-21 DOME NUT 1
68 380-036-66 "O" RING 1
69 400-019-31 OUTER CASING 1
70 175-017-80 DIFFUSER 1
71 160-002-30 DIFFUSER HOLDER 1
72 710-011-22 DIFFUSER WASHER 4
73 010-007-26 ZINC ANODE 2
74 640-013-21 STRAINER 1
75 030-006-30 BASE PLATE 1
76 705-001-21 SPRING WASHER 4
77 045-016-21 HEX HD.BOLT 4
78 375-011-66 "O" RING SET 1