GORMAN-RUPP PUMPS JDV4H60-E19 230/3 User manual

OM−03501−02
June 14, 2007
D
THE GORMAN-RUPP COMPANY 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
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
SUBMERSIBLE PUMPS
MODELS
JDV4H60−E19 230/3 JDV4H60−E19 460/3

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:

JDV4A−B−COM−03500
TOC PAGE−1
TABLE OF CONTENTS
INTRODUCTION PAGE I−1. . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY − SECTION A PAGE A−1. . . . . . . . . . . . . . . . . . . . .
INSTALLATION − SECTION B PAGE B−1. . . . . . . . . . . . . .
PREINSTALLATION INSPECTION PAGE B−1. . . . . . . . . . . . . . . . . . . .
LUBRICATION PAGE B−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Dimensions PAGE B−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Motor Specifications PAGE B−3. . . . . . . . . . . . . . . . . . . . . . .
PUMP INSTALLATION PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning the Pump PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piping PAGE B−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL CONNECTIONS PAGE B−4. . . . . . . . . . . . . . . . . . . . . . .
Field Wiring Connections (Incoming Power) PAGE B−4. . . . . . . .
Voltage Limits PAGE B−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dual Voltage PAGE B−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Cable Grounding Test PAGE B−4. . . . . . . . . . . . . . . . . . . . .
Conductor Identification PAGE B−5. . . . . . . . . . . . . . . . . . . . . . . . .
Control Box Connections PAGE B−5. . . . . . . . . . . . . . . . . . . . . . . .
Liquid Level Devices PAGE B−5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram PAGE B−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION − SECTION C PAGE C−1. . . . . . . . . . . . . . . .
PERFORMANCE CURVES PAGE C−1. . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX AND OPTIONAL CONTROLS PAGE C−4. . . . . . . . . .
PUMP OPERATION PAGE C−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Temperature and Overheating. PAGE C−4. . . . . . . . . . . . .
Impeller Rotation PAGE C−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING, STOPPING, AND OPERATIONAL CHECKS PAGE C−5.
Starting PAGE C−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping PAGE C−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Checks PAGE C−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Preservation PAGE C−5. . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING − SECTION D PAGE D−1. . . . . . . .
TROUBLESHOOTING CHART PAGE D−1. . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL TESTING PAGE D−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment PAGE D−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Imbalance PAGE D−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor and Power Cable Continuity PAGE D−3. . . . . . . . . . . . . . . .

OM−03500JDV4A−B−C
TOC
PAGE−2
Insulation Resistance PAGE D−3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE & REPAIR − SECTION E PAGE E−1. . . .
PARTS LISTS:
Pump Models PAGE E−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Assemblies PAGE E−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP AND MOTOR DISASSEMBLY AND REASSEMBLY PAGE E−6
PUMP END DISASSEMBLY PAGE E−6. . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Pump From Stand PAGE E−6. . . . . . . . . . . . . . . . . . . . .
Removing Volute Casing PAGE E−6. . . . . . . . . . . . . . . . . . . . . . . . .
Removing Impeller PAGE E−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Seal Assembly PAGE E−7. . . . . . . . . . . . . . . . . . . . . . . .
MOTOR DISASSEMBLY PAGE E−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Motor Cover PAGE E−7. . . . . . . . . . . . . . . . . . . . . . . . .
Removing Rotor and Shaft Assembly PAGE E−8. . . . . . . . . . . . . .
Removing Bearings PAGE E−8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION AND CLEANING PAGE E−8. . . . . . . . . . . . . . . . . . . . . . .
Bearings PAGE E−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Reusable Parts (Except Seal Assembly) PAGE E−8. . . . . .
Cleaning Seal Assembly PAGE E−9. . . . . . . . . . . . . . . . . . . . . . . . .
PUMP AND MOTOR REASSEMBLY PAGE E−9. . . . . . . . . . . . . . . . . . .
MOTOR REASSEMBLY PAGE E−9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Bearings PAGE E−9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Shaft and Rotor Assembly PAGE E−10. . . . . . . . . . . . . . .
Installing Motor Cover PAGE E−10. . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP END REASSEMBLY PAGE E−11. . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Seal Assembly PAGE E−11. . . . . . . . . . . . . . . . . . . . . . . . .
Seal Testing PAGE E−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Impeller PAGE E−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Volute Casing PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Pump on Stand PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Oil PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condition Of Oil PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding Oil PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM−03501JDV SERIES
PAGE I − 1INTRODUCTION
INTRODUCTION
Thank You for purchasing a Gorman-Rupp pump.
Read this manual carefully to learn how to safely
install and operate your pump. Failure to do so
could result in personal injury or damage to the
pump. This Installation, Operation, and Mainte-
nance Manual is designed to help you achieve the
best performance and longest life from your Gor-
man-Rupp J Series submersible pump.
These J Series pumps are driven by a waterproof
submersible electric motor. The motor is shipped
from the factory wired only for the voltage shown
on the nameplate. On dual voltage models, con-
tact the factory before attempting to change to
the alternative voltage.
The pump motor must be operated through an ap-
propriate control box matching the voltage and
other characteristics of the motor. The control box
must also provide for proper operation of the motor
protection devices such as the integral moisture
and thermal switches. Control boxes and other
control devices other than those integral to the
pump motor are not covered in this manual. Refer
to other literature accompanying the pump.
Pump construction is cast iron, with stainless steel
shaft and hardware. These pumps have a 4-inch
discharge, and will handle solids up to 3.23 inches
(82 mm) in diameter.
If there are any questions regarding the pump or
motor which are not covered in this manual or in
other literature accompanying this unit, please
contact your Gorman-Rupp distributor or the Gor-
man-Rupp Company:
The Gorman-Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901−1217
Phone: (419) 755−1011
or:
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631−2870
The following are used to alert personnel to proce-
dures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel:
Immediate hazards which WILL result in
severe personal injury or death. These
instructions describe the procedure re-
quired and the injury which will result
from failure to follow the procedure.
Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.
Hazards or unsafe practices which COULD
result in minor personal injury or product or
property damage. These instructions de-
scribe the requirements and the possible
damage which could result from failure to
follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.

JDV SERIES OM−03501
PAGE A − 1
SAFETY
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-
structions contained in the pages which follow.
In addition to this manual, see the separate litera-
ture covering the control box and other control ac-
cessories which will be used with this pump. This
literature contains essential information on install-
ing and operating the pump, and on making elec-
trical connections.
Before attempting to install, operate, or
service this pump, familiarize yourself
with this manual, and with all other liter-
ature shipped with the pump. Unfamil-
iarity with all aspects of pump operation
covered in this manual could lead to de-
struction of equipment, injury, or death.
This pump is designed to handle raw
sewage and industrial wastes at tem-
peratures of 104F (40C); do not apply
at higher temperatures. Do not attempt
to pump volatile, flammable, or corro-
sive liquids which may damage the
pump or endanger personnel as a result
of pump failure.
The electrical power used to operate
this pump is high enough to cause inju-
ry or death. Obtain the services of a qu-
alified electrician to make all electrical
connections.
230/460 volt models are dual-voltage;
however, they are wired at the factory
only for the voltage shown on the name-
plate. Do not attempt to change the volt-
age in the field. If desired to have the
voltage changed, return the pump to the
factory or to an authorized Gorman-
Rupp repair facility only. Otherwise,
damage to the pump and injury or death
to personnel can result.
Do not connect the pump motor directly
to the incoming power lines. The pump
motor is designed to operate through a
Gorman-Rupp approved control box
which provides overload protection and
power control; otherwise, the pump
warranty will be voided. Make certain
that the pump and control box are prop-
erly grounded and that the incoming
power matches the requirements of the
pump and controls. Install and operate
the control box in accordance with the
National Electric Code and all local
codes. Failure to follow the instructions
in this warning could result in injury or
death to personnel.
Do not attempt to lift this pump by the
motor power cable or the piping. Attach
proper lifting equipment to the lifting
handle, and make certain that the hook
of the lifting device is securely posi-
tioned in the apex of the handle. If
chains or cables are wrapped around

OM−03501 JDV SERIES
PAGE A − 2 SAFETY
the pump to lift it, make certain that they
are positioned so as not to damage the
pump, and so that the load will be bal-
anced.
After the pump has been installed, make
certain that the pump and all piping or
hose connections are secure before op-
eration. Loose connections can result in
damage to equipment and serious inju-
ry to personnel.
If this pump is used to handle sewage,
take necessary precautions during
maintenance and repair to prevent per-
sonal contamination which could result
in illness.
The following precautions should be
taken before attempting to open or ser-
vice the pump; otherwise, injury or
death could result.
1. Lock out the power to the control pan-
el to ensure that the pump will remain
inoperative.
2. Allow the pump to cool if over heated.
3. Close the discharge valve (if used).

JDV SERIES OM−03501
PAGE B − 1
INSTALLATION
INSTALLATION − SECTION B
Review all SAFETY information in Section A.
This section is intended only to summarize recom-
mended installation practices for this pump. If
there are any questions concerning your specific
installation, contact your Gorman-Rupp distributor
of the Gorman-Rupp Company.
Automatic liquid level controls are available from
Gorman-Rupp as options. For information on in-
stalling and operating these controls, see the tech-
nical data accompanying them.
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be-
fore shipment from the factory. Before installation,
check for damage which may have occurred dur-
ing shipment. Check as follows:
a. Inspect the pump assembly for cracks, dents,
damaged threads, and other obvious dam-
age.
b. Check for and tighten loose attaching hard-
ware. Since gaskets tend to shrink after dry-
ing, check for loose hardware at mating sur-
faces.
c. The standard pump is provided with 26 ft. (8
m.) of power cable. Inspect the cable for cuts
or damage.
d. Check that amperes, phase, voltage, and
Hertz indicated on the motor name plate
match the ratings on the control box.
e. Carefully read all tags, decals, and markings
on the pump assembly, and perform all duties
indicated.
f. Check for any oil leaks. If there is any indica-
tion of an oil leak, see LUBRICATION in
MAINTENANCE AND REPAIR − SECTION
E.
LUBRICATION
These pumps are equipped with a mechanical
double seal. The lower seal prevents the liquid be-
ing pumped from entering the seal housing cavity
from the pump end. The upper seal prevents oil
from escaping from the seal housing into the motor
housing, and acts as backup protection in the
event of lower seal failure.
Both ends of the shaft seal are lubricated by oil in
the seal housing (see LUBRICATION in MAINTE-
NANCE AND REPAIR − SECTION E).
The shaft bearings are permanently lubricated.
There is no other lubrication in the pump.
Pump Dimensions
See Figure B-1 for the approximate physical di-
mensions of this pump.

OM−03501 JDV SERIES
PAGE B − 2 INSTALLATION
FIGURE B−1. PUMP DIMENSIONS

JDV SERIES OM−03501
PAGE B − 3
INSTALLATION
Pump Motor Specifications
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
(104F) ambient, plus 115C (239F) temperature
rise.
See Table B−1 for motor specifications.
TABLE B-1. PUMP MOTOR SPECIFICATIONS
MODEL VOLTAGE SIZE
RPM
MOTOR MAX NO LOCKEDH.P.
NUMBER LOAD LOAD ROTOR
JDV4H60−E19 230/3 4" 19 3450 46.4A 16.4A 408.0A
/PHASE
JDV4H60−E19 460/3 4" 19 3450 23.2A 8.2A 204.0A
PUMP INSTALLATION
Lifting
Pump unit weights will vary depending on the
mounting and drive provided. Check the shipping
tag on the unit packaging for the actual weight, and
use lifting equipment with appropriate capacity.
Drain the pump and remove all customer-installed
equipment such as suction and discharge hoses
or piping before attempting to lift existing, installed
units.
Positioning the Pump
NOTE
Before installing and operating the pump, check
the direction of impeller rotation to ensure that the
pump is properly wired at the control box. See IM-
PELLER ROTATION, SECTION C.
This pump is designed to be mounted on a stand in
a dry pit with an optional 4 x 6 inch suction elbow.
See Figure B−1 for a typical stand/elbow installa-
tion.
Refer to Section E, Figure E−1. Install and secure
the stand in the floor of the dry pit. Install the upper
seal (79) on the stand, and position the pump on
the stand. Install the lower seal on the suction el-
bow, and secure the elbow to the stand and pump
with the screws (21).
Align the elbow with the system suction piping, and
secure. Align the volute casing flange with the sys-
tem discharge piping, and secure.
Reel in any slack control cable, and wire the motor
as indicated in the wiring diagrams in this section.