GORMAN-RUPP PUMPS JS Series Operating instructions

PUBLICATION NUMBER MR−03955
August 9, 1993
THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
eCopyright by the Gorman-Rupp Company
JS SERIES PUMPS
MOTOR FRAME SIZE 4
FM
APPROVED
X-PROOF MOTORS FOR CLASS 1,
DIV. 1, GROUPS C & D LOCATIONS

MR−03955 JS SERIES PUMPS
FM
APPROVED
PAGE I − 1INTRODUCTION
INTRODUCTION
Thank You for purchasing a Gorman-Rupp JS
Series FM-Approved Pump. Read this manual
carefully to learn how to safely maintain and ser-
vice your pump. Failure to do so could result in per-
sonal injury or damage to the pump.
A set of three manuals accompanies your pump.
The Installation/Operation Manual contains essen-
tial information on installing and operating the
pump, and on making electrical connections. The
Parts List Manual provides performance curve(s),
a pump model cross-section drawing, and parts
list for your pump.
This Maintenance and Repair Manual provides
troubleshooting and maintenance instructions re-
quired to properly diagnose operational problems,
and to service the pump hydraulic components.
Pump motor maintenance may be performed only
by a Gorman-Rupp authorized FM-Approved re-
pair facility, or the factory. Otherwise, the pump
warranty will be negated, and damage to the
pump, and injury or death to personnel can result.
Contact the factory for the authorized repair facility
closest to you.
The pump is driven by a water-proof, explosion-
proof, submersible electric motor that is FM-ap-
proved for Class 1, Division 1, Group C and D loca-
tions.
If there are any questions regarding the pump
which are not covered in this manual or in other lit-
erature accompanying the unit, please contact
your Gorman-Rupp distributor or the Gorman-
Rupp Company:
The Gorman-Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901−1217
or:
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
CONTENTS
SAFETY − SECTION A
TROUBLESHOOTING − SECTION B
ELECTRICAL TESTING PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Imbalance PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor and Power Cable Continuity PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulation Resistance PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP MAINTENANCE AND REPAIR − SECTION C
GENERAL INFORMATION PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TYPICAL PUMP ASSEMBLY PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PART IDENTIFICATION LIST PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEAL AREA DETAIL PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEAL AREA DETAIL PART IDENTIFICATION LIST PAGE C − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP END DISASSEMBLY PAGE C − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION AND CLEANING PAGE C − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP END REASSEMBLY PAGE C − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEAL TESTING PAGE C − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION PAGE C − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MR−03955JS SERIES PUMPS
FM
APPROVED
PAGE I − 2 INTRODUCTION
RECORDING MODEL AND
SERIAL NUMBERS
Please record the pump model, serial number, volt-
age, and motor frame size in the spaces provided
in the separate Installation/Operation Manual ac-
companying your pump. Your Gorman-Rupp dis-
tributor needs this information when you require
parts or service.
WARRANTY INFORMATION
The warranty provided with your pump is part of
Gorman-Rupp’s support program for customers
who operate and maintain their equipment as de-
scribed in this and the other accompanying litera-
ture. Please note that should the equipment be
abused or modified to change its performance be-
yond the original factory specifications, the war-
ranty will become void and any claim will be de-
nied.
The motor powering this pump is FM-Approved for
Class 1, Division 1, Groups C and D environments.
All repairs to the pump, other than seal, impeller
and other hydraulic components, must be per-
formed by a Gorman-Rupp authorized repair facil-
ity or the factory. Any repairs to the motor assembly
performed by the customer or an unauthorized re-
pair facility negates the FM Approval and the motor
warranty.
The following are used to alert personnel to procedures 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.

MR−03955 JS SERIES PUMPS
FM
APPROVED
PAGE A − 1SAFETY
SAFETY − SECTION A
The following information applies
throughout this manual to Gorman-
Rupp JS Series FM-Approved Submers-
ible pumps.
This manual contains essential informa-
tion on troubleshooting and maintain-
ing the pump. In addition to this manual,
see the separate literature covering in-
stallation and operation, pump parts,
and any optional equipment shipped
with the pump.
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
to personnel.
When installing or servicing the pump
or controls, follow all requirements for
the installation of wiring or electrical
equipment in hazardous locations as
outlined in the National Electric Code.
When entering the pump wet well for in-
stallation or service, follow all safety re-
quirements for confined space entry.
Failure to observe these requirements
could result in injury or death to person-
nel.
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.
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 these could re-
sult in injury or death to personnel.
This pump is not designed to pump vol-
atile, flammable, or corrosive liquids.
The maximum temperature of the liquid
being pumped should not exceed 104_F
(40_C); do not apply the pump at higher
temperatures. Do not attempt to pump
any liquids which may damage the
pump or endanger personnel as a result
of pump failure.

JS SERIES PUMPS MR−03955
FM
APPROVED
PAGE A−2 SAFETY
The following precautions should be
taken before attempting to service the
pump; otherwise, injury or death could
result.
1. Familiarize yourself with this man-
ual and with all other literature
shipped with the pump.
2. Lock out incoming power to the
pump or control box to ensure that
the pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Close the discharge valve (if
used).
Do not attempt to lift this pump by the
motor power cable or the piping. Attach
proper lifting equipment to the lifting
device fitted to the pump, and make cer-
tain that the hook of the lifting device is
securely positioned in the center of the
pump lifting device. If chains or cables
are wrapped around 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 balanced.
If this pump is used to handle liquids
which may cause illness or disease
through direct exposure, take neces-
sary precautions during maintenance
and repair to prevent personal contami-
nation.
The motor powering this pump is FM-Ap-
proved for Class 1, Division 1, Groups C
and D environments. All repairs to the
pump, other than seal, impeller and other
hydraulic components, must be per-
formed by a Gorman-Rupp authorized re-
pair facility or the factory. Any repairs to the
motor assembly performed by the custom-
er or an unauthorized repair facility ne-
gates the FM Approval and the motor war-
ranty.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO
START
MR−03955 JS SERIES PUMPS
FM
APPROVED
TROUBLESHOOTING PAGE B − 1
TROUBLESHOOTING − SECTION B
Review all SAFETY information in Section A.
The following precautions should be
taken before attempting to service the
pump; otherwise, injury or death could
result.
1. Familiarize yourself with this man-
ual and with all other literature
shipped with the pump.
2. Lock out incoming power to the
pump or control box to ensure that
the pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates or
plugs.
4. Close the discharge valve (if
used).
NOTE
Many of the probable remedies listed below re-
quire use of electrical test instruments; for specific
procedures, see ELECTRICAL TESTING following
the chart.
No power to motor. Check for blown fuse or open
circuit breaker.
Impeller jammed. Check Impeller; disassemble and
repair as necessary.
Motor, voltage or control box incompat- Check ratings on pump nameplate
ible; defective connections. and control box; check incoming
voltage; check connections.
Motor cable damaged. Check (see Electrical Testing).
Control box current interrupting or Check control box; check for leaking
moisture-sensing devices tripped. shaft seals, cut O-rings, or moisture
wicking through cable.
Open circuit in motor windings or cable. Check continuity (see Electrical
Testing).
Motor overheated, thermal switches Allow motor to cool.
tripped.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
MOTOR RUNS BUT
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
PUMP STARTS
THEN SHUTS OFF
EXCESSIVE
NOISE OR VIBRA-
TION
JS SERIES PUMPS MR−03955
FM
APPROVED
TROUBLESHOOTINGPAGE B − 2
Pump running backwards. Check and correct impeller rotation
(see Rotation in Installation and
Operation Manual).
Voltage too low or too high; excessive Check incoming voltage; check
voltage drop between pump and control. cable length.
Discharge head too high. Reduce discharge head, or install
staging adaptor and additional pump.
Discharge throttling valve partially Open discharge valve; check piping
closed; check valve improperly installed. installation.
Impeller or discharge line clogged. Check and clear as necessary.
Liquid being pumped too thick. Dilute liquid if possible.
Impeller worn or damaged. Replace.
Insufficient liquid in wet well. Stop pump until liquid level rises;
install liquid level devices.
Clogged suction port or impeller Clear blockage; reset overload
causing motor to overload. device in control box.
Motor overheated; thermal switch Allow pump to cool.
tripped.
Moisture sensing device tripped. Return pump to factory or authorized
repair facility.
Motor bearings defective. Return pump to factory or authorized
repair facility.
Motor cable damaged. Check (see Electrical Testing).
Insufficient liquid in wet well. Stop pump until liquid level rises;
install liquid level devices.
Pump operating outside designed Check discharge head and flow;
operating range. adjust as required to meet perform-
ance specifications.
Impeller clogged. Clear blockage.
Impeller loose or damaged. Check impeller; replace if necessary.
Motor shaft or bearings defective. Replace.
Pumping entrained air. Check wet well liquid level; install
baffles if required.

MR−03955 JS SERIES PUMPS
FM
APPROVED
TROUBLESHOOTING PAGE B − 3
ELECTRICAL TESTING
Make the electrical checks which follow to deter-
mine if pump malfunctions are being caused by
problems in the motor or in the power cable.
Test Equipment
A volt/amp/ohmmeter and megohmmeter of ade-
quate range and quality are required to conduct
the electrical tests which follow. Use commercially
available equipment as listed below.
Equipment Use
Ammeter To check AC Voltage
and current (amperage)
Ohmeter To measure resistance
(ohms) to ground
Refer to the wiring diagram(s) accompany-
ing the motor and control box before re-
connecting any electrical leads which have
been disconnected. Connections to the
wrong terminals may damage the motor
and/or control devices.
Voltage Imbalance
Use a voltmeter to read each phase of the incom-
ing 3-phase power. Each phase must balance with
the other two as closely as can be measured with a
commercial instrument. If the phases are out of
balance, contact your power company. If the
phases are balanced, check out the motor as de-
scribed in the following steps:
a. Use a voltmeter, Amprobe, or equivalent in-
strument to read the voltage of incoming
power lines 1 and 2, 2 and 3, and 1 and 3 at the
control box. Voltage must match as closely as
can be measured. If possible, measure the
voltage at the control box with:
1. The pump off.
2. The pump running in air.
3. The pump submerged and running under
full load.
The voltage measured under each condition must
be the same.
b. If voltage is balanced when the pump is off but
is imbalanced when the pump is running,
thoroughly check the power source, all inter-
connecting cables, and the pump motor to
isolate the defect.
c. Use an Amprobe or equivalent instrument to
measure the current draw (amperage) of
each phase while the pump is running under
full load, and with no load. In each condition,
the amperage readings for all three phases
must match as closely as can be measured.
Normal amperage values are listed in Table 1,
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-
balance it. Test as follows:
a. Shut off incoming power to the control box,
and disconnect the motor power cable leads.
Connect the megohmmeter test leads to any
two power cable leads, and note the megohm
meter reading. A high resistance reading indi-
cates an open or broken circuit in the power
cable or motor windings, or a bad connection
between the motor and cable.
b. Repeat Step a. with each set of leads. The
three readings should be as close as can be
measured.
c. If readings indicate that continuity problems
exist in the motor or power cable, the motor
must be returned to the factory or to a Gor-
man-Rupp authorized repair facility.

JS SERIES PUMPS MR−03955
FM
APPROVED
TROUBLESHOOTINGPAGE B − 4
Insulation Resistance
Set the megohmmeter at R x 100, and zero-ba-
lance it. Test as follows:
a. Shut off incoming power to the control box,
and disconnect the motor power cable leads.
Connect one megohmmeter test lead to the
motor cable green/yellow ground lead. Touch
the other test lead to each of the motor cable
leads in turn. Note the readings.
b. Readings will indicate resistance values in
both the power cable and motor windings.If
resistance reads infinity (1), insulation is
good. If resistance reads between infinity (1),
and 1 megohm, insulation is acceptable but
should be rechecked regularly. If resistance
reads less than 1 megohm, insulation should
be checked more closely and frequently.
c. If readings indicate that a ground exists, the
motor must be returned to the factory or to a
Gorman-Rupp authorized repair facility.

MR−03955 JS SERIES PUMPS
FM
APPROVED
PAGE C − 1MAINTENANCE AND REPAIR
PUMP MAINTENANCE AND REPAIR − SECTION C
GENERAL INFORMATION
Review all SAFETY information in Section A.
Do not attempt to service the pump end
assembly unless all power to the motor
has been shut off at the control box;
otherwise, injury or death could result.
Use a lifting device with sufficient ca-
pacity. If slings or chains are used to
move the pump or components, make
sure that the load is balanced; other-
wise serious personal injury or death
could result.
The maintenance and repair instructions in this
manual are keyed to the sectional views, Figures
1 and 2, and the corresponding parts identification
lists. Refer to the separate Parts List Manual for re-
placement parts.
Select a suitable location, preferably indoors, to
perform required maintenance. All work must be
performed by qualified personnel.
The motor powering this pump is FM-Ap-
proved for Class 1, Division 1, Groups C
and D environments. All repairs to the
pump, other than seal, impeller and other
hydraulic components, must be per-
formed by a Gorman-Rupp authorized re-
pair facility or the factory. Any repairs to the
motor assembly performed by the custom-
er or an unauthorized repair facility ne-
gates the FM Approval and the motor war-
ranty.
This Maintenance and Repair Manual provides
troubleshooting and maintenance instructions re-
quired to properly diagnose operational problems,
and to service the pump hydraulic components.
Pump motor maintenance may be performed only
by a Gorman-Rupp authorized repair facility, or the
factory. Otherwise, the pump warranty will be ne-
gated, and damage to the pump, and injury or
death to personnel can result. Contact the factory
for the authorized repair facility closest to you.
Check TROUBLESHOOTING, Section B to deter-
mine causes and remedies of pump problems.
Disassemble the pump only as far as required.
Lifting
Use lifting equipment with a capacity of at least
five times the weight of the pump, including the
weight of any options or customer-installed acces-
sories. The approximate maximum weight for this
pump is 441 lbs. (200 kg.). Discharge hose or pip-
ing must be removed before attempting to lift the
pump.

JS SERIES PUMPS MR−03955
FM
APPROVED
MAINTENANCE AND REPAIRPAGE C − 2
SECTION DRAWING
Figure C−1. Typical JS Series Motor Frame Size 4 Pump Assembly

ITEM PART NAME
NO.
MR−03955 JS SERIES PUMPS
FM
APPROVED
PAGE C − 3MAINTENANCE AND REPAIR
Typical JS Series Motor Frame Size 4 Pump Assembly
Part Identification List
Refer to the separate Parts List Manual for serviceable parts, part numbers and quantities.
1 MOTOR ASSEMBLY
5 IMPELLER
6 IMPELLER KEY
10 IMPELLER SCREW
11 VOLUTE CASING
13 SCREW
31 RUBBER SEAL
38 GUIDE SHOE
41 CAPSCREW
53 NAMEPLATE
54 RIVET
74 ADJUSTING SCREW

JS SERIES PUMPS MR−03955
FM
APPROVED
MAINTENANCE AND REPAIRPAGE C − 4
SECTION DRAWING
Figure C−2. JS Series Motor Frame Size 4 Seal Area Detail

ITEM PART NAME
NO.
MR−03955 JS SERIES PUMPS
FM
APPROVED
PAGE C − 5MAINTENANCE AND REPAIR
JS Series Motor Frame Size 4 Seal Area Detail
Part Identification List
Refer to the separate Parts List Manual for serviceable parts, part numbers and quantities.
213 LOWER BEARING HOUSING
218 UPPER SEAL ASSEMBLY
251 O-RING
254 SCREW
257 SEAL HOUSING
260 LOWER SEAL ASSEMBLY
261 SEAL CLAMP
264 LOCKING RING
265 RETAINING RING
266 RETAINING SCREW
268 PLUG
269 O-RING

JS SERIES PUMPS MR−03955
FM
APPROVED
MAINTENANCE AND REPAIRPAGE C − 6
PUMP END DISASSEMBLY
References are to Figure C−1.
NOTE
The pump end components may be separated from
the motor without draining the oil from the motor.
If necessary to pry components apart to
separate them, use levers on both sides of
the component, and apply pressure even-
ly. Be careful not to mar mating surfaces.
When removing parts from the rotor/shaft
assembly, be careful not to mar the surface
or tapered end of the shaft.
Use a suitable lifting device to remove the pump
from the wet well, and position it horizontally on a
flat surface.
Loosening Impeller Capscrew
1. The impeller capscrew (10) should be loosened
before removing the volute casing (11). Block
impeller rotation by wedging a wood block or
soft brass bar into the impeller vanes through
the pump discharge.
2. Reach through the pump suction with a socket
wrench and loosen, but do not remove, the im-
peller capscrew (10). Remove the wood block
or brass bar and proceed as follows.
Removing Motor Assembly
1. Position the pump vertically, and remove the
screws (13) securing the motor assembly (1) to
the pump casing. Use the adjusting screws (74)
to jack the motor assembly out of the volute
casing . It is not necessary to remove the adjust-
ing screws unless replacement is required.
2. Use the lifting device to lift the motor assembly
and pump end components from the volute
casing. Re-position the pump horizontally on a
work bench or other suitable surface for further
disassembly.
3. If desired, remove the hardware (41), and sepa-
rate the guide shoe (38) from the volute casing.
Remove the rubber seal (31).
Removing Impeller
1. Remove the impeller screw (10).
2. To remove the impeller, use two screwdrivers to
apply equal pressure 180_apart to the back of
the impeller, and strike the end of the impeller
shaft sharply with a soft-faced mallet. Repeat as
necessary until the impeller comes free of the
shaft. Retain the impeller key (6).
Removing Seal Assembly
References are to Figure C−2.
To maintain peak operating efficiency, it is
strongly recommended that the seal be
replaced if the pump is disassembled. In
the event that the seal will be reused, han-
dle seal parts with extreme caution to pre-
vent damage. Use care not to contaminate
the precision-finished faces; even finger-
prints on the faces can shorten seal life.
1. See LUBRICATION at the end of this section,
remove the lower (seal cavity) plug and O-ring
(268 and 269), and drain the oil from the seal
housing.
NOTE
Use caution in Step 2, tension on the seal clamp
springs will be released.
2. Loosen the retaining screws (266), and remove
the retaining ring (265).
3. Turn the seal spring to disengage it from the ro-
tating element, and remove the spring and
spring retainer.
4. Lightly oil the shaft and remove the seal rotating
element and O-ring.
5. Remove the locking ring (264) and seal clamp
(261) from the seal housing (257). Slide the low-
er seal stationary element off the shaft.

MR−03955 JS SERIES PUMPS
FM
APPROVED
PAGE C − 7MAINTENANCE AND REPAIR
If no further disassembly is required, refer to IN-
SPECTION AND CLEANING, followed by PUMP
END REASSEMBLY.
Upper Seal Removal
References are to FIGURES C−2 and C−3.
1. Remove the screws (254) securing the seal
housing housing (257) to the stator housing.
Use a soft-faced mallet to tap around the seal
housing until it comes free of the lower bearing
housing (213). Slide the seal housing off the
shaft.
NOTE
Use caution in Step 2, tension on the seal clamp
springs will be released.
2. Loosen the drive screw, and remove the retain-
er and springs.
3. Lightly oil the shaft, and remove the seal rotat-
ing element and O-ring.
4. Work a pair of stiff wires with hooked ends be-
tween the stationary seal seat and the bearing
housing (213), and pull the stationary seat and
O-ring out of the bearing housing.
If no further disassembly is required, refer to IN-
SPECTION AND CLEANING, followed by PUMP
END REASSEMBLY.
INSPECTION AND CLEANING
Carefully inspect all O-ring seating areas to deter-
mine if they formed a proper seal. If sealing was
faulty, determine the cause before reassembling
the pump. After inspection, remove and discard all
O-rings.
Most cleaning solvents are toxic and
flammable. Use them only in a well-ven-
tilated area free from flame, sparks, and
excessive heat. Read and follow all pre-
cautions printed on solvent containers.
Reusable Parts (Except Seal Assemblies)
1. Thoroughly clean all reusable parts.
2. Inspect all mating surfaces for nicks or burrs,
and restore to original contours with emery
cloth or a fine file. If the surface cannot be re-
stored, replace the part.
Cleaning Seal Assemblies
Seal faces are precision-finished and sub-
ject to wear patterns which cannot be re-
aligned during assembly. The seal assem-
bly should be replaced completely at each
overhaul to ensure trouble-free operation.
If necessary to use an old seal in an emer-
gency, never mix old and new seal parts;
seal performance will be severely affected.
1. Inspect the seal assembly for wear, scoring,
grooves, and other damage that might cause
leakage.
2. Wash all seal parts in fresh cleaning solvent and
allow to dry thoroughly. Re-inspect the parts af-
ter cleaning.
3. If needed, clean the seal faces with a clean, lint-
free cloth. Wipe lightly in a concentric pattern to
avoid scratching the faces.

JS SERIES PUMPS MR−03955
FM
APPROVED
MAINTENANCE AND REPAIRPAGE C − 8
PUMP END REASSEMBLY
Installing Upper Seal Assembly
References are to Figure C−2.
If a new seal is being installed, do not un-
wrap it until ready to install; seal compo-
nents must be kept clean. Handle seal
parts with extreme caution to prevent dam-
age. Use care not to contaminate the preci-
sion-finished faces; even fingerprints on
the faces can shorten seal life.
NOTE
Use hand pressure only to install seal components.
A push tube cut from plastic pipe approximately the
same O.D. as the stationary seat is a useful aid
when installing these components. It is recom-
mended that the pump be inverted during seal as-
sembly.
LOWER BEARING
HOUSING
STATIONARY
SEAT
SPRING
RETAINER
SEAL
HOUSING
STATIONARY
SEAT
SPRING
RETAINER
SPRING
RETAINING
RING
O-RING
O-RING
ROTATING
ELEMENT
DRIVE
SCREW
O-RING
SEAL CLAMP
LOCKING RING
O-RING
ROTATING
ELEMENT
RETAINING
SCREW
UPPER
SEAL
ASSEMBLY
LOWER
SEAL
ASSEMBLY
Figure C−3. Seal Assemblies
1. Inspect the end of the shaft for scoring or key-
way damage. Remove nicks and burrs with a
fine file or emery cloth, and restore original con-
tours. Clean the shaft of all grit and filings.
2. Lubricate the motor shaft and the seal cavity of
the lower bearing housing (213). Replace the
bearing housing O-ring (251).
3. Unwrap the seal components. Check that the
seal faces are clean and undamaged. If neces-
sary to clean, use a clean tissue and wipe in a
concentric pattern.
4. Lightly oil the seal stationary seat O-ring and in-
stall it in the bearing housing. Place a clean tis-
sue over the stationary seat seal face, and
press it into the bearing housing with the seal
face up.
5. Install the rotating element and O-ring on the
shaft flush against the stationary seat.
6. Place a spot of grease in the cups of the spring
retainer to hold the springs in place, and install
the springs in the cups. Make certain that the
springs are in place, and install the spring re-

MR−03955 JS SERIES PUMPS
FM
APPROVED
PAGE C − 9MAINTENANCE AND REPAIR
tainer in the rotating element. Align the retainer
with the step in the shaft, and secure with the
drive screw.
Installing Lower Seal Assembly
References are to FIGURES C−2 and C−3.
1. Lubricate the motor shaft and the seal cavity of
the lower bearing housing (213).
2. Unwrap the seal components. Check that the
seal faces are clean and undamaged. If neces-
sary to clean, use a clean tissue and wipe in a
concentric pattern.
3. Place a clean, lint-free cloth over the stationary
seat seal face, and install the stationary seat
and O-ring in the seal housing.
4. Install the seal clamp (261) in the seal housing,
and secure it with the locking ring (264).
5. Slide the assembled seal parts and seal hous-
ing (257) over the shaft, and use a soft-faced
mallet to tap the seal housing into place until ful-
ly seated against the lower bearing housing
(213). Use caution not to damage the O-ring
(251). Secure the seal housing to the stator
housing with the screws (254).
6. Install the rotating element flush against the sta-
tionary seat. Lightly lubricate and install the ro-
tating element O-ring.
7. Install the seal spring retainer against the rotat-
ing element O-ring. Install the seal spring, and
engage it in the groove in the rotating element.
8. Install the spring retaining ring (265). Compress
the spring until the retaining ring is even with the
chamfer on the shaft, and secure it with the re-
taining screws (266).
NOTE
See Seal Testing before assembling the remaining
pump end components.
9. After the pump is fully assembled, lubricate the
seal housing as indicated in LUBRICATION at
the end of this section.
SEAL TESTING
The seal assembly should be tested under pres-
sure and submerged in water before the pump end
is assembled.
NOTE
The compressed air used in testing must be dry.
Moist air in the motor housing will cause the mois-
ture switch inside the motor to trip.
There are two screw plugs along the flange of the
motor housing, and a third in the body of the hous-
ing; the third (upper) plug is used in testing only.
Test 1:
1. Remove either of the two screw plugs and O-
rings (268 and 269) along the flange of the mo-
tor housing. Thread an air hose adaptor into the
hole, and install an air hose.
2. Remove the screw plug and O-ring in the top of
the motor housing. Thread an air hose adaptor
into the hole, and install an air hose.
3. Submerge the pump in water and apply 14−15
psi maximum to the lower air hose. Check for
air bubbles. If air bubbles appear, the seal(s)
are leaking. Disassemble the seal(s), and find
and correct the cause of the leak.
4. Re-run the test after corrective action has been
taken.
Test 2:
1. Install air hoses as in Test 1.
This test is conducted with the pump un-
der power. Refer to the appropriate wir-
ing diagram in this section and observe
all precautions outlined in PUMP SAFE-
TY − SECTION A when connecting the
motor cable to the control box; other-
wise, the pump could be damaged, and
personnel exposed to injury or death.

JS SERIES PUMPS MR−03955
FM
APPROVED
MAINTENANCE AND REPAIRPAGE C − 10
2. Connect the motor cable leads to the control
box. Do not apply power to the motor at this
time.
3. Submerge the motor assembly so that both
hose connections are covered. Apply 14−15
psi pressure maximum to both air hoses.
In the following steps do not apply power
for more than 10 seconds; otherwise, the
unlubricated seal will overheat and may
burn.
4. Briefly apply power to the motor, and check for
air bubbles. If air bubbles appear, shut off
power, then apply again. If air bubbles persist,
the seal(s) are leaking.
5. Disassemble the seal(s), and find and correct
the cause of the leak.
6. Re-run the test after corrective action has been
taken.
7. After the seals have been tested, remove the air
hoses. Lubricate a new O-ring, and install and
tighten the screw plug in the top of the motor
housing. The lower screw plug will be used in
LUBRICATION.
Installing Impeller
References are to FIGURE C−1.
1. Check the impeller (5) for broken vanes,
cracks, or excessive wear. Replace as neces-
sary.
2. Oil the end of the motor shaft and the keyway.
Install the impeller key (6) in the shaft keyway.
Position the impeller (5) on the shaft, and en-
gage the key in the impeller keyway.Press the
impeller onto the shaft until fully seated.
The threads of the impeller screw (10) and
its mating surfaces must be lubricated to
reduce friction and prevent corrosion.
3. Lubricate the threads of the impeller screw (10)
and its mating surfaces with SAE 10W 30 oil. In-
stall the impeller screw. Torque the impeller
screw as described in Installing Volute
Casing, after the casing is installed.
Installing Volute Casing
1. Use a suitable lifting device to lower the motor
assembly into the volute casing, and secure it
with the screws (13).
2. Insert a wood block through the pump dis-
charge opening and block impeller rotation.
Reach through the pump suction opening with
a wrench, and torque the impeller screw (10) to
40 ft. lbs. (480 in. lbs. or 5,5 m. kg.). Remove the
wood block from the discharge opening.
3. If the guide shoe (32) and rubber seal (31) were
removed, position the seal in the guide shoe,
and secure the guide shoe to the volute casing
with the hardware (41).
Impeller Clearance
NOTE
Impeller clearance should always be adjusted
when the volute casing or impeller have been re-
moved from the pump.
1. Use a feeler gauge to measure the clearance
between the bottom of the impeller (5) and the
volute casing. Loosen the screws (13), and
tighten or loosen the adjusting screws in an al-
ternating sequence to set the impeller clear-
ance between 0.020 and 0.035 inches (0,5 and
0,9 mm) at all points.
3. After the impeller clearance has been set, fully
tighten the screws (13) securing the volute cas-
ing to the motor assembly.
Final Assembly
1. If the hose connector (32) was removed, install
a new O-ring (30), and secure the connector to
the volute casing with the hardware (36).

MR−03955 JS SERIES PUMPS
FM
APPROVED
PAGE C − 11MAINTENANCE AND REPAIR
2. Install the pump on the stand (26), and secure it
with the screws (21).
3. Lubricate the pump as indicated in LUBRICA-
TION before returning the pump to service.
LUBRICATION
All references are to FIGURE C−2.
The upper screw plug (268) in the motor
housing is used for testing only; do not
add oil through this plug.
Before installing or removing the screw plugs
(268), always clean the area around the plugs to
prevent contamination of the oil.
Discard the plug O-rings (269) if the plugs are re-
moved. Lubricate the new O-rings with oil - not
grease - before installing them.
The seal assemblies (218 and 260) are lubricated
by a reservoir of oil in the seal housing (257).
Draining Oil
1. Lay the pump flat on a work surface with one of
the two screw plugs (268) in the seal housing
(257) facing up; slowly open the plug to release
any pressure.
2. Place a clean container under the lower plug,
remove, and roll the pump on its side to drain
the seal housing.
Condition Of Oil
1. Check the condition of the oil drained from the
pump.
2. If the oil is clear, it can be reused.
3. If the oil is milky or contains a small amount of
water, it must be changed.
4. If the oil contains a large amount of water, it
must be changed, and the lower seal assembly
(260) must be checked before the pump is put
back in operation.
Adding Oil
1. Lay the pump flat on a work surface with one of
the two screw plugs (268) in the seal housing
(257) facing up; slowly open the plug to release
any pressure.
2. Remove the second (lower) screw plug in the
seal housing, and add SAE 10W 30 motor oil
through the top plug hole until it escapes from
the lower plug hole.
3. Lubricate and install new O-rings (269), and in-
stall and tighten the plugs (269).