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.