GORMAN-RUPP PUMPS JSV3A60-E2.7 200/3 Application guide

OM-03626−OM04
March 21, 1997
Rev. B 01/22/01
CDER
THE GORMAN-RUPP COMPANY MANSFIELD, OHIO
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
JSV3A60−E2.7 200/3 JSV3A60−E2.7 230/3 JSV3A60−E2.7 460/3 JSV3A60−E2.7 575/3
JSV3B60−E2.7 200/3 JSV3B60−E2.7 230/3 JSV3B60−E2.7 460/3 JSV3B60−E2.7 575/3
JSV3C60−E2.7 200/3 JSV3C60−E2.7 230/3 JSV3C60−E2.7 460/3 JSV3C60−E2.7 575/3
JSV3D60−E4 200/3 JSV3D60−E4 230/3 JSV3D60−E4 460/3 JSV3D60−E4 575/3
MODELS

OM−03626 JSV3A−B−C−D60 DV
PAGE−1TOC
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−6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram PAGE B−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION − SECTION C PAGE C−1. . . . . . . . . . . . . . . .
PERFORMANCE CURVES PAGE C−1. . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX AND OPTIONAL CONTROLS PAGE C−5. . . . . . . . . .
PUMP OPERATION PAGE C−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Temperature and Overheating. PAGE C−5. . . . . . . . . . . . .
Impeller Rotation PAGE C−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING, STOPPING, AND OPERATIONAL CHECKS PAGE C−6.
Starting PAGE C−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping PAGE C−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Checks PAGE C−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Preservation PAGE C−7. . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . .
Insulation Resistance PAGE D−3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

JSV3A−B−C−D60 DV OM−03626
TOCPAGE−2
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 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. . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Oil PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condition Of Oil PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding Oil PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM−03626 JSV3A−B−C−D60
PAGE I − 1INTRODUCTION
INTRODUCTION
This Installation, Operation, and Maintenance
Manual is designed to help you achieve the best
performance and longest life from your Gorman-
Rupp J Series submersible pump.
The manual applies only to the submersible pump
models listed on the cover and in MAINTENANCE
AND REPAIR − SECTION E. Refer to the name-
plate on your pump to determine the specific
model, voltage, and horsepower.
These J Series pumps are driven by a waterproof
submersible electric motor. The motor is dual volt-
age, but is shipped from the factory wired only for
the voltage shown on the nameplate. Contact the
factory before attempting to change to the alter-
native 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.
Pump construction is cast iron, with stainless steel
shaft and hardware. These pumps are equipped
with an integral guide shoe which engages an op-
tional base elbow with a 3−inch discharge; they
will handle solids up to 3−inches in diameter. The
pumps are designed to operate fully or partially
submerged mounted on guide rails installed in a
wet well, and to handle raw, unscreened sewage
and effluents. Installation of the guide rail system
and other wet well hardware is not covered in this
manual. Refer to other literature accompanying the
pump.
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 or Gorman-Rupp of Canada Limited
P.O. Box 1217 70 Burwell Road
Mansfield, Ohio 44901−1217 St. Thomas, Ontario N5P 3R7
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.

OM−03626 JSV3A−B−C−D60
PAGE A − 1SAFETY
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, control accessories,
guide rails and other installation hardware
shipped with this pump. This literature contains
essential information on installing and operating
the pump, and on making electrical 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 (70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.
This pump is dual voltage, 230/460−3
phase. Your pump was wired at the fac-
tory only for the voltage shown on the
nameplate. Do not attempt to change
the voltage 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 in-
jury 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

JSV3A−B−C−D60 OM−03626
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.
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).
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.

OM−03626 JSV3A−B−C−D60
PAGE B − 1INSTALLATION
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
or the Gorman-Rupp Company.
The motor in these pumps is not designed
to be operated in air for more than 10 min-
utes without overheating. The pumps must
be operated through liquid level controls to
maintain the level of liquid in the wet well so
that power to the motor is cut off when liq-
uid falls below the midpoint of the motor
housing in single pump operation, and be-
low the level of the discharge flange in du-
plex pump operation.
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.

JSV3A−B−C−D60 OM−03626
PAGE B − 2 INSTALLATION
FIGURE B−1. PUMP DIMENSIONS 16020

OM−03626 JSV3A−B−C−D60
PAGE B − 3INSTALLATION
Pump Motor Specifications
The motor furnished with this pump is a 60 Hz.,
Squirrel Cage, Induction Start, G-R Frame Size No.
1; Class F Insulation Rated 155C (311F), 40C
(104F) ambient, plus 115C (239F) temperature
rise.
See Table B−1 for motor specifications.
575/3
JSV3C60−E2.7
TABLE B-1. PUMP MOTOR SPECIFICATIONS
MODEL VOLTAGE SIZE
RPM
MOTOR MAX NO LOCKEDH.P.
NUMBER LOAD LOAD ROTOR
JSV3A60−E2.7
JSV3A60−E2.7
200/3
460/3
3"
3"
2.7
2.7
1750
1750
11.0A 6.0A 51.7A
/PHASE
3.8A 2.8A 22.5A
JSV3B60−E2.7
JSV3B60−E2.7
230/3
460/3
3"
3"
2.7
2.7
1750
1750
8.4A 5.9A 47.0A
4.0A 2.8A 22.5A
JSV3C60−E2.7
JSV3C60−E2.7
230/3
460/3
3"
3"
2.7
2.7
1750
1750
9.6A 5.9A 47.0A
4.6A 2.8A 22.5A
JSV3D60−E4
JSV3D60−E4
230/3
460/3
3"
3"
4.0
4.0
1750
1750
12.8A 5.9A 48.1A
6.1A 2.8A 22.9A
JSV3A60−E2.7 575/3 3" 2.7 1750 3.0A 2.2A 18.0A
JSV3B60−E2.7 575/3 3" 2.7 1750 3.0A 2.2A 18.0A
3" 2.7 1750 3.0A 2.2A 18.0A
JSV3D60−E4 575/3 3" 4.0 1750 3.0A 2.2A 18.0A
JSV3D60−E4 200/3 3" 4.0 1750 11.1A 5.1A 41.8A
JSV3C60−E2.7 200/3 3" 2.7 1750 8.4A 5.1A 41.0A
JSV3B60−E2.7 200/3 3" 2.7 1750 7.3A 5.1A 41.0A
JSV3A60−E2.7 230/3 3" 2.7 1750 7.9A 5.9A 47.0A
PUMP INSTALLATION
Lifting
Use lifting equipment with a capacity of at least 660
lbs. (300 kg.). Each version of these pumps
weighs approximately 132 lbs. (60 kg.), including
the weight of standard cable, but not including the
weight of customer-installed accessories such as
the elbow/baseplate and discharge piping. Dis-
charge hose or piping must be removed before at-
tempting to lift the pump.
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 operated mounted on
guide rails and a discharge elbow/baseplate of-
fered as an option. See Figure B−1 for a typical el-
bow/baseplate installation.
The pump is equipped with a rail guide shoe which
connects to the discharge optional elbow/
baseplate. When lowered into place, the pump is
automatically and securely connected to the el-
bow/baseplate and the piping system. For infor-
mation on installing the guide rails, see the litera-
ture accompanying them.
NOTE
When engaging the guide shoe and elbow/base-
plate, make sure that the connection is not impeded

JSV3A−B−C−D60 OM−03626
PAGE B − 4 INSTALLATION
by mounting hardware, and that the guide shoe is
fully seated in the baseplate.
Engage the guide shoe at the top of the guide rails,
and lower the pump into the sump. When the
pump and guide shoe engages the discharge el-
bow/baseplate, it will form an automatic seal.
Reel in any slack control cable so that it is not
dragged into the pump suction.
Piping
NOTE
Refer to PERFORMANCE CURVES in OPERA-
TION − SECTION C when determining the most ef-
ficient piping installation.
No suction piping is required in a standard sub-
merged operation.
The optional elbow/baseplate is drilled for a
3−inch or 4−inch discharge flange connection.
Either hose or rigid pipe may be used to make dis-
charge connections. The discharge line must be
independently supported to avoid vibration and
strain on the pump. For maximum pumping capac-
ity, keep the line as short and straight as possible.
Elbows and fittings used in a discharge line in-
crease friction losses; minimize their use.
It is recommended that a check valve or throttling
valve be installed in the discharge line to control si-
phoning or back flow when the pump is shut off.
ELECTRICAL CONNECTIONS
Install and operate this pump in accor-
dance with the National Electrical Code
and all local codes. Have a qualified
electrician perform all checks and con-
nections in this section.
Never attempt to alter the length of the
pump motor cable or to repair it with a
splice. The power cable and pump mo-
tor must be kept completely waterproof.
Serious damage to the pump and injury
or death to personnel can result from
any alteration to the cable.
Field Wiring Connections (Incoming Power)
Field wiring is not provided with this pump, and
must be supplied by the user. The field wiring must
be of the proper size and type to ensure an ade-
quate voltage supply to the pump. Voltage avail-
able at the motor must be within the range indi-
cated in Table B-2.
TABLE B-2. MOTOR VOLTAGE LIMITS
NOMINAL
VOLTAGE
3230 210 250
PHASE MINIMUM
VOLTAGE
MAXIMUM
VOLTAGE
3460 420 500
3575 520 630
3200 180 220
Use conduit cable clamps to secure the incoming
field wiring to the control box. Make certain all con-
nections are tight. If necessary, support the cable
weight to prevent excessive strain on cable clamps
and cable.
Dual Voltage
230V and 460V versions of this pump are
dual-voltage; however, they are wired at
the factory only for the voltage shown on
the nameplate. Do not attempt to
change the voltage in the field. If de-
sired to have the voltage changed, re-
turn the pump to the factory or to an au-
thorized Gorman-Rupp repair facility
only. Otherwise, damage to the pump
and injury or death to personnel can re-
sult.