GORMAN-RUPP PUMPS JSV3H60-E5 230/1 Application guide

OM−05229−OM01
February 22, 2001
Rev. C 05-30-03
CER
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
MODEL
JSV3H60−E5 230/1

OM−05229 JSV3H
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 Motor Specifications PAGE B−1. . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP INSTALLATION PAGE B−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting PAGE B−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning the Pump PAGE B−2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piping. PAGE B−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL CONNECTIONS PAGE B−2. . . . . . . . . . . . . . . . . . . . . . .
Field Wiring Connections (Incoming Power) PAGE B−3. . . . . . . .
Motor Cable Grounding Test PAGE B−3. . . . . . . . . . . . . . . . . . . . .
Conductor Identification PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram and Control Box Connections PAGE B−3. . . . .
Liquid Level Devices PAGE B−5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION − SECTION C PAGE C−1. . . . . . . . . . . . . . . .
PERFORMANCE CURVE PAGE C−1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROLS PAGE C−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP OPERATION PAGE C−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Temperature and Overheating. PAGE C−2. . . . . . . . . . . . .
Impeller Rotation PAGE C−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING, STOPPING, AND OPERATIONAL CHECKS PAGE C−3.
Starting PAGE C−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping PAGE C−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Checks PAGE C−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Preservation PAGE C−4. . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . .

JSV3H OM−05229
PAGE 2 TOC
MAINTENANCE AND REPAIR − SECTION E PAGE E−1.
PARTS LISTS:
Pump Model PAGE E−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Assembly PAGE E−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP AND MOTOR DISASSEMBLY 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 Assemblies) 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−11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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−05229 JSV3H
PAGE I − 1
INTRODUCTION
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 shipped
from the factory wired only for the voltage shown
on the nameplate.
The pump motor is designed to be operated
through an appropriate 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 J Series pumps are
equipped with an integral guide shoe which en-
gages an optional base elbow with a 3−inch dis-
charge; they will handle solids up to 3.15 inches
(80 mm) in diameter. They are designed to operate
fully or partially submerged mounted on guide rails
installed in a wet well, and to handle raw, un-
screened 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−05229 JSV3H
PAGE A − 1SAFETY
SAFETY − SECTION A
These warnings are 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.
This pump is wired at the factory only for
the voltage shown on the nameplate. Do
not attempt to run the pump on alternate
voltage. 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
the pump to lift it, make certain that they
are positioned so as not to damage the

OM−05229JSV3H
PAGE A − 2 SAFETY
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 completely cool if
over heated.
3. Close the discharge valve (if used).

JSV3HOM−05229
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 grease lubricated.
There is no other lubrication in the pump.
Pump Motor Specifications
The motor furnished with this pump is a 60 Hz.,
Squirrel Cage, Induction Start, G-R Frame Size No.
2; 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
LOAD
AMPS
LOCKED
ROTOR
AMPS
H.P.
NUMBER
JSV3H60−E5 230/1 3" 5 1750 23.3A 5.8A 52.0A
/PHASE
NO
LOAD
AMPS

OM−05229JSV3H
PAGE B − 2 INSTALLATION
PUMP INSTALLATION
Lifting
Use lifting equipment with a capacity of at least 990
lbs. (450 kg.). This pump weighs approximately
198 lbs. (90 kg.), including the weight of standard
cable, but not including the weight of customer-
installed accessories such as piping. Discharge
hose or piping must be removed before attempting
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 with an automatic sub-
mersible connection which allows the pump to be
removed and/or installed without personnel enter-
ing the wet well.
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. See Figure
B−1 for a typical elbow/baseplate installation. For
information on installing the guide rails, see the lit-
erature accompanying them.
NOTE
When engaging the guide shoe and elbow/base-
plate, make sure that the connection is not impeded
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 discharge flange connection. Either hose
or rigid pipe may be used to make discharge con-
nections. The discharge line must be independ-
ently supported to avoid vibration and strain on the
pump. For maximum pumping capacity, keep the
line as short and straight as possible. Elbows and
fittings used in a discharge line increase 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.

JSV3HOM−05229
PAGE B − 3
INSTALLATION
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
3200 180 220
PHASE MINIMUM
VOLTAGE
MAXIMUM
VOLTAGE
3230 205 260
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.
Motor Cable Grounding Test
Do not connect the pump control cable
to the control box or incoming voltage
before verifying the pump ground;
otherwise, personnel will be exposed to
serious injury or death.
Connect one lead of lamp, bell or similar testing de-
vice to motor cable green/yellow ground lead.
Connect second test lead to an uninsulated point
on the pump body. The test circuit should close.
If the test circuit does not close there is a defect in
the cable or motor which must be corrected.
Conductor Identification
The conductors in the pump cable are labeled
when shipped from the factory. If the conductors
are shortened in the field, resulting in loss of identi-
fication markers, they can still be identified by their
location relative to the ground wire.
Refer to FIGURE B−1; as seen from the free end of
the cable, the conductor immediately adjacent to
and clockwise from ground (green/yellow) is as-
signed number T1. The second clockwise conduc-
tor is T2, etc.
The conductors labeled P1 and P2 are for thermal
and moisture sensor connections, respectively.
If the conductors are relabled, they should be iden-
tified with wire markers from the factory.
Wiring Diagram and Control Box Connections
The pump warranty is void if the motor is
not operated through a control box ap-
proved by Gorman-Rupp.
This pump is shipped completely wired for the volt-
age shown on the nameplate, and is ready for op-
eration through an approved control box.
Ground the control box in accordance with the in-
structions accompanying it.
Refer to FIGURE B−1, and wire the motor to a con-
trol which will provide the connections shown.
Control leads P1 and P2 provide the motor with
moisture and thermal protection. Note that thermal
protection is supplementary only; separate Class
10 overload relays are required for motor running
protection.
The thermal protection contacts will auto-
matically reclose when the motor cools to
the established safe operating tempera-
ture. Whenever automatic restarting is not
desirable, connect only to controls which
are wired for manual restart.

OM−05229JSV3H
PAGE B − 4 INSTALLATION
FIGURE B−1. INTERNAL MOTOR WIRING