GORMAN-RUPP PUMPS JSV4F60-E8.7 230/3 Application guide

OM−03592−OM01CER
NOVEMBER 30, 1990
Rev. B
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
MODELS
JSV4F60−E8.7 230/3
DUAL VOLTAGE
JSV4F60−E8.7 460/3
JSV4G60−E11 230/3 JSV4G60−E11 460/3

OM−03592−OM01 JSV4F−G60 DV
TOC PAGE−1
TABLE OF CONTENTS
INTRODUCTION PAGE I−1. . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY − SECTION A PAGE A−1. . . . . . . . . . . . . . . . . . . . .
INSTALLATION − SECTION B PAGE B−1. . . . . . . . . . . . . .
PREINSTALLATION INSPECTION PAGE B−1. . . . . . . . . . . . . . . . . . . .
LUBRICATION PAGE B−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Dimensions PAGE B−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Motor Specifications PAGE B−3. . . . . . . . . . . . . . . . . . . . . . .
PUMP INSTALLATION PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning the Pump PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piping PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL CONNECTIONS PAGE B−4. . . . . . . . . . . . . . . . . . . . . . .
Field Wiring Connections (Incoming Power) PAGE B−4. . . . . . . .
Dual Voltage PAGE B−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conductor Identification PAGE B−4. . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Cable Grounding Test PAGE B−5. . . . . . . . . . . . . . . . . . . . . .
Control Box Connections PAGE B−5. . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams PAGE B−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIQUID LEVEL DEVICES PAGE B−6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION − SECTION C PAGE C−1. . . . . . . . . . . . . . . .
PERFORMANCE CURVES PAGE C−1. . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX AND OPTIONAL CONTROLS PAGE C−3. . . . . . . . . .
PUMP OPERATION PAGE C−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Temperature and Overheating. PAGE C−3. . . . . . . . . . . . . .
Impeller Rotation PAGE C−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING, STOPPING, AND OPERATIONAL CHECKS PAGE C−4.
Starting PAGE C−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping PAGE C−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Preservation PAGE C−4. . . . . . . . . . . . . . . . . . . . . . .
Operations Checks PAGE C−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING − SECTION D PAGE D−1. . . . . . . .
TROUBLESHOOTING CHART PAGE D−1. . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL TESTING PAGE D−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment PAGE D−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Imbalance PAGE D−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor and Power Cable Continuity PAGE D−3. . . . . . . . . . . . . . . . .
Insulation Resistance PAGE D−4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

JSV4F−G60 DV OM−03592−OM01
TOCPAGE−2
MAINTENANCE & REPAIR − SECTION E PAGE E−1. . . .
PARTS LIST − FIGURE E−1 PAGE E−3. . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS PAGE E−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS LIST − FIGURE E−2 PAGE E−5. . . . . . . . . . . . . . . . . . . . . . . . .
PUMP AND MOTOR DISASSEMBLY AND REASSEMBLY PAGE E−6
PUMP END DISASSEMBLY PAGE E−6. . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Volute Casing PAGE E−6. . . . . . . . . . . . . . . . . . . . .
Removing the Impeller PAGE E−6. . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR DISASSEMBLY PAGE E−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Junction Box Cover Disassembly PAGE E−7. . . . . . . . . . . . . . . . . .
Removing the Stator/Motor Housing PAGE E−7. . . . . . . . . . . . . . .
Seal Disassembly PAGE E−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Bearings PAGE E−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION AND CLEANING PAGE E−9. . . . . . . . . . . . . . . . . . . . . . .
Bearings PAGE E−9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Reusable Parts (Except Seal Assembly) PAGE E−9. . . . . .
Cleaning Seal Assembly PAGE E−9. . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP AND MOTOR REASSEMBLY PAGE E−9. . . . . . . . . . . . . . . . . . .
MOTOR REASSEMBLY PAGE E−9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Junction Box Cover Reassembly PAGE E−9. . . . . . . . . . . . . . . . . .
Installing Bearings PAGE E−11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating Assembly PAGE E−11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Reassembly PAGE E−11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Testing PAGE E−12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP END REASSEMBLY PAGE E−13. . . . . . . . . . . . . . . . . . . . . . . . . .
Installing The Impeller PAGE E−13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing The Volute Casing PAGE E−13. . . . . . . . . . . . . . . . . . . . . .
Impeller Clearance PAGE E−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Oil PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condition Of Oil PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding Oil PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

JSV4F−G60 DV
OM−03592−OM01
INTRODUCTION PAGE I−1
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. 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 4−inch dis-
charge; they will handle solids up to 3−inches in
diameter. The pumps are designed to operate fully
or partially submerged mounted on guide rails in-
stalled 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 accompa-
nying 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:
NOTE
Instructions to aid in installation, operation, and maintenance, or which clarify a procedure.
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
CAUTION
INSTRUCTIONS WHICH MUST BE FOLLOWED TO AVOID CAUSING DAMAGE TO THE PRODUCT OR
OTHER EQUIPMENT INCIDENTAL TO THE INSTALLATION. THESE INSTRUCTIONS DESCRIBE THE
REQUIREMENTS AND THE POSSIBLE DAMAGE WHICH COULD RESULT FROM FAILURE TO FOL-
LOW THE PROCEDURE.
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
WARNING
INSTRUCTIONS WHICH MUST BE FOLLOWED TO AVOID CAUSING INJURY OR DEATH TO PER-
SONNEL. THESE INSTRUCTIONS DESCRIBE THE PROCEDURE REQUIRED AND THE INJURY
WHICH COULD RESULT FROM FAILURE TO FOLLOW THE PROCEDURE.

JSV4F−G60 DV OM−03592−OM01
INTRODUCTIONPAGE I−2
This page intentionally blank.

OM−03592−OM01 JSV4F−G60 DV
SAFETY PAGE A−1
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, 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.
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
WARNING
BEFORE ATTEMPTING TO INSTALL, OPERATE,
OR SERVICE THIS PUMP, FAMILIARIZE YOUR-
SELF WITH THIS MANUAL, AND WITH ALL
OTHER LITERATURE SHIPPED WITH THE
PUMP. UNFAMILIARITY WITH ALL ASPECTS OF
PUMP OPERATION COVERED IN THIS MAN-
UAL COULD LEAD TO DESTRUCTION OF
EQUIPMENT, INJURY, OR DEATH.
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
WARNING
THIS PUMP IS DESIGNED TO HANDLE RAW
SEWAGE AND INDUSTRIAL WASTES AT TEM-
PERATURES OF 104_F; DO NOT APPLY AT
HIGHER TEMPERATURES. DO NOT ATTEMPT
TO PUMP VOLATILE, FLAMMABLE, OR COR-
ROSIVE LIQUIDS WHICH MAY DAMAGE THE
PUMP OR ENDANGER PERSONNEL AS A RE-
SULT OF PUMP FAILURE.
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
WARNING
THE ELECTRICAL POWER USED TO OPERATE
THIS PUMP IS HIGH ENOUGH TO CAUSE IN-
JURY OR DEATH. OBTAIN THE SERVICES OF A
QUALIFIED ELECTRICIAN TO MAKE ALL ELEC-
TRICAL CONNECTIONS.
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
WARNING
THIS IS A DUAL−VOLTAGE PUMP. ANY
CHANGE IN VOLTAGE SHOULD BE PER-
FORMED BY YOUR GORMAN−RUPP DISTRIB-
UTOR, AUTHORIZED SERVICE CENTER, OR
THE FACTORY. DO NOT CHAGE VOLTAGE IN
THE FIELD WITHOUT CONTACTING THESE
SOURCES. OTHERWISE, THE PUMP MAY BE
DAMAGED, AND PERSOONEL MAY SUFFER
INJURY OR DEATH.
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
WARNING
DO NOT CONNECT THE PUMP MOTOR DI-
RECTLY 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; OTH-
ERWISE, THE PUMP WARRANTY WILL BE
VOIDED. MAKE CERTAIN THAT THE PUMP AND
CONTROL BOX ARE PROPERLY 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 INSTRUC-
TIONS IN THIS WARNING COULD RESULT IN
INJURY OR DEATH TO PERSONNEL.
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
WARNING
DO NOT ATTEMPT TO LIFT THIS PUMP BY THE
MOTOR POWER CABLE OR THE PIPING. AT-
TACH PROPER LIFTING EQUIPMENT TO THE
LIFTING HANDLE, AND MAKE CERTAIN THAT
THE HOOK OF THE LIFTING DEVICE IS SE-
CURELY POSITIONED 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 PUMP, AND SO
THAT THE LOAD WILL BE BALANCED.

OM−03592−OM01JSV4F−G60 DV
SAFETYPAGE A−2
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
WARNING
THE FOLLOWING PRECAUTIONS SHOULD BE
TAKEN BEFORE ATTEMPTING TO OPEN OR
SERVICE THE PUMP; OTHERWISE, INJURY OR
DEATH COULD RESULT.
1. LOCK OUT THE POWER TO THE
CONTROL PANEL TO ENSURE THAT
THE PUMP WILL REMAIN INOPERA−
TIVE.
2. ALLOW THE PUMP TO COOL IF OVER-
HEATED.
3. CLOSE THE DISCHARGE VALVE (IF
USED).
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
ÍÍÍÍÍÍ
WARNING
IF THIS PUMP IS USED TO HANDLE SEWAGE,
TAKE NECESSARY PRECAUTIONS DURING
MAINTENANCE AND REPAIR TO PREVENT
PERSONAL CONTAMINATION WHICH COULD
RESULT IN ILLNESS.

OM−03592−OM01 JSV4F−G60 DV
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 these pumps. If
there are any questions concerning your specific
installation, contact your Gorman−Rupp distribu-
tor or the Gorman−Rupp Company.
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
CAUTION
THE MOTOR IN THESE PUMPS IS NOT DE-
SIGNED TO BE OPERATED IN AIR FOR MORE
THAN 10 MINUTES 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 MO-
TOR HOUSING IN SINGLE PUMP OPERATION,
AND BELOW THE LEVEL OF THE DISCHARGE
FLANGE IN DUPLEX 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. Check the pump assembly for cracks,
dents, damaged threads, and other obvi−
ous damage.
b. Check for loose attaching hardware. Since
gaskets tend to shrink after drying, check
for loose hardware at mating surfaces.
c. The standard pump is provided with 26 ft.
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 mark−
ings on the pump assembly, and perform all
duties indicated.
f. Check for any oil leaks. If there is any indi−
cation of an oil leak, see LUBRICATION in
MAINTENANCE AND REPAIR − SECTION
E.
LUBRICATION
The shaft seal I is lubricated by oil in the seal hous-
ing (see LUBRICATION in MAINTENANCE AND
REPAIR − SECTION E).
The shaft bearings are grease lubricated.
There is no other lubrication in the pump.
Pump Dimensions
See Figure B-1 for the approximate physical di-
mensions of this pump.

OM−03592−OM01JSV4F−G60 DV
PAGE B−2 INSTALLATION
FIGURE B−1. PUMP DIMENSIONS

OM−03592−OM01 JSV4F−G60 DV
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. 3 model; 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 for each
pump model.
TABLE B-1. PUMP MOTOR SPECIFICATIONS
MODEL VOLTAGE SIZE
RPM
MOTOR MAX NO LOCKEDH.P.
NUMBER LOAD LOAD ROTOR
JSV4E60−E8.7
JSV4E60−E8.7
230/3
460/3
4"
4"
8.7
8.7
1750
1750
27.6A 15.9A 160.1A
/PHASE
13.2A 7.6A 76.6A
JSV4F60−E11
JSV4F60−E11
230/3
460/3
4"
4"
11
11
1750
1750
31.8A 15.9A 159.0A
15.2A 7.6A 76.0A
PUMP INSTALLATION
Lifting
Use lifting equipment with a capacity of at least
1,850 lbs. Each version of these pumps weighs
approximately 369 lbs., not including the weight of
customer−installed accessories such as the el-
bow/baseplate and piping. Discharge hose or pip-
ing 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 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 optional discharge elbow/base−
plate. When lowered into place, the pump is auto-
matically and securely connected to the elbow/
baseplate and the piping system; the pump can be
removed or installed without personnel entering
the wet well.
For information on installing the guide rails, see the
literature accompanying them.
NOTE
When engaging the guide shoe and elbow/base-
plate, make sure that the connection is not imped-
ed 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 guide shoe engages the discharge elbow/
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 OPERATION
− SECTION C when determining the most efficient
piping installation. The recommended maximum
submergence depth is 65 feet.
No suction piping is required in a standard sub-
merged operation.