GORMAN-RUPP PUMPS SBM-00192 User manual

OM-05724-01
August 17, 2004
CR
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
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
SUBMERSIBLE PUMP
SBM-00192
(JD12AB60-E54 460/3)
MODEL

OM-05724 JD Series
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-3......................
Field Wiring Connections (Incoming Power) PAGE B-4........
Motor Cable Grounding Test PAGE B-4.....................
Conductor Identification PAGE B-5.........................
Control Box Connections PAGE B-5........................
IEC TO NEMA Cross‐Reference PAGE B-5..................
Wiring Diagram PAGE B-6.................................
Liquid Level Devices PAGE B-7............................
OPERATION - SECTION C PAGE C-1................
PERFORMANCE CURVE PAGE C-1...........................
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............................

JD Series OM-05724
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 Pump From Stand PAGE E-6.....................
Suction Cover and Volute Casing Removal PAGE E-6........
Impeller Removal PAGE E-7...............................
Lower Seal Removal PAGE E-7............................
PUMP END REASSEMBLY PAGE E-7.........................
Lower Seal Installation PAGE E-7...........................
Impeller Installation PAGE E-8.............................
Volute Casing and Suction Cover Installation PAGE E-8.......
Impeller Clearance and Final Assembly PAGE E-8............
Securing Pump to Stand PAGE E-8.........................
MOTOR DISASSEMBLY PAGE E-9...........................
Upper Seal Removal PAGE E-9............................
Bearing Removal PAGE E-9...............................
Motor Cover Removal and Disassembly PAGE E-10...........
INSPECTION AND CLEANING PAGE E-10......................
Bearings PAGE E-11......................................
Other Reusable Parts (Except Seal Assemblies) PAGE E-11....
Cleaning Seal Assemblies PAGE E-11.......................
MOTOR REASSEMBLY PAGE E-12.............................
Motor Cover Reassembly and Installation PAGE E-12..........
Bearing Installation PAGE E-13.............................
Upper Seal Installation PAGE E-14..........................
SEAL TESTING PAGE E-15....................................
LUBRICATION PAGE E-16.....................................
Draining Oil PAGE E-16....................................
Condition of Oil PAGE E-17.................................
Adding Oil PAGE E-17.....................................

OM-05724 JD Series
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
model listed on the cover and in MAINTENANCE
AND REPAIR - SECTION E.
This J Series pump is driven by a waterproof sub
mersible electric motor. The pump motor must 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 ac
companying the pump.
Pump construction is cast iron, with stainless steel
shaft and hardware. This pump will handle solids
up to 5.7 inches (145 mm) in diameter.
This pump is equipped with a cooling jacket, which
does not require an outside source of cooling wa
ter; liquid being pumped is forced through a nar
row opening behind the impeller and circulated
through the cooling jacket. The pump is designed
to operate in a fixed piping system in a dry pit. Be
cause of its waterproof integrety, the pump will
continue to operate if the dry pit becomes flooded.
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
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: [phone]
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: [phone]
The following are used to alert personnel to proce
dures 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-05724 JD Series
PAGE A - 1SAFETY
SAFETY - SECTION A
The following information is specific to the Gor
man‐Rupp J Series Submersible pump listed on
the cover and in MAINTENANCE AND REPAIR -
SECTION E. They apply throughout this manual
to the instructions 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.
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
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.

JD Series OM-05724
SAFETYPAGE A - 2
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
panel to ensure that the pump will
remain inoperative.
2. Allow the pump to completely cool
if overheated.
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-05724 JD Series
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
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 and engine for cracks,
dents, damaged threads, and other obvious
damage.
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
The shaft seal 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.

JD Series OM-05724
PAGE B - 2 INSTALLATION
FIGURE B-1. PUMP DIMENSIONS

OM-05724 JD Series
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.
9; 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 NO LOCKEDH.P.
NUMBER LOAD LOAD ROTOR
JD12AB60-E54 460/3 12”
/PHASE
54 870 74.5A 33.0A 402.3A
PUMP INSTALLATION
Lifting
Pump unit weights will vary depending on the
mounting and drive provided. Check the shipping
tag on the unit packaging for the actual weight, and
use lifting equipment with appropriate capacity.
Drain the pump and remove all customer‐installed
equipment such as suction and discharge hoses
or piping before attempting to lift existing, installed
units.
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
a stand with an optional suction elbow. See FIG
URE B-1 for a typical stand/elbow installation.
1. See FIGURE E-1 in MAINTENANCE AND
REPAIR - SECTION E, during pump installa
tion.
2. Install and secure the stand (26) in the floor of
the dry pit.
3. Secure the suction flange (150) to the suction
piping.
4. Secure the volute discharge flange to the sys
tem discharge piping.
Make certain that the pump and stand sit level in
the wet well.
Piping
NOTE
Refer to PERFORMANCE CURVES in OPERA
TION - SECTION C when determining the most ef
ficient piping installation.
The volute discharge is 12 inches in diameter. Ei
ther hose or rigid pipe may be used to make dis
charge connections.
Both suction and discharge lines must be inde
pendently supported to avoid vibration and strain
on the pump. For maximum pumping capacity,
keep the lines as short and straight as possible. El
bows 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.

JD Series OM-05724
PAGE B - 4 INSTALLATION
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.
NOMINAL
VOLTAGE
TABLE B‐2. MOTOR VOLTAGE LIMITS
PHASE MINIMUM
VOLTAGE
MAXIMUM
VOLTAGE
3460/3 420 500
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.
FIGURE B-2. FIELD CONNECTIONS
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.