Grundfos JP Operating instructions

JP
Service instructions
GRUNDFOS INSTRUCTIONS

2

English (GB)
3
English (GB) Service instructions
CONTENTS
Page
1. General information
1.1 Hazard statements
The symbols and hazard statements below may appear in
Grundfos installation and operating instructions, safety
instructions and service instructions.
The hazard statements are structured in the following way:
1.2 Notes
The symbols and notes below may appear in Grundfos
installation and operating instructions, safety instructions and
service instructions.
1. General information 3
1.1 Hazard statements 3
1.2 Notes 3
2. Safety information for working on the product 4
3. Maintainance 4
4. Mounting the handle 5
5. Dismantling the product 5
5.1 Before dismantling the product 5
5.2 Dismantling the pump housing 5
5.3 Replacing the plugs 6
5.4 Dismantling the hydraulic parts 6
5.5 Dismantling the motor shell 7
5.6 Disconnecting the power cable from the terminal box 7
5.7 Removing the motor fan 7
5.8 Removing the impeller 8
5.9 Removing the shaft seal 8
6. Assembling the product 9
6.1 Before assembling the product 9
6.2 Fitting the shaft seal 9
6.3 Fitting the impeller 10
6.4 Fitting the motor fan 10
6.5 Fitting the motor shell 11
6.6 Connecting the power cable in the terminal box 11
6.7 Fitting the hydraulic parts 12
6.8 Fitting the pump housing 12
7. Additional information 13
7.1 Lubricant 13
7.2 Torques 13
7.3 Nameplate 13
7.4 Type key 13
7.5 Fault finding the product 13
7.6 Exploded view 14
Read this document before starting service work on
the product. Installation and service work must
comply with local regulations and accepted codes of
good practice.
Observe the safety instructions in the installation and
operating instructions for the product.
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious personal injury.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious personal injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate personal injury.
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.
Observe these instructions for explosion-proof
products.
A blue or grey circle with a white graphical symbol
indicates that an action must be taken.
A red or grey circle with a diagonal bar, possibly with
a black graphical symbol, indicates that an action
must not be taken or must be stopped.
If these instructions are not observed, it may result in
malfunction or damage to the equipment.
Tips and advice that make the work easier.

English (GB)
4
2. Safety information for working on the product
3. Maintainance
The product is maintenance-free during normal operation. For
cleaning, use a dry and dust-free cloth.
WARNING
Electric shock
Death or serious personal injury
- Switch off the power supply before you start any
work on the product. Make sure that the power
supply cannot be switched on accidentally.
WARNING
Electric shock
Death or serious personal injury
- The product is supplied with a grounding
conductor and grounding-type attachment plug. To
reduce the risk of electric shock, be certain that the
product is connected only to a properly grounded,
grounding-type receptacle (protective earth).
WARNING
Electric shock
Death or serious personal injury
- Power cables without a plug must be connected to
a supply disconnecting device incorporated in the
fixed wiring according to the local wiring rules.
WARNING
Electric shock
Death or serious personal injury
- If the product is used for cleaning or maintenance
of swimming pools, garden ponds or similar
places, make sure that the product is supplied
through a residual-current device (RCD) with a
rated residual operating current not exceeding 30
mA.
WARNING
Chemical hazard
Death or serious personal injury
- Make sure that the product has only been used for
water. If the product has been used for pumping
aggressive liquids, flush the system with clean
water before you start work on the product.
WARNING
Pressurised system
Death or serious personal injury
- Before dismantling the pump, drain the system or
close the isolating valves on both sides of the
pump. Slowly loosen the drain plug and
unpressurise the system
CAUTION
Impurities in the water
Minor or moderate personal injury
- Before the pump is used for supplying drinking
water, flush the pump thoroughly with clean water.
CAUTION
Crushing of feet
Minor or moderate personal injury
- Wear safety shoes when handling the product.
CAUTION
Hot surface
Minor or moderate personal injury
- Use protective gloves if the liquid or ambient
temperature is higher than 40 °C.
CAUTION
Hot or cold liquid
Minor or moderate personal injury
- Make sure that escaping hot or cold liquid does not
cause injury to persons or damage to the
equipment.
Only qualified persons are allowed to service the
pump.
Do not turn on the power supply until the pump has
been filled with liquid.

English (GB)
5
4. Mounting the handle
1. Fit the handle (190) on the motor flange.
Fig. 1 Mounting the handle
2. Place each screw (190b) with the washer on top and the
hexagon nut at the bottom.
Fig. 2 Fastening the screws on the handle
5. Dismantling the product
5.1 Before dismantling the product
• Disconnect the power supply to the motor.
• Remove the power cable in accordance with local regulations.
• Gradually loosen the valves to release the pressure in the
pump.
• Remove the drain plug (31) to drain the pump.
5.2 Dismantling the pump housing
Fig. 3 Dismantling the pump housing
1. Place the pump vertically with the inlet facing upwards.
2. Unscrew the clamp ring (92) by loosening screw (93) and nut
(94).
3. Remove the clamp ring (92) from the recess. Use two flat
screw drivers to lift the clamp ring from the recess.
Fig. 4 Removing the clamp ring
4. Remove the pump housing (1) including the hydraulic parts
(20 and 21).
5. Remove the O-ring (28).
Position numbers of parts (numbers in brackets) refer
to section 7.6 Exploded view.
TM07 3807 0519TM07 3834 0519
190
190b
Position numbers of parts (numbers in brackets) refer
to section 7.6 Exploded view.
TM07 3808 0519TM07 3809 0519
28
92
1
94 93
1
92

English (GB)
6
5.3 Replacing the plugs
Fig. 5 Replacing the plugs
1. Remove the two plugs (31) by turning each plug
counterclockwise with a big flat screwdriver.
2. Lubricate the O-ring seats on the pump housing (1). See
section 7.1 Lubricant.
3. Place the new plugs (31) and O-rings (32). Fasten the plugs
(31) by turning the plug clockwise with a big flat screwdriver.
5.4 Dismantling the hydraulic parts
Fig. 6 Hydraulic parts and pump housing
1. Place the pump housing (1) vertically with the inlet facing
upwards.
2. Use a suitable tool which fits inside the inlet and gently press
down on the venturi tube (21) to loosen the hydraulic parts
(20, 21, 21a and 13).
Fig. 7 Removal of hydraulic parts
Fig. 8 How not to remove the diffuser
TM07 3810 0519TM07 3811 0519
31 32
1
32
31
1
21
20
13 21a
TM07 3812 0519
Do not try to remove the diffuser (20) by using
screwdrivers or similar tools, as it might break.
TM07 3813 0519
1
21
20
20

English (GB)
7
5.5 Dismantling the motor shell
Fig. 9 Dismantling the motor shell
1. Remove the terminal box cover (52) by loosening the three
screws (53).
2. Disconnect the power cable as required. Follow the
instructions in section 5.6 Disconnecting the power cable from
the terminal box.
3. Remove the upper motor shell (44) by loosening the six
screws (45).
4. Remove the shell grid (43).
5. Remove the foot (56) by loosening the screw and nut (26).
6. Remove the lower motor shell (42).
5.6 Disconnecting the power cable from the terminal
box
1. Locate the power-supply terminal and cable clamp inside the
terminal box.
Fig. 10 Disconnecting the power cable
2. Loosen the three cable conductorsfrom the terminal box.
3. Loosen the screw that holds the cable clamp.
4. Pull the cable through the cable gland located on the side of
the terminal box.
5.7 Removing the motor fan
Fig. 11 Removing the motor fan
1. Remove the motor fan (14) from the shaft with two large flat
screw drivers. Make sure to use sufficiently large screw
drivers. Place the screw drivers between motor flange and fan
at any two points.
TM07 3814 0519
44
45
52
53
43
14
56
42
26
If you are replacing the motor shell (42, 44),
disconnect the power cable in the terminal box.
If you are replacing the impeller (19) or shaft seal
(16, 16a), you do not need to disconnect the power
cable in the terminal box.
TM07 3836 0519TM07 3816 0519
14

English (GB)
8
5.8 Removing the impeller
1. Place the motor vertically with the impeller (19) facing
upwards.
2. Clamp the motor shaft end in a vice with soft copper or
aluminium jaw faces to protect the shaft end.
Fig. 12 Placing the motor shaft in a vice
3. Turn the impeller (19) counterclockwise by hand and remove
it.
Fig. 13 Removing the impeller
5.9 Removing the shaft seal
Fig. 14 Shaft seal and seal disc
Fig. 15 How to correctly hold the shaft seal
TM07 3817 0519TM07 3818 0519
19
19
Do not touch the seal faces.
TM07 3819 0519TM07 3820 0519
16 16a 15
16
16a

English (GB)
9
1. Remove the rotating part of the shaft seal (16) by inserting two
flat screw drivers in the shaft seal spring. Lever the screw
drivers against any two points at the edge of the seal disc.
Fig. 16 Removing the rotating part of the shaft seal
2. Remove the seal disc (15) including the stationary part of the
shaft seal (16a).
3. Remove the stationary shaft seal ring (16a) from the seal disc
(15) by pushing gently with a finger from below. Hold the seal
ring on the lower side and on the rubbery outer diameter. Do
not touch the seal face.
Fig. 17 Removing the stationary part of the shaft seal
6. Assembling the product
6.1 Before assembling the product
• Clean and check all parts.
• Replace defective parts.
6.2 Fitting the shaft seal
Fig. 18 Shaft seal and seal disc
Fig. 19 How to correctly hold the shaft seal
TM07 3821 0519TM07 3822 0519
Position numbers of parts (numbers in brackets) refer
to section 7.6 Exploded view.
Do not touch the seal faces.
TM07 3819 0519TM07 3820 0519
16 16a 15
16
16a

English (GB)
10
1. Clamp the motor shaft end in a vice with soft copper or
aluminium jaw faces to protect the shaft end. See fig. 12.
2. Lubricate the seal disc opening. See section 7.1 Lubricant.
Fig. 20 Lubricating the seal disc
3. Fit the stationary part of the shaft seal (16a) inside the seal
disc (15).
Fig. 21 Fitting the stationary part of the shaft seal
4. Lubricate the shaft. See section 7.1 Lubricant.
5. Place the seal disc (15) with the stationary part of the shaft
seal (16a) on the shaft and make sure the seal disc (15)
centres on the motor flange.
Fig. 22 Lubricating the shaft and placing the rotating part of
the shaft seal.
6. Place the rotating part of the shaft seal (16) on the shaft and
press it down with two fingers.
Fig. 23 Fitting the rotating part of the shaft seal
6.3 Fitting the impeller
1. Fit the impeller (19) on the shaft.
2. Spin the impeller (19) clockwise and tighten by hand until you
feel the resistance of the mechanical stop.
Fig. 24 Fitting the impeller
6.4 Fitting the motor fan
1. Place the pump in a vertical position with the shaft end facing
upwards. The surface must be smooth or soft to protect the
impeller (15) facing downwards.
2. Fit the motor fan (14) on the shaft by hand.
Fig. 25 Fitting the motor fan
TM07 3823 0519TM07 3824 0519TM07 3825 0519TM07 3826 0519
TM07 3827 0519TM07 3828 0519
19
14