Installation, Operation, and

Maintenance Manual
JCU
 Table of Contents

Table of Contents
1 Introduction and Safety .................................................................................................................................... 2
1.1 Safety ........................................................................................................................................................ 2
1.1.1 Safety terminology and symbols ..................................................................................................... 3
1.1.2 Environmental safety....................................................................................................................... 3
1.1.3 User safety ...................................................................................................................................... 4
1.1.4 Safety regulations for Ex-approved products in potentially explosive atmospheres ....................... 6
1.1.5 Product approval standards ............................................................................................................ 8
1.1.6 Product warranty ............................................................................................................................. 8

2 Transportation and Storage............................................................................................................................ 10

2.1 Receive the unit....................................................................................................................................... 10
2.2 Unpack the unit ....................................................................................................................................... 10
2.3 Pump handling ........................................................................................................................................ 10
2.3.1 Lifting methods.............................................................................................................................. 10
2.4 Pump storage requirements .................................................................................................................... 11
2.5 Preservation and Storage ....................................................................................................................... 12

3 Installation........................................................................................................................................................ 13
3.1 Inspect the Pump .................................................................................................................................... 13
3.2 Install the sump ....................................................................................................................................... 13
3.3 Install the motor....................................................................................................................................... 13
3.4 Install the pump ....................................................................................................................................... 13
3.5 Slide rail system (optional) ...................................................................................................................... 13
3.5.1 Install the base component assembly ........................................................................................... 13
3.5.2 Install the guide bracket / pivot bracket assembly......................................................................... 14
3.5.3 Install the lifting bracket assembly ................................................................................................ 14
3.5.4 Install the slide rail......................................................................................................................... 15

4 Commissioning, Startup, Operation, and Shutdown ................................................................................... 18

4.1 Start the pump......................................................................................................................................... 18

5 Maintenance..................................................................................................................................................... 19
5.1 Maintenance............................................................................................................................................ 19
5.1.1 Maintenance - O-ring, pump flange to slide rail base flange......................................................... 19
5.2 Disassembly ............................................................................................................................................ 19
5.2.1 Disassembly precautions .............................................................................................................. 19
5.2.2 Disassemble the pump.................................................................................................................. 20
5.3 Pre-assembly .......................................................................................................................................... 20
5.3.1 Pre-assembly inspections ............................................................................................................. 20
5.3.2 Replacement guidelines................................................................................................................ 20
5.4 Reassembly............................................................................................................................................. 21
5.4.1 Reassemble the pump .................................................................................................................. 21

6 Troubleshooting .............................................................................................................................................. 25
6.1 Troubleshooting....................................................................................................................................... 25

JCU Installation, Operation, and Maintenance Manual 1

1 Introduction and Safety

1 Introduction and Safety

1.1 Safety
WARNING:
• The operator must be aware of the pumpage and take appropriate safety precautions to
prevent physical injury.
• Risk of serious injury or death. If any pressure-containing device is over-pressurized, it
can explode, rupture, or discharge its contents. It is critical to take all necessary meas-
ures to avoid over-pressurization.
• Risk of death, serious personal injury, and property damage. Installing, operating, or
maintaining the unit using any method not prescribed in this manual is prohibited. Prohib-
ited methods include any modification to the equipment or use of parts not provided by
ITT. If there is any uncertainty regarding the appropriate use of the equipment, please
contact an ITT representative before proceeding.
• Risk of serious personal injury. Applying heat to impellers, propellers, or their retaining
devices can cause trapped liquid to rapidly expand and result in a violent explosion. This
manual clearly identifies accepted methods for disassembling units. These methods must
be adhered to. Never apply heat to aid in their removal unless explicitly stated in this
manual.
• Risk of serious personal injury or property damage. Dry running may cause rotating parts
within the pump to seize to non-moving parts. Do not run dry.
• Running a pump without safety devices exposes operators to risk of serious personal in-
jury or death. Never operate a unit unless appropriate safety devices (guards, etc.) are
properly installed. See specific information about safety devices in other sections of this
manual.
• Risk of death, serious personal injury, and property damage. Heat and pressure buildup
can cause explosion, rupture, and discharge of pumpage. Never operate the pump with
suction and/or discharge valves closed.
• Risk of severe physical injury or death from explosion of trapped liquid. Never use heat to
remove parts unless explicitly stated in this manual.
• Always lockout power to the driver before performing pump maintenance.
• Never operate any pumping system with a blocked suction and discharge. Operation,
even for a brief period under these conditions, can cause confined pumped fluid to over-
heat. If pump becomes plugged, shut down and unplug prior to restarting pump.
• Precautions must be taken to prevent physical injury. The pump may handle hazardous
and/or toxic fluids. Proper personal protective equipment should be worn. Pumpage must
be handled and disposed of in conformance with applicable environmental regulations.
• If the pump or motor is damaged or leaking, electric shock, fire, explosion, liberation of
toxic fumes, physical harm, or environmental damage may result. Do not operate the unit
until the problem has been corrected or repaired.

CAUTION:
Risk of injury and/or property damage. Operating a pump in an inappropriate application can
cause over pressurization, overheating, and/or unstable operation. Do not change the service
application without the approval of an authorized ITT representative.

2 JCU Installation, Operation, and Maintenance Manual

 1.1 Safety

1.1.1 Safety terminology and symbols

About safety messages
It is extremely important that you read, understand, and follow the safety messages and regulations
carefully before handling the product. They are published to help prevent these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction

Hazard levels

Hazard level Indication

DANGER: A hazardous situation which, if not avoided, will result in death or seri-
ous injury

WARNING: A hazardous situation which, if not avoided, could result in death or

serious injury

CAUTION: A hazardous situation which, if not avoided, could result in minor or

moderate injury

NOTICE: • A potential situation which, if not avoided, could result in unde-

sirable conditions
• A practice not related to personal injury

Hazard categories
Hazard categories can either fall under hazard levels or let specific symbols replace the ordinary hazard
level symbols.
Electrical hazards are indicated by the following specific symbol:

ELECTRICAL HAZARD:

These are examples of other categories that can occur. They fall under the ordinary hazard levels and
may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard

1.1.2 Environmental safety

The work area
Always keep the station clean to avoid and/or discover emissions.

Waste and emissions regulations

Observe these safety regulations regarding waste and emissions:

JCU Installation, Operation, and Maintenance Manual 3

1.1 Safety

• Appropriately dispose of all waste.

• Handle and dispose of the processed liquid in compliance with applicable environmental regula-
tions.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.

WARNING:
If the product has been contaminated in any way, such as from toxic chemicals or nuclear radi-
ation, do NOT send the product to ITT until it has been properly decontaminated and advise
ITT of these conditions before returning.

Electrical installation
For electrical installation recycling requirements, consult your local electric utility.

1.1.2.1 Recycling guidelines

Always follow local laws and regulations regarding recycling.

1.1.3 User safety

General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.

Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within the work
area:
• Hardhat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices

Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, nation-
al, state, and local regulations. For more information about requirements, see sections dealing specifical-
ly with electrical connections.

4 JCU Installation, Operation, and Maintenance Manual

 1.1 Safety

Noise

WARNING:
Sound pressure levels may exceed 80 dbA in operating process plants. Clear visual warnings
or other indicators should be available to those entering an area with unsafe noise levels. Per-
sonnel should wear appropriate hearing protection when working on or around any equipment,
including pumps. Consider limiting personnel’s exposure time to noise or, where possible, en-
closing equipment to reduce noise. Local law may provide specific guidance regarding expo-
sure of personnel to noise and when noise exposure reduction is required.

Temperature

WARNING:
Equipment and piping surfaces may exceed 130ºF (54ºC) in operating process plants. Clear
visual warnings or other indicators should alert personnel to surfaces that may reach a poten-
tially unsafe temperature. Do not touch hot surfaces. Allow pumps operating at a high tempera-
ture to cool sufficiently before performing maintenance. If touching a hot surface cannot be
avoided, personnel should wear appropriate gloves, clothing, and other protective gear as nec-
essary. Local law may provide specific guidance regarding exposure of personnel to unsafe
temperatures.

1.1.3.1 Precautions before work

Observe these safety precautions before you work with the product or are in connection with the product:
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Recognize the site emergency exits, eye wash stations, emergency showers and toilets.
• Allow all system and pump components to cool before you handle them.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage property.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Make sure that the product is thoroughly clean.
• Make sure that there are no poisonous gases within the work area.
• Make sure that you have quick access to a first-aid kit.
• Disconnect and lock out power before servicing.
• Check the explosion risk before you weld or use electric hand tools.

1.1.3.2 Precautions during work

Observe these safety precautions when you work with the product or are in connection with the product:

CAUTION:
Failure to observe the instructions contained in this manual could result in personal injury
and/or property damage, and may void the warranty. Read this manual carefully before instal-
ling and using the product.

• Never work alone.

• Always wear protective clothing and hand protection.

JCU Installation, Operation, and Maintenance Manual 5

1.1 Safety

• Stay clear of suspended loads.

• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level control.
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.

1.1.3.3 Hazardous liquids

The product is designed for use in liquids that can be hazardous to your health. Observe these rules
when you work with the product:
• Make sure that all personnel who work with biologically hazardous liquids are vaccinated against
diseases to which they may be exposed.
• Observe strict personal cleanliness.
• A small amount of liquid will be present in certain areas like the seal chamber.

1.1.3.4 Wash the skin and eyes

1. Follow these procedures for chemicals or hazardous fluids that have come into contact with your
eyes or your skin:

Condition Action
Chemicals or hazardous fluids 1. Hold your eyelids apart forcibly with your fingers.
in eyes 2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
Chemicals or hazardous fluids 1. Remove contaminated clothing.
on skin 2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.

1.1.4 Safety regulations for Ex-approved products in potentially explosive

atmospheres
Guidelines for compliance

WARNING:
Risk of serious personal injury. Applying heat to impellers, propellers, or their retaining devices
can cause trapped liquid to rapidly expand and result in a violent explosion. This manual clear-
ly identifies accepted methods for disassembling units. These methods must be adhered to.
Never apply heat to aid in their removal unless explicitly stated in this manual.

If there are any questions regarding these requirements, the intended use, or if the equipment requires
modification, contact an ITT representative before you proceed.

Personnel requirements
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
These are the personnel requirements for Ex-approved products in potentially explosive atmospheres:

6 JCU Installation, Operation, and Maintenance Manual

 1.1 Safety

• All work on the product must be carried out by certified electricians and ITT-authorized
mechanics. Special rules apply to installations in explosive atmospheres.

• All users must know about the risks of electric current and the chemical and physical
characteristics of the gas and/or vapor present in hazardous areas.

• Any maintenance for Ex-approved products must conform to international and national
standards.

Product and product handling requirements

These are the product and product handling requirements for Ex-approved products in potentially explo-
sive atmospheres:
• Only use the product in accordance with the approved motor data stated on the nameplates.
• The Ex-approved product must never run dry during normal operation. Dry running during service
and inspection is only permitted outside the classified area.
• Before you start working with the product, make sure that the product and the control panel are iso-
lated from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the approval
classification of the product.
• Intrinsically safe circuits are normally required for the automatic level-control system by the level
regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the product
specification.
• Do not modify the equipment without approval from an authorized ITT representative.
• Only use parts that have been provided by an authorized ITT representative.

Figure 1: ATEX identification

Equipment for monitoring

For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not
limited to these devices:

JCU Installation, Operation, and Maintenance Manual 7

1.1 Safety

• Pressure gauges
• Flow meters
• Level indicators
• Motor load readings
• Temperature detectors
• Bearing monitors
• Leak detectors
• PumpSmart control system

1.1.5 Product approval standards

Regular standards

WARNING:
Use of equipment unsuitable for the environment can pose risks of ignition and/or explosion.
Ensure the pump driver and all other auxiliary components meet the required area classifica-
tion at the site. If they are not compatible, do not operate the equipment and contact an ITT
representative before proceeding.

All standard products are approved according to CSA standards in Canada and UL standards in USA.
The drive unit degree of protection follows IP68 See the nameplate for maximum submersion, according
to standard IEC 60529.
All electrical ratings and performance of the motors comply with IEC 600341.

Explosion-proofing standards

CSA certification
Intrinsically safe for:
• Class I, Div. 1, Groups A, B, C, D
• Class II, Div. 1, Groups E, F, G
• Class III
• Certified to Canadian and US requirements

SERIAL NO.& YEAR OF

MANUFACTURE HERE.

1.1.6 Product warranty

Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an ITT representative within the warranty period.

8 JCU Installation, Operation, and Maintenance Manual

 1.1 Safety

• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in use.
• All service and repair work is done by ITT-authorized personnel.
• Genuine ITT parts are used.
• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved prod-
ucts.

Limitations
The warranty does not cover faults caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting ITT
• Incorrectly executed repair work
• Normal wear and tear
ITT assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses

Warranty claim
ITT products are high-quality products with expected reliable operation and long life. However, should
the need arise for a warranty claim, then contact your ITT representative.

JCU Installation, Operation, and Maintenance Manual 9

2 Transportation and Storage

2 Transportation and Storage

2.1 Receive the unit
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
4. Pump should be placed in upright position only.

2.2 Unpack the unit

1. Remove packing materials from the unit.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the unit to determine if any parts have been damaged or are missing.
3. Contact your ITT representative if anything is out of order.
4. Pump should be placed in upright position only.

2.3 Pump handling

WARNING:
Dropping, rolling or tipping units, or applying other shock loads, can cause property damage
and/or personal injury. Ensure that the unit is properly supported and secure during lifting and
handling.

CAUTION:
Risk of injury or equipment damage from use of inadequate lifting devices. Ensure lifting devi-
ces (such as chains, straps, forklifts, cranes, etc.) are rated to sufficient capacity.

2.3.1 Lifting methods

WARNING:
• Risk of serious personal injury or equipment damage. Proper lifting practices are critical
to safe transport of heavy equipment. Ensure that practices used are in compliance with
all applicable regulations and standards.
• Safe lifting points are specifically identified in this manual. It is critical to lift the equipment
only at these points. Integral lifting eyes or eye bolts on pump and motor components are
intended for use in lifting the individual components only.
• Lifting and handling heavy equipment poses a crush hazard. Use caution during lifting
and handling and wear appropriate Personal Protective Equipment (PPE, such as steel-
toed shoes, gloves, etc.) at all times. Seek assistance if necessary.

Use the supplied lifting lugs and suitable slings in order to lift the entire pump to a vertical position and
lower the unit into the sump. Then use the lifting lugs on the motor and a suitable sling, or optional slide
rail system to hoist the motor into position. Use a tag line attached to the casing end in order to prevent
the pump from swinging.

10 JCU Installation, Operation, and Maintenance Manual

 2.4 Pump storage requirements

Examples

Figure 2: Example of proper lifting method using lifting lugs

2.4 Pump storage requirements

Requirements
Submersible units require proper preparation for storage and regular maintenance during storage. The
unit is considered in storage when it has been delivered to the job site and is awaiting installation.
For specific requirements for storing motors, gearboxes, engines, panels, sealing plans and other auxilia-
ries, contact the equipment manufacturer.

Storage preparation

Condition Proper preparation

Indoor storage area (preferred) • Pave the area.
• Clean the area.
• Drain the area and keep it free from flooding.
Outdoor storage area (when indoor • Observe all indoor storage requirements.
storage is not available)

JCU Installation, Operation, and Maintenance Manual 11

2.5 Preservation and Storage

Condition Proper preparation

• Use weather-proof coverings such as flame-resistant sheeting or
tarpaulins.
• Place coverings in a manner that maximizes drainage and air circu-
lation.
• Tie coverings down in order to protect the pump from wind damage.
Placement of pumps and compo- • Place the unit on skids, pallets, or shoring higher than 15 cm | 6 in.
nent parts from the ground for good air circulation.
• Sort the parts in order to permit easy access for inspection and/or
maintenance without excessive handling.
• Pump should be stored in upright position only.
Stacking of units or component • Make sure that racks, containers, or crates bear the full weight of
parts units or parts in order to prevent distortion.
• Keep identification markings readily visible.
• Immediately replace any cover you remove for internal access.
• Store pump/motor in upright position.
Rotation of the pump and bowl as- • Rotate the shaft and bowl assembly shaft counterclockwise once a
sembly shaft month, at a minimum.
• Make sure that the shaft rotates freely.
Controlled storage facilities • Maintain an even temperature of 6°C | 10°F or higher above the
dew point.
• Keep the relative humidity to less than 50%.
• Make sure that there is little or no dust.
Uncontrolled storage facilities that • Inspect the unit periodically to make sure that all preservatives are
have uneven temperatures, higher intact.
humidity, and/or dusty conditions) • Seal all pipe threads and flanged pipe covers with tape.

When pump is not in regular operation

If a pump has been installed, but is not in regular operation for an extended period of time, such as dur-
ing a seasonal shutdown, then operate it for at least 15 minutes every two weeks.

2.5 Preservation and Storage

ITT Goulds Pump Division's normal domestic shipping and storage preparation is suitable for protecting
the pump during shipment in covered trucks. Although this is a submersible pump, storage in a clean, dry
area will help preserve the paint and prevent corrosion. Hand rotation of the shaft every thirty days is
recommended to keep the seals free and the bearings lubricated. For additional storage requirements,
reference ABB/Baldor/Reliance Submersible motor Instruction Manual.

12 JCU Installation, Operation, and Maintenance Manual

 3 Installation

3 Installation
3.1 Inspect the Pump

3.2 Install the sump

1. The sump floor should be level and firm where the pump will be placed.
2. Make sure the sump and sump inlet line are free from large pieces of debris which could eventually
obstruct the pump inlet.

3.3 Install the motor

The motor is furnished with thermal protection and a moisture probe.
1. Wire the motor according to the motor manufacturer's wiring diagram in the motor IOM.
2. Recheck the protective circuits after the wiring is completed to avoid a possible motor failure be-
cause of an oversight.
3. The motor must be completely submerged for continuous operation. It can be operated for a maxi-
mum of 15 minutes without being submerged, The sump controls should be set to allow a maximum
possible run of 15 minutes after the motor is no longer completely submerged if the sump is large
enough to not have completed the pump-down in that time. Motor is rated for a maximum 10 starts
per hour.

NOTICE:
The motor is rated for full horsepower with liquid temperatures of 104°F (40°C) or lower, unless
noted otherwise on nameplate or ITT documentation.

3.4 Install the pump

1. Make sure the lifting device is securely fastened to the motor lugs or hooks so the unit will not be
dropped when it is lowered into the sump.
2. Check the 1/8" vent hole in the adapter plate, between the motor and the casing, to make certain it
is not plugged and then carefully lower the unit into position in the sump.
3. Check the pump for being approximately level.
4. Support the discharge pipe to prevent excessive loads from being transmitted to the pump flange
and casing.

3.5 Slide rail system (optional)

3.5.1 Install the base component assembly

1. Apply gasket adhesive to item #360W and place on side shown in Section Y-Y to base upright.

NOTICE:
Quantity two 1/2" holes may need to be punched or cut in gasket to allow clearance for items
#372K.

JCU Installation, Operation, and Maintenance Manual 13

3.5 Slide rail system (optional)

2. Position item #787G, sump flange adapter, as shown in section Y-Y and secure to base upright us-
ing items #372K.
3. Apply gasket adhesive to item #360W and place in section Y-Y and secure to base upright.
4. Insert short-threaded end of stubs, items #787U, through base uprights and into the top two holes
of the sump flange adapter, item #787G.
5. Position top two holes of the discharge elbow, item #315, over the two studs, items #787U, and
thread nuts, items #787V, onto studs finger tight. Insert items #370S, hex head cap screws, through
remaining elbow and base upright holes, and thread into sump flange adapter finger tight.
6. Level discharge flange then tighten nuts and hex head cap screws, items #370S and #787V.
7. Secure item #787H, adjusting bracket, to sump flange adapter using items 370T, hex head cap
screws.
8. Thread quantity one nut, item #357, onto the entire length of item #787J, adjusting bolts, and insert
into the hole centered in item #787H, adjusting bracket.

NOTICE:
The adusting bolt's head should face towards the sump flange adapter.

3.5.2 Install the guide bracket / pivot bracket assembly

Apply Loctite 242 on all hardware unless otherwise specified.
1. Apply gasket adhesive to item #360W and place on side shown in Section "Y"-"Y" to base upright.
Note, quantity two 1/2" holes may need to be punched or cut in gasket to allow clearance for items
2. Position item #787G, sump flange adapter, as shown in section "Y"-"Y" and secure to base upright
using items #372K.
3. Apply gasket adhesive to item #360W and place on opposite side shown in Section "Y"-"Y" to base
upright..
4. Insertshort-threaded end of studs, items #787U, through base upright and into the top two holes of
the sump flange adapter, item#787G.
5. Position top two holes of the discharge elbow, item #315, over the two studs, items #787U, and
thread nuts, items #787V, onto studs finger tight. Insert items #370S, hex head cap screws, through
remaining elbow and base upright holes, and thread into sump flange adapter finger tight.
6. Level discharge flange then tighten nuts and hex head cap screws, items #370S and #787V.
7. Secure item #787H, adjusting bracket, to sump flange adapter using items 370T, hex head cap
screws.
8. Thread quantity one nut, item #357, onto the entire length of item #787J, adjusting bolt, and insert
into the hole centered in item #787H, adjusting bracket. Note, the adjusting bolt's head should face
towards the sump flange adapter.

3.5.3 Install the lifting bracket assembly

Apply Loctite 271 to all lifting bracket hardware.
1. Position left and right lifting brackets as shown on the top and elevation views of the drawing. Insert
item #370R, hex head cap screw, through the right lifting bracket, the motor's lifting lug, and out left
lifting bracket. Thread item #357C onto item #370R finger tight.
2. Place washers, items #788B, over items # 788A, hex head cap screws, and insert them into the
holes located in the motor adapter, item #240, finger tight. Note, drill and tap holes in motor adapter
at the location shown on page 4 of the slide rail installation instructions. Pump does not need to be
disassembled for drill and tap operation.
3. Insert item #371G, hex head cap screw, through both lifting brackets and thread heavy hex nut, item
#357A, finger tight. Do not apply Loctite 271to items #371G and #357A at this time. Text of third
step.
4. Tighten items #788A and #357C.

14 JCU Installation, Operation, and Maintenance Manual

 3.5 Slide rail system (optional)

5. Remove items #371G and #357A and position lift cable loop between lifting brackets. Apply Loctite
271 and reinsert item #371G, hex head cap screw, through cable and lifting brackets and thread
heavy hex nut, item #357A, and item #415A, jam nut, onto item #371G. Check cable clamps..

3.5.4 Install the slide rail

Refer to drawing B1-445153SLR and B2-445153SLR
1. With anchor bolts in position, lower the base, item #787A, onto a flat, clean foundation and tighten
anchor bolt nuts.
2. Insert the slide rails, items #787C over the cylinders on the base and insert intermediate bracket,
item #787P, cylinders into the tops of the slide rails. Allow .25" gap between the top of the slide rails
and the intermediate bracket for thermal expansion. Secure the intermediate bracket to the sump
wall. Repeat as necessary with the remainder of the rails and brackets.
3. Install the discharge pipe.
4. Lift the pump using the lift cable and lower it to have the guide bracket fit between the rail pipes.
The pump should be reasonably level to keep the guide bracket from exerting too much force on
the rail pipes when the pump is lowered or raised
5. Carefully lower the pump into position. Turn the adjusting bolts, items #787J, to provide the proper
o-ring compression. The pump may need to be raised and lowered back into position a few times
until the proper adjustment is found. The pump should properly lock into place with no visible gap
between the o-ring and sump flange adapter. Tighten items #357, hex nuts, against items #787H,
adjusting brackets, to prevent movement of adjusting bolts.

JCU Installation, Operation, and Maintenance Manual 15

3.5 Slide rail system (optional)

Figure 3: Slide rail system (optional)

16 JCU Installation, Operation, and Maintenance Manual

 3.5 Slide rail system (optional)

Figure 4: Slide rail system (optional)

JCU Installation, Operation, and Maintenance Manual 17

4 Commissioning, Startup, Operation, and Shutdown

4 Commissioning, Startup, Operation, and

Shutdown
4.1 Start the pump
The most important concern is the prevention of motor overloading.
1. Refer to the motor nameplate for full load ampere rating of the motor.
2. Install an ammeter on the motor leads and check the motor draw immediately after the unit is start-
ed.

NOTICE:
A lower than expected current draw with a 3-phase motor may be an indication of incorrect ro-
tation. If the amps are lower than expected, check rotation.

a) Observe the discharge for flow rate. If it is lower than expected change two of the three motor
leads to reverse the direction of rotation.

NOTICE:
Single-phase motors are internally wired for correct rotation.

b) Check the motor overload at some other condition from that encountered at start-up
The ammeter on the motor leads should be checked for overload at all sump level heights with the
liquid that will be normally pumped. The horsepower will tend to increase as the level in the sump
rises, due to increased flow.

18 JCU Installation, Operation, and Maintenance Manual

 5 Maintenance

5 Maintenance
5.1 Maintenance
5.1.1 Maintenance - O-ring, pump flange to slide rail base flange
Whenever the pump is removed from the sump using the slide rail system, the pump flange to slide rail
base flange O-ring should be inspected for wear. If it does not appear to be in good condition, a replace-
ment O-ring should be installed after the groove has been cleaned and dried so the adhesive will bond to
the metal and rubber.

NOTICE:
Cleaning the guide bracket around the hinge pin 9868 will help ensure proper operation when
the pump is lowered back into place.

5.2 Disassembly
5.2.1 Disassembly precautions

WARNING:
• Failure to disconnect and lock out driver power may result in serious physical injury or
death. Always disconnect and lock out power to the driver before performing any installa-
tion or maintenance tasks.
• Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local rules.
• Refer to driver/coupling/gear manufacturer's installation and operation manuals
(IOM) for specific instructions and recommendations.
• Risk of serious personal injury. Applying heat to impellers, propellers, or their retaining
devices can cause trapped liquid to rapidly expand and result in a violent explosion. This
manual clearly identifies accepted methods for disassembling units. These methods must
be adhered to. Never apply heat to aid in their removal unless explicitly stated in this
manual.
• Handling heavy equipment poses a crush hazard. Use caution during handling and wear
appropriate Personal Protective Equipment (PPE, such as steel-toed shoes, gloves, etc.)
at all times.
• Precautions must be taken to prevent physical injury. The pump may handle hazardous
and/or toxic fluids. Proper personal protective equipment should be worn. Pumpage must
be handled and disposed of in conformance with applicable environmental regulations.
• Risk of serious physical injury or death from rapid depressurization. Ensure pump is iso-
lated from system and pressure is relieved before disassembling pump, removing plugs,
opening vent or drain valves, or disconnecting piping.
• Risk of serious personal injury from exposure to hazardous or toxic liquids. A small
amount of liquid will be present in certain areas like the seal chamber upon disassembly.

JCU Installation, Operation, and Maintenance Manual 19

5.3 Pre-assembly

CAUTION:
• Avoid injury. Worn pump components can have sharp edges. Wear appropriate gloves
while handling these parts.

5.2.2 Disassemble the pump

1. Disconnect all electrical service. Mark leads for reassembly.
2. Remove cap screws 370E that fasten suction cover to casing. Remove cover and suction cover lin-
er.
3. Remove impeller cap screw 370C. Pull impeller out of casing. If impeller cannot be easily removed,
proceed to next step.
If the impeller could not be easily removed, carefully pry the mount away from the motor. Use two
locations on opposite sides simultaneously to prevent possible damage to motor.
4. Remove cap screw 370K which fastens motor-to-motor mount 340. Carefully pull mount with casing
attached away from motor.
5. Remove cap screws 370J (or flat head screws 372J) and separate motor mount from casing.

NOTICE:
The motor shall be disassembled only by an authorized repair center. Failure to comply will re-
sult in voiding warranty.
For motor instructions see ABB/Baldor/Reliance Electrical Manual B-3629.

5.3 Pre-assembly

5.3.1 Pre-assembly inspections

Guidelines
Before you assemble the pump parts, make sure you follow these guidelines:
• Inspect the pump parts according to the information in these pre-assembly topics before you reas-
semble your pump. Replace any part that does not meet the required criteria.
• Make sure that the parts are clean. Clean the pump parts in solvent in order to remove oil, grease,
and dirt.

NOTICE:
Protect machined surfaces while cleaning the parts. Failure to do so may result in equipment
damage.

5.3.2 Replacement guidelines

Casing check and replacement

WARNING:
Risk of death or serious injury. Leaking fluid can cause fire and/or burns. Inspect and ensure
gasket sealing surfaces are not damaged and repair or replace as necessary.

20 JCU Installation, Operation, and Maintenance Manual

 5.4 Reassembly

Inspect the casing for cracks and excessive wear or pitting. Thoroughly clean gasket surfaces and align-
ment fits in order to remove rust and debris.
Repair or replace the casing if you notice any of these conditions:

Casing areas to inspect

The arrows point to the areas to inspect for wear on the casing:

Impeller replacement
Inspect impeller vane edges for excessive cracks, pitting or corrosion damage. Replace impeller if exces-
sively worn or defective.

Gaskets, O-rings, and seats replacement

WARNING:
Risk of death or serious injury. Leaking fluid can cause fire and/or burns. Replace all gaskets
and O-rings at each overhaul or disassembly.

WARNING:
Risk of serious personal injury or property damage. Fasteners such as bolts and nuts are criti-
cal to the safe and reliable operation of the product. Ensure appropriate use of fasteners during
installation or reassembly of the unit.
• Use fasteners of the proper size and material only.
• Replace all corroded fasteners.
• Ensure that all fasteners are properly tightened and that there are no missing fasteners.

Motor support
Inspect the motor support for any cracks or excessive corrosion damage. Replace if necessary.

Motor shaft check

Check the shaft for straightness or excessive wear, including thread wear or galling. If damage is evi-
dent, contact Baldor authorized motor repair center for motor repairs.

5.4 Reassembly
5.4.1 Reassemble the pump
1. Check the vent hole in the adapter 340 to be sure it is clear.
2. Clean and remove any burrs from all mating metal surfaces, including shaft and impeller bore.
3. Install new O-ring (496).
4. Fasten casing and motor mount together.
5. Install mount on motor flange, align and fasten.
6. Push impeller on the shaft until seated. Push suction cover liner into casing and measure clearance
between impeller and liner. Feeler gauges can be used with larger pumps by reaching in the suction
opening.
An alternate method, recommended for smaller pumps, is to bend a short length (1") of soft solder
over each vane and tap the liner into position. Measure the thickness of the compressed solder
strip.

JCU Installation, Operation, and Maintenance Manual 21

5.4 Reassembly

7. Use impeller shims (330) for total thickness of the measured thickness, minus the amount shown in
the impeller shim thickness table below.
8. Remove liner and impeller and install shim in impeller bore.
9. Install key and reinstall impeller on motor shaft. Secure with washer (199) and cap screw (370C).
Tighten impeller hardware according to information in Impeller hardware torque values table.
10. Push suction cover liner into casing bore. Check that the lip contacts the casing rather than the face
against the impeller.
11. Install the O-ring (412F) around the liner lip and install suction cover with cap screws (370E) and
washers (528K). Check for free rotation by turning impeller clockwise by hand with wrench on im-
peller screw.
12. When connecting electrical service, make sure polarity is correct to give counterclockwise rotation
when looking into the suction opening.

Table 1: Typical Parts List

Item Qty / Pump Part Name

100 1 Casing
100B * 1 Liner, Suction Cover
101 * 1 Impeller
182 1 Suction Cover
199 1 Washer. Impeller
330 * 1 set Shim, Impeller
340 1 Motor Mount
370C 1 Hex Cap Screw, Impeller
370E varies Hex Cap Screw
370J varies Hex Cap Screw
370K varies Hex Cap Screw
412F * 1 O-ring
496 * 1 O-ring
528K varies Washer
9700 1 Motor

* Recommended spare parts, including outer mechanical seal for motor.

22 JCU Installation, Operation, and Maintenance Manual

 5.4 Reassembly

Table 2: Impeller Shim Thickness

Impeller Diameter (inches) Measure Clearance Minus Shim Thickness (in-

ches)
up to 11 .010 to .015
11 to 14 .015 to .020
over 14 .020 to .025

NOTICE:
• For 360TY with 320TY mounting flange motors only, delete impeller washer (199) and
impeller screw (370C) and replace with impeller nut (304) of 316SS for all pump con-
structions.
• Flat head screws (372J) furnished instead of hex cap screw (370J) on 3" JCU with
210TYZB motor.
• Threaded hardware coated with Loctite 242, or equal. When impeller nut is used, Loc-
tite 272 with primer should be used.

Table 3: Impeller hardware torque values

Motor Frame Impeller Mounting Hardware Required Torque, Lubricated (ft/

lbs)
180TY 1/2"-13 UNC bolt w/washer 27
210TYZ 5/8"-11 UNC bolt w/washer 54
250TY 5/8"-11 UNC bolt w/washer 54
320TY 3/4"-10 UNC bolt w/washer 66

JCU Installation, Operation, and Maintenance Manual 23

5.4 Reassembly

Motor Frame Impeller Mounting Hardware Required Torque, Lubricated (ft/

lbs)
360TY 1-1/2"-12 UNF nut 623

NOTICE:
1. Loctite 242 shall be applied to impeller bolt prior to each assembly. When impeller nut
is used, Loctite 272 with primer should be applied. Refer to Loctite for thread-lock appli-
cation instructions.
2. Impeller mounting hardware is designed for one time use only. New hardware shall be
installed during each assembly.
3. Torques in this table are based on a 416 stainless steel motor shaft material and
bolt/nut materials of SAE F593 Groups 1 & 2. For other material combinations, refer to
factory for torque value.

24 JCU Installation, Operation, and Maintenance Manual

 6 Troubleshooting

6 Troubleshooting
6.1 Troubleshooting
Symptom Cause Remedy
Insufficient or no dis- Speed too low (usually due to low volt- Verify proper voltage
charge age)
System head too high Verify discharge pressure
Insufficient NPSH or submergence Verify liquid level is above minimum required
Wear of pump parts Review pump parts for wear
Wrong direction of rotation Verify rotation, or swap two of the three electrical
leads
Pump not completely primed (plugged Check vent hole
vent hole)
Suction opening or discharge pipe Clean suction area, and check discharge piping for
clogged clogs
Viscosity of slurry too high Check for solids settling that increases viscosity
Excessive current Pump operating at a high horsepower Increase discharge pressure by partially closing
draw area of the pump curve (capacity is discharge valve
greater than the design capacity)
Impeller rubbing or mechanical defect Check impeller clearance as previously described
in the motor in these instructions
Specific gravity or viscosity too high Check for solids settling that increases viscosity
Low voltage Verify proper voltage

JCU Installation, Operation, and Maintenance Manual 25

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USA
Form IOM.JCU.en-US.2021-06

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The original instruction is in English. All non-English instructions are translations of the original instruction.