Grundfos JP Operating instructions

Service instructions

GRUNDFOS INSTRUCTIONS

English (GB)

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)

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)

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

94 93

English (GB)

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

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

English (GB)

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

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

English (GB)

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

Do not touch the seal faces.

TM07 3819 0519TM07 3820 0519

16 16a 15

16a

English (GB)

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

16a

English (GB)

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

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