Operating Instructions and Parts Manual
Maintenance
(Continued)
ADDITIONAL REPAIRS
To replace bearings, shaft seal, gaskets, rotor, follow the instructions listed below.
1.Disconnect electrical cord from power supply.
2.Relieve pressure in system.
3.Disconnect inlet and outlet lines.
4.Empty water from pump housing.
5.Place pump on bench with motor end up and remove brushes as described in BRUSH REPLACEMENT instructions. If brushes are to be reused, mark the location from which each came. Replace brushes in original orientation upon com- pletion of repair.
6.Remove the four cap screws hold- ing motor housing and pump hous- ing together. Motor housing is now free and can be removed. Take care not to lose commutator bearing fin- ger spring.
7.With a screwdriver, pry the rotor- backhead assembly out of the pump housing.
8.Remove the impeller by turning counter clockwise (righthand thread on shaft). Save any washers which were between impeller hub and shaft.
9.Remove backhead (the bearing is press fit into the backhead).
10.Place backhead on flat surface with impeller side down and press out shaft seal.
11.Place impeller on flat surface with vane side down and with screwdriv- er and hammer break ceramic seal ring into several pieces and remove. Next, remove rubber seal ring cup from impeller.
12.Remove bearings from armature shaft
13.Inspect the armature commutator bars. The environment in which the unit has been operating will have influence on the condition of the commutator. Airborne dust an dirt will accelerate wear. A rough or scarred appearance may dictate having commutator reconditioned before reassembly.
14.To reassemble, install new bearings on the shaft. Always press against the inner race to prevent bearing damage. Make sure bearings are tight against the shaft shoulders.
15.Press shaft seal into backhead. When pressing shaft seal into place, apply force to the cup flange. Avoid touching the polished seal surface; oil or scratches on this surface may cause premature failure of the seal.
16.Press ceramic side of seal into impeller, ceramic side out. Avoid touching ceramic with hands as oil may cause premature failure of the seal. Wipe oil off both sides of seal with a soft,
17.Reassemble unit in reverse order, beginning with step 9.
18.After reassembly check shaft for free rotation with screwdriver in fan through air exit openings.
Troubleshooting Chart
| Symptom | Possible Cause(s) | Corrective Action |
|
|
|
|
|
|
| Pump will not start | 1. Blown fuse | 1. If blown, replace with proper sized fuse or reset breaker | |
| or run | 2. Low line voltage | 2. If voltage is under 108 volts, check wiring size | |
|
| 3. Worn brushes | 3. Replace brushes | |
|
| 4. Impeller blocked | 4. Remove blockage | |
|
| 5. Defective motor | 5. Replace motor or pump | |
|
|
|
|
|
| Pump will not prime | 1. Air leak in suction line | 1. Repair or replace suction line | |
| or retain prime after | 2. Impeller blocked | 2. Remove blockage | |
| operating | 3. Worn seal | 3. Replace seal | |
|
| 4. Suction lift too high | 4. Lower pump | |
|
| 5. Hose kinked or looped | 5. Straighten hose | |
|
| 6. Fittings not tight | 6. Tighten fittings | |
|
| 7. Suction hose out of water | 7. Submerge suction hose end | |
|
| 8. Clogged inlet | 8. Clean inlet | |
|
|
|
|
|
| Flow rate is too low | 1. Piping or hose is fouled or | 1. Clean or replace | |
|
| damaged |
|
|
|
| 2. Low line voltage | 2. If voltage is under 108 volts, check wiring size | |
|
|
|
|
|
| Seal leaks | 1. Worn seal | 1. Replace seal | |
|
| 2. Shaft grooved | 2. Replace rotor | |
|
| 3. Pump head loose on motor | 3. Insure proper assembly and no obstruction, tighten bolts | |
|
|
|
|
|
|
|
| www.waynepumps.com | |
3
