Pumpex P 601 Original operating manual

P 601 - P 3001
SERVICE INSTRUcTION

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
2 (22)
Pump- 3-fas 1-fas
modell
220 V 346-500 V 110 V 220V
P 601 10 A 6 A 16 A 10 A
P 701 10 A 6 A 16 A 10 A
P 801 16 A 10 A
P 1001 16 A 10 A 16 A
P 1501 25 A 16 A
P 2001 25 A 16 A
P 3001 63 A 35 A
These Service Instructions apply to PUMPEX electric submersible
drainage pump models P 601-701-801-1001-1501-2001 and 3001.
All configurations; including, centerline, high volume, normal head,
and high head.
Pump models P601 P 701 and P 1001 and P 2001 are available in
either 3-phase or single-phase operation; other models for 3-phase
operation only. All pumps for 3-phase operation are equipped for
D.O.L. start, and do not require an external start control. Model P
2001W is equipped as 230v 1-phase, and is supplied with a factory
control box. Only a factory supplied control box should be used on
this pump.
All 3-phase pumps are fitted with a built-in contactor unit and thermal
switches in the stator windings, connected in series with the contactor
coil. Single phase pumps have start capacitors or factory supplied
control box. In case of the motor overheating, the thermal switches
open and disconnect the contactor and the power supply to the pump.
Note!! When the motor has cooled down the thermal switches close
and re-start the pump automatically.
Connection at the job site
Check that the pump is connected for the actual mains voltage.
Reconnection between 230 volts and 460 volt 3-phase is made by
changing the contactor coil and reconnect according to the wiring
diagram.
If the contactor is not equipped with a dual voltage contactor coil, the
coil must be replaced to coincide with the desired voltage at the site.
Separate external motor protector is not required, but fuses of correct
size should be installed as short-circuit protection. Use time lag fuses
according to the following table.
Check the direction of rotation in all 3-phase pumps. Tilt the pump and
start it. It should jerk in a counter clockwise direction as indiciated by
an arrow on the pump. If it jerks in the other direction, two phases
should be shifted. If the bottom of the sump is soft and muddy, place
the pump on some planks, put it into a bucket, or suspend it from a
rope to prevent it from digging itself into the mud.
Never lift or pull the pump by the electric cable. Note!! Harm to the
pump cable may cause injury or death.
Always disconnect the pump from the power supply before opening
any part of the pump. Always use a qualified electrical technician
when servicing pump.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
3 (22)
If the seals are worn so severely that the oil has leaked out and only
water mixed with mud and sand remains, the pump must be dis-
mantled for a complete overhaul.
Maintenance
Inspection at regular intervals and preventive maintenance should be
performed in order to reduce the number of functional troubles and to
avoid serious break-down of the pump unit. During normal opera-tion
service is not required until a reduction of the pump capacity is noted.
Inspection must be performed once a year, or 2000 operating hours.
When the pump is taken out of service for seasonal storage, a full
maintenance service should be carried out. Special attention should
be paid to the following points.
Cleaning and Removal of Lime Deposits
At a construction site the pump is often working in water mixed with
clay, concrete, lime, etc. When it is taken out of service it should be
flushed out in fresh water and fully inspected before it is put into
storage.
Hard and solid lime deposits are easily removed if the pump is fully
submersed in a vessel with a mixture of one part formic acid (HCOOH)
and 15 parts water.
Remove the pump after 5 minutes and flush it in fresh water. Some
deposits may remain, and a second treatment may be necessary. Not
all deposits may be removed.
Inspection of Shaft Seals
Check the condition of the shaft seal by inspection of the oil in the oil
chamber. Proceed as follows:
Remove base plate and outer casing. If it is difficult to remove the
casing due to deposits or build-up on the inside, the diffuser can be
removed together with the casing.
Unscrew the oil plug and drain the oil into a clean can and inspect it.
If the oil is clean and contains no water, the primary seal is free from
defects and can be used again. If the oil contains water and appears
”milky”, the seals must be changed and ball bearings checked. After
inspection and possible change of shaft seals new oil should be filled
into the oil chamber.
Oil type: Oil type: White oil with a viscosity of 10-15cSt, such as BP
Enerpar M 002 or equivalent.
Oil quantity: P 601 0.35
P 801 0.35
P 701 0.50
P 1001 0.50
P 1501 0.50
P 2001 0.90
P 3001 0.90
Replace inspection plug O-ring

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
4 (22)
Inspection of Hydraulic Parts
Remove the diffuser, and check the rubber coating for wear, missing
or heavly scored material, and deposits.
Minor wear is easily compensated by tightening the nuts for the
diffuser thus reducing the clearance from the impeller to .0004 in.
Replace diffuser and wear plate if the rubber coating is worn to the
point where the metal backing is showing, or if any pieces of rubber
material are missing or severly gouged.
Inspection of electric cable
Check that the cable is undamaged, if the outer sheath is damaged,
water may wick into the motor housing along the inner core. If the
cable is damaged, repair or replace. Also check that the cable has
not been stretched or deformed. Hard jerks or pulls on the cable may
have damaged the bushing in the cable gland.
Trouble shooting
The most frequent functional troubles are usually caused by improper
electrical installation, cables, or wiring connections. Always have
pumps installed by a qualified electrician. A volt ohm meter and valid
wiring diagram for the correct voltage are required in order to trouble-
shoot the electrical portion of the equipment.
All troubleshooting should be carried out with the equipment
disconnected from the electric power supply. The power supply
must be locked out when performing routine maintenance, or
troubleshooting pump. Always check that no other person is working
with the pump before connecting the pump to power supply and
energizing the pump. All work with the electrical installation must be
carried out by a qualified electrician, or under the supervision of an
authorized electrician.
A. The pump will not start.
May be caused by:
1. Dead incoming power lines.
2. Blown fuses or breakers.
3. Defective cable.
4. Defective contactor unit or burned motor
5. Blocked impeller
B. The motor trips out.
May be caused by:
1. Wrong direction of rotation
2. Pump overloaded due to material build up.
3. Excessive water temperature. (Max 105 F)
4. Impeller blocked by stones, pieces of wood.
5. Blocked rotor.
6. Low voltage due to long cables, or inadequate power supply
(generator).
7. Phase failure.
8. Burned motor caused by water entering pump either through shat
seal or cable entry area.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
5 (22)
C. Water inside top cover, and /or main cover
May be caused by:
1. Pump cable damaged or cut permitting water to penetrate into top
of pump
2. Loose cable gland or faulty assembly of gland.
3. Damaged 0-ring , foreign matter between motor housing and main
cover, or top cover
4. Wire(s) pinched between top cover and main cover.
5. Loose or missing nuts that secure top cover to main cover.
D. Pump operating at too low capacity
May be caused by:
1. Wrong direction of rotation.
2. Worn or damaged impeller and / or diffuser.
3. Clogged strainer.
4. Sharp bends, folds or restrictions
of the discharge hose.
5. Total Delivery Head (static head + friction losses) too high
E. Water-in-the-oil-chamber
May be caused by:
1. Defective shaft seal
2. Faulty assembly of 0-rings, mechanical seal, wear plate or

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
6 (22)
Complete overhaul
A complete overhaul of the pump should be carried out if there has
been water or oil in the motor housing, or if the pump has been in daily
operation for one year or 2000 operating hours. At low utilization the
pumps overhaul intervals can be extended.
Dismantle the pump completely, replace damaged and worn parts.
Clean all sealing surfaces and check that they are not damaged. If
water or oil has leaked into the motor housing, inspect and replace
ball bearings and shaft seals as required.
Warning
Prior to any work being carried out, always check that the pump is
disconnected from the power supply, and cannot be energized.
Dismantling
Loosen the bottom nuts/screws and remove the base plate. Unscrew
the nuts for the diffuser. Remove outer casing and diffuser with a crow
bar applied between diffuser and impeller nut. Pull out the diffuser
from the outer casing.
Unscrew the oil plug and drain the oil into a clean can and inspect it.
Check the oil. See maintenance of Shaft Seals.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
7 (22)
Impeller
Remove the rubber covers from the stud bolts. Hold the impeller with
a large screwdriver or similar between the vanes and unscrew the
impeller nut with an 8 mm Allen key.
Prize the impeller loose with two screwdrivers under the impeller hub.
Remove the key from the shaft. Replace if damaged.
Shaft Seals
Pull out the rotating ring of the primary seal with sleeve and spring and
remove the 0-ring from the shaft.
Unscrew the stud bolts. Withdraw the wear plate and remove the
stationary ring of the primary seal.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
8 (22)
Cut the lock washer part No. 00471 with a pair of nippers. Pull out the
lock washer carefully in order to avoid scratching the shaft. Remove
any possible scratches before pulling out the rotating part of the
secondary shaft seal. Screw puller part No. 00470 into the stationary
ring of secondary seal and pull out the ring.
Rotor Unit
Unscrew the screws which hold stator housing and oil casing together.
Turn the housing about 15oand prize it loose from the casing with a
screwdriver. Remove the stator unit.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
9 (22)
Remove the external circlip on the shaft (inside secondary seal) with
a pair of circlip pliers for Dia. 25 mm.
The rotor shaft has to be pressed out of the ball bearing. Put the rotor
into a tube of the same length as the rotor shaft and with an inner dia-
meter slightly larger than the outer diameter of the bearing seat.
Press against the end of the shaft until the rotor comes loose. If a
high pressure is needed, screw the impeller nut fully on the shaft end
in order to protect it.
Ball Bearing
Remove the internal circlip and Nilos ring for the ball bearing and
press out the bearing. If necessary, the bearing seat can be heated
quickly with LP-gas to facilitate the removal.
Remove the washer and circlip in the bottom of the bearing seat. Pull
out the upper ball bearing with a puller.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
10 (22)
Cover and Cable Gland
Unscrew the cap nuts for the cover. Lift off the cover and disconnect
the cable from the contactor (3-phase units only).
If water has penetrated through the cable gland, the cable seal should
be replaced. Remove strain relief clamp prior to unscrewing cable
gland body. Pull out cable, rubber bushing and washers.
NOTE!! It is very important that the replacement parts be correctly
sized for the cable. Incorrect sizing can cause severe damage to the
pump.
Stator Unit with Contactor
Unscrew the nuts for main cover and remove the main cover from the
stator unit.
The motor insulation should always be tested in connection with
service or repair. Measure insulation resistance between the different
phase windings, between windings and ground, and between win-
dings and thermal switch circuit. The insulation resistance should be
measured with 500 V megohm-meter, and the reading should be at
least I megaohm. If the reading is lower, but not completely open,
drying the stator may recover usage of the motor.
If insulation resistance test shows motor open, the stator unit should
be rewound, or replaced.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
11 (22)
The insulation between the separate turns in the winding should also
be checked. This can be done by measuring the resistance of the
phase windings, which should give the same reading for all three win-
dings for 3-phase motors. For single-phase motors, the resistance in
the auxiliary field is roughly double that in the main field.
The circuit with the three built-in thermal contacts should be checked
for continuity, using an ohmmeter or buzzer.
If the circuit reads open, the defective contact should be identified by
checking each individual thermal contact. The faulty thermal contact
can be by-passed in accordance with the adjacent wiring diagram.
Disconnect all stator leads from the contactor and remove the
contactor. Check that the contactor holding coil is free from defects,
and that the contact points are not burned. Replace holding coil, or
entire contactor if necessary.
Removal of Stator
Loosen nuts for the 6-hole seals and pull out the seals. Pull out the
cables and arrange them so as to avoid jamming when the stator is
falling out of the housing.
Remove the 0-ring in the upper bearing seat. Block up the housing so
that the stator can drop freely out of the housing. It is important that
the sealing surfaces of the housing not get damaged.
Heat the housing quickly with two LP- gas flames at the stator lami-
nations and downwards, until the stator drops out at a temperature of
about 250o C (480o F).
Caution!! Housing and stator will be very hot!!
Clean the housing and check it for damage or cracks, particularly
on sealing surfaces and in ball bearing seat. If damage cannot be
corrected, the housing must be replaced.
Block up the new stator and make sure that the housing can be fully
pushed down onto the stator.Protect the stator insulation from damage
and insert the terminal wires (free from insulation resin, clean and
smooth) into the stator.
Note!! avoid contact with the hot housing during assembly. Burns
may occur.
Heat the housing with two LP-gas flames to about 250o C (480o F).With
two nozzles, this will take about one minute.Take the hot housing with
heat resistant gloves and push it down to its stop over the housing.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
12 (22)
Note!! Locate the holes for the terminal cables in the housing about 4
inches from the exit of the cable groups on the winding head.
When the housing has been mounted it may be cooled with compressed
air. When the housing has cooled down, the terminal cables can be
pulled up through the holes in the housing with a hook made of steel
wire. Mount the cable bushings (6-hole seals) on the two groups of
cables.
The thermal switches are connected in series and the connections
should be well insulated.
Assembly
Prior to assembly, clean all parts carefully, especially 0-ring grooves
and mating surfaces.
Grease or oil 0-rings to eliminate damage during assembly. Lubricate
screw threads to protect them and to simplify future disassembly.
Stator Unit, Contactor and Main Cover
Grease and mount the 0-ring in the upper bearing seat. Connect all
stator leads to the contactor according to wiring diagram and mount
the contactor at the bottom of the contactor chamber to the mounting
rail.
Grease and mount the 0-ring between stator unit and main cover.
Mount the main cover on the housing and tighten it against the stator
housing with the nuts. Check that the 0-ring or stator leads have not
been jammed.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
13 (22)
Cable Gland and Cover
Measure inner diameter of cable rubber bushing to see that it
corresponds to cable diameter. Place rubber bushing and washers
(one on each side of the bushing) on the cable.
Pull cable through the junction box cover, far enough to let the rubber
bushing seat on a non-deformed portion of the cable.Tighten the cable
gland body and the strain relief clamp.
Grease and mount the 0-ring in the cover. Connect the phase leads to
the contactor according to wiring diagram and screw the green ground
lead in the main cover.
Mount the cover on the main cover and arrange the leads so that they
are not jammed or block the functioning of the contactor. Tighten the
cover with the cap nuts.
Ball Bearings
Clean the oil casing and all sealing surfaces thoroughly. Remove burrs
and scratches. Pack the ball bearing up to 2/3 of its volume with a
ball bearing grease e.g. Shell Alvania Grease 3 or SKF Alfalub LGMT
3/1.
Mount the washer in the bottom of the bearing seat on the circlip.
Heat the bearing seat with LP-gas to about 150o C (340o F), and mount
the bearing in the seat. Mount the nilos ring and circlip on top of the
bearing.
Place the oil casing on a press with hole for the rotor shaft and
resting against the inner ring of the ball bearing. Place upper bearing
on the shaft and press both bearings into position against the shaft
shoulders.
Mount washer and circlip on the shaft below lower bearing. Turn the
rotor by hand and check that it turns freely without seizing.
Grease and mount the 0-ring between stator housing and oil casing,
put grease on the casing side. Slip the stator unit onto the rotor unit
and check that the 0-ring is not jammed or pinched. Tighten the stator
housing to the oil casing with the screws.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
14 (22)
Secondary seal
Clean and grease the seal seat in the oil casing and mount the
stationary ring with 0-ring part No. 00461. Push it down to the bottom
of the seat with tool part No. 00478.
Push the rotating part of the secondary seal onto the shaft with tool
part No. 00472. Mount lock washer (included) part No. 00471, using
the same tool. Push the tool down to its stop against the shaft end.
Shaft seal should then be fully seated.
00478

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
15 (22)
Primary Seal
Mount stationary ring of primary seal with 0-ring in its seat in the oil
casing.The clearance between the lock washer and the stationary ring
of the primary shaft seal should be about .001".
Before the outer 0-ring is mounted on the oil casing, check that the
wear plate is sealed tightly against 0-ring.
Grease and mount 0-ring in casing, and assemble wear plate with
washers and stud bolts.
Mount the rubber covers on the stud bolts and over the knobs on stator
housing and oil casing.
Grease and mount a new 0-ring (included in new replacement seal)
on the shaft. Oil the sealing surfaces of the mechanical seal and
carefully push the rotating ring onto the shaft. Avoid touching seal
face, contaminants from fingers may damage seal face. Assemble the
seal spring and spring sleeve.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
16 (22)
Impeller
Mount the impeller on the shaft, securing it with key, spring washer
and nut. Check that impeller runs free of wear plate with a clearance
of 0.5- 1 mm (0.02"-0.04"). For P 601/801 the clearance should be 1-2
mm (0.04"-0.08"). Adjust the clearance with shims between impeller
and shaft if necessary.
Fill new oil in the oil chamber, check quantity by model.
Oil type: White oil with a viscosity of 10-15cSt, such as BP Enerpar
M 002 or equivalent.
Correct quantities of oil are as follows:
P 601-801 0.35 liters (0.75 pint)
P 1001-1501 0.50 liters (1.5 pt.)
P 2001 0.90 liters (1 qt.)
P 3001 0.90 liters (1 qt.)
Tighten the oil plug using a new 0- ring.
Diffuser and Outer casing
Insert the coil springs onto the stud bolts (P 2001-3001). Mount the
diffuser on the stud bolts and screw one nut onto each stud bolt.
Grease and mount the O-ring on the main cover. Also grease the
outer diameter of the diffuser. Push the outer casing over the diffuser
towards the main cover, and check that the O-ring is not pinched or
caught between the outer case and the main cover.
Tighten the nuts for the diffuser alternately until the impeller runs free
from the diffuser with a clearance of 0.1-0.3 mm (0.004-0.012").
Loosen the nuts about 1/3 turn and lock with jam nuts.For single phase
pumps and Enduro Lining™ the diffusers should be adjusted with a
clearance of 0.3 mm (0.012") minimum. Mount the rubber sleeves on
the stud screws.
Mount the base plate and tighten it firmly with lock nuts.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
17 (22)
Testing
Connect power cable to power supply and start the pump. Check
the direction of rotation. Seen from above, the pump should make a
counter-clockwise jerk.
If possible, operate the pump in water and measure the head against
a PSI gauge. Measure the PSI and use formula-Feet = PSI X 2.31
Check against pump curve, it should be close to max lift.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
18 (22)
P 3001 H - 50 Hz
Assembly and adjusting the diffuser and impellers (two
impellers).
Please note that the second impeller, 353477, is adjusted by washer
03176 and locked by a distance sleeve, having the same length as the
hub of the first impeller, 03016.
The guide vane, 03174, is screwed together with the diffuser, 03210,
by three screws, 03189, + Loctite in the treads.Nuts, 03031, are placed
between the diffusor and the guide vane. Partly mounted details are
put down on the stud bolts, 03249. Then put six pcs of washer 03121
and six pcs of nuts, 03031, on the guide vane.
Adjust the diffuser, 03210, against the impeller. After this the nuts are
slacked loosen (opened) a quater of one turn. It is important that the
impeller is close to the diffuser in order for the pump to give the pro-
mised high head.
That the diffuser is correct installed (parallell) can be checked by
measuring the distance from the guide vane up to the motor. The
distance between the upper side of the impeller and the guide vane is
adjusted by shims, 00179, to about 1 to 1,5 mm. Please note that the
shaft key, 03149, should be fitted after the shims.
The washers, 03121(six pcs), are placed on the stud bolts and
thereafter the diffuser, 03172. The distance between the impeller and
the diffuser are adjusted by one or several adjusting shims, 03235. It
has to be the same amount on each stud bolt. The distance should be
about 0,1 to 0,2 mm. Two nuts on eachother are then locking it all.
After this there are only the rubber sleeves, 03179, on the nuts, the
outer casing and the bottomplate left to mount and the pump is ready
to use again.
It is advisable, to save time, that the pump is always started for a
few seconds to check that the impellers are rotating while still in the
workshop. If the nuts are screwed on too tight the impellers are too
close tho the diffusers.

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
19 (22)
1
15
2
3
4
62
8
14
16
17
22
62
24
33
34
35
37
38
39
40
41
49
67
62
64
73
62
73
21
36
20
63
18
23
19
13
12
29
30
31
32
31
43
44
45
47
54
55
56
50
57
58
57
66
60
71
25
26
27
28
11
42
46 (Oil)
45
72 (Motor)
7
9
61
70
68
69
59
74
10
51
52
53
6
5

SERVICE INSTRUCTION
P 601 - P 3001
P 601/701/801/1001/1501/2001/3001.58.0308.Eng/Digital
20 (22)
4
5
12
3
6
F1F0
L3L2L1
F1
7 865432
L3L2 F0 L1
1
THERMAL PROTECTION
MOTOR
TERMINAL BOARD
Yellow
Green/
BLUE
BLACK
GREY (GREEN)
YELLOW
BROWN
RED
YÄ
Y+FSV 82 Ä+FSV 82
YÄ
8765432
F0 F1
350074AA
1
L1 L2 L3
THERMAL PROTECTION
MOTOR
TERMINAL BOARD
Yellow
Green/
BLUE
BLACK
GREY (GREEN)
YELLOW
BROWN
RED
350071 AC350072 AC
350073 AA
50 / 60 Hz