Service Manual - Subaru Industrial Power
Contents
1. 2 Remove outer casing and volute as an assembly Tip backwards not allowing the volute to drop out of the casing l 3 Note the locating slot that is cast into the volute This must align with the notch cast into the outer casing when re assembling 4 Tip the outer casing on its back and pull out the volute If the O ring on the back side of the volute causes the volute to stick when trying to remove use two hands to lift out the volute while holding the outer casing 99 Service Centrifugal Pumps PKX 5 Inspect the volute for damage Check for cracks and bent castings 6 Check the condition of the O ring on volute Check for nicks cracks and gouges Bad O rings could cause poor priming and loss of pump performance 7 Remove the impeller with a hard rubber mallet Hit one of the blades in the counter clockwise position It is best to not block the engine for this procedure Only use a flywheel strap when it does become necessary 8 Slowly turn the impeller off the crankshaft Watch that the impeller does not drop off the crankshaft when reaching the end of the threads Use two hands if necessary Watch for loose parts such as the spring or shims 30 Service Centrifugal Pumps PKX 9 Inspect the impeller for defects 10 Carefully remove the spring from the crankshaft It can be replaced in either direction 11 Remove the shim s from the crankshaft Count the number that is2. 25 After the seal has been installed place the pump back plate over the crankshaft and loosely install one of the bolts to hold it in position 26 Asmall amount of thread locker compound should be used on the tip of the bolts This thread locker should be a service replaceable type such as Permatex Blue or Purple 27 After placing the bolts into the back plate tighten the bolts snugly Proper torque clearance should be 2 2 to 3 7 ft Ibs 28 If the pump came installed with shim s they must be replaced with same number that came off If none were installed originally then do no put a new shim on unless gap between impeller and volute is wider than the tolerance allows sie PTG109 Service PTG109 29 The side of the rotating seal that has the colored warning mark on it must be facing towards the impeller and not facing towards the other seal face 30 To help installation of the seal and rubber grommet that holds it in the impeller it might become necessary to place a little liquid dish washing soap and water around the seal to help slip it into the cavity of the impeller 31 Using two thumbs press the seal into the cavity making sure that the rubber grommet does not bind The seal should be even and level 32 Turn the impeller on the crankshaft in a clockwise position until hand tight ee Service PTG109 33 Tighten the impeller with a rubber mallet by hitting on one of blades in a clo
3. SERVICE MANUAL Models PTG109 PKV101 PKX201H PKX201 PKX301 PKX201T PKX301T PKX2015ST PKX301ST Step by Step Procedure for Removal or Repair of Pump Components on Subaru Robin Pumps This Includes Mechanical Seal Replacement and Proper Shimming PUB PSO001 Rev 09 05 esv SUBARU Robin America Inc 905 Telser Road Lake Zurich IL 60047 Phone 847 540 7300 Fax 847 438 5012 e mail sales robinamerica com lt www subarupower com Copyright 2005 Robin America Inc GROUP INDEX Group NING piae EEE EAE EEA RANSE E REHE Page S Len e E E E E EEE E R E 4 ERI E E 16 PKX201 PKX301 CentriTugdal reese ectceeedensrcvsemasteneemncemetcenRemene semen acuece ne sueeendosaedanrasaegiecias 28 PKX2011 PRK ASOT T Trash aaaea aaae eana TTT aian 42 PKX201ST PKX301ST Sem Trash ecnecenesueeeosaedanedeaegiesciue 60 N EENT a HION FSS UNS aca ecto rrasrecracren sats eae eve EO Eare A REE a AERE Aai 74 PTG109 Service PTG 109 MADE IN JAPAN MODEL PTG109 f CONNECTION DIA 1inch DELIVERY VOLUME 32usg min L TOTAL HEAD 41 Kft SPEC NO PTG10900380 Always refer to the pump ID tag when ordering parts for the pump The engine has a separate ID tag as well Refer to the engine tag when ordering engine parts Service PTG109 1 Remove the four outer pump housing bolts 2 Remove the outer pump housing cover 3 Remove the volute from the pump ba
4. Damaged O rings can cause loss of pump prime as well as pumping performance 6 Check O ring on the back plate for nicks or cracking It should be soft and plyable When reinstallling clean surfaces free from corrosion and apply dish washing soap for easier installation 7 Remove impeller by hitting one of the blades counter clockwise with a soft mallet 8 After the impeller is broken lose slowly turn the impel ler couter clockwise Make sure any loose parts such as the spring and shims do not drop out when the im peller comes off the crankshaft 18 Service PKV101 9 Inspect the impeller for cracks in the casting or chips in the blades 10 Remove the spring and set aside 11 The shim s should be located over the crankshaft in this position 12 Remove the shim s Count the number taken off and make sure to replace the same amount when reinstall ing 240 Service PKV101 13 It is possible that the shim s will get stuck to the in side of the impeller housing Take a small screwdriver and slowly remove trying not to bend or distort Re place with new shim s if necessary 14 Squirt some liquid detergent or soapy water on the shaft and seals This lubrication will keep the seals from tearing when removing 15 Remove the outer seal very carefully with a pliers Note Do not squeeze the seal Place a small amount of dish washing soap or light oil on the crankshaft to keep th
5. This reading should be obtained within 5 seconds 58 Service Semi Trash Pumps PKX PKX201ST amp PKX301ST ON d0 d 4291101 21S00001 00 23 Z E L Ll o i gt ESS o SS SE O S Always refer to the pump ID tag when ordering parts for the pump The engine has a separate ID tag as well Refer to the engine tag when ordering engine parts 60 Service semi Trash Pumps PKX 1 Drain the water from the reservoir and remove the 4 bolts that hold the outer casing to the pump back plate 2 Remove outer casing and volute as an assembly Keep tilted backwards so not to allow the volute to fall out 3 Note the slot that is cast into the volute This must align with the notch cast into the outer casing when re assembling 4 Tip the outer casing on its back and pull the volute from the outer casing If the volute seems to be stuck due to the O ring sticking then use two hands while holding the outer casing with another person or vise 61 Service semi Trash Pumps PKX 5 Inspect the volute for damage Check for cracks or bent castings 6 Check condition of O ring on volute Check for nicks cracks and gauges Defective O rings will cause poor priming and loss of pump performance 7 Remove impeller with rubber mallet Hit one of the blades in the counter clockwise position It is best to not block the engine for this procedure Onl
6. FUJI HEAVY ASTRES LTD Always refer to the pump ID tag when ordering parts for the pump The engine has a separate ID tag as well Refer to the engine tag when ordering engine parts 74 Service High Pressure Pumps PKX 1 Drain water from the reservoir and remove the 4 bolts that hold the outer casing to the pump back plate 2 Remove outer casing and volute as an assembly Tip backwards not allowing the volute to drop out of the casing 3 Correct voulte placement is shown in picture Discharge chute is pointing upward 4 Tip the outer casing on its back and pull the volute from the outer casing If the volute seems to be stuck due to the O ring sticking then use two hands while holding the outer casing with another person or vise 75 High Pressure Pumps PKX Service 5 Inspect the volute for damage Check for cracks or bent castings Note the locator casting marks in volute These marks need to be placed between cast in notch in outer pump casing when reinstalling 6 Check condition of O ring on volute Check for nicks cracks and gauges Defective O rings will cause poor priming and loss of pump performance 7 Remove impeller with rubber mallet Hit one of the blades in the counter clockwise position It is best to not block the engine for this procedure Only use a flywheel strap when it does become necessary 8 Slowly turn the impeller off the crankshaft Watch that the impell
7. pump housing Note position of gasket Check gasket for cracks nicks or other areas that might cause a air leak 86 Service High Pressure Pumps PKX 49 There is a correct way and a wrong to install the inlet gasket The casting marks must face towards the engine If in doubt look at the picture in step 50 50 This picture shows correct way to install gasket Make sure gasket is flat against the outer housing when reinstalling cover Align holes and thread the three bolts into the nozzle and cover 51 After reinstalling bolts torque bolts to 4 5 to 6 ft Ibs Note The gasket tab must point upward to be installed correctly 52 Pull the engine over with rope start to make sure there is no binding of pump components Then fill with gas oil and prime water Start engine and allow to warm up for afew seconds then run the throttle at full speed Place vacuum tester over intake opening and check guage reading The needle should rise to 20 to 25 inches of vacuum within a few seconds If reading is lower recheck the volute to impeller clearance as well as possible air leaks around gasket areas 87
8. re shim according to the re shimming guide located in the service manual 15 Placing some liquid water and liquid detergent on the crankshaft This will create slippery surfaces to help in removal 16 Using two screwdrivers pry the seal outward evenly Should this prove to not work it will become necessary to remove the backing plate and push out from the backside See step 22 for explanation 64 Service Semi Trash Pumps PKX 17 Slide the seal over the crankshaft 18 After removing from the back plate inspect the surfaces closely No cracks chips or eneven wear should show If pump was run without water the surface of the seals will have a worn and burnt appearance 19 This is a good time to check the condition fo the O ring that seals the outer pump housing to the back plate Check for nicks cracks and replace with new part if necessary 20 If it becomes necessary to remove the back plate for servicing the engine use an allen wrench to remove the 4 bolts that attach it to the engine 65 Service Semi Trash Pumps PKX 21 Lift the back plate out of the way and inspect for damage This is also the way to remove the seal if it is stuck in backplate 22 If the seal still does not come out it may become necessary to push on the back of the seal with a screwdriver to remove from its position 23 Behind the pump backplate is a smaller engine adapter plate that will need to be
9. the rotating seal from the impeller it might become necessary to apply some liquid soapy water to loosen it from the impeller After the soapy water loosens the seal in the impeller take a small screw driver and pry gently upward making sure not to gouge the surface 16 The impeller must be inspected for no cracks chips and blades that are missing or broken off Replace with new if these conditions apply Service 17 Check the condition of the volute seal for cracks worn spots and overall condition Replace with new if necessary 18 Check the condition of the volute If cracked chipped or bent it must be replaced 19 When reinstalling the back plate to the engine make sure the weep hole faces downward Weep hole must be free from debris 20 When replacing with a new seal silicone compound is not needed However if original seal is removed and replaced back into pump back plate then a small amount of silicone sealant will help seal it Place a thin bead of sealant around the metal part of the seal PTG109 Service PTG109 21 Place the seal over the pump back plate for alignment 22 Using a 1 inch socket place the socket over the seal for installation 23 After setting the seal in the pump back plate set the socket over the top 24 Tap the seal into position looking at the position of the seal after each blow of the hammer to make sure it is installing evenly TE Service
10. used and replace with the same amount Should the impeller or volute be replaced with new it will become necessary to re shim accord ing the re shimming guide located in service manual 12 If the shim s get stuck inside the impeller Carefully pry the shim s out with a small screwdriver If shim s get bent or are flattened beyond use replace with new one s 31 Service Centrifugal Pumps PKX 13 This is what the shims will look like if in good condition 14 Before trying to pull the rotating seal half carbon side off the crankshaft it might become necessary to clean the crankshaft with an emery cloth Applying soapy water to the crankshaft as well as on the seal will help prevent the sealing lip from tearing when removed 15 Using a pliers carefully pull the rotating half carbon side off the crankshaft Note Squeezing to hard will ruin the seal The best way to remove the seal would entail removing the back ing plate as shown in Step 22 The pulling force of the entire backplate will help remove the seal with out bending or distortion 16 After removing from pump inspect the surfaces close ly No cracks chips or uneven wear should show If pump was run without water the surface of the seals will have a worn and burnt appearance lt 39 Service Centrifugal Pumps PKX 17 Use a small screwdriver to pry between the ceramic seal and the black rubber seal that holds it in place 1
11. will be distorted and squeezed when overtightening these bolts The recommend tightenting torque is 3 3 to 4 8 ft lbs 43 Pull the engine over by the start pull cord making sure nothing is binding in the pump 44 After adding priming water and fuel start the unit and check with test vacuum plate to make sure there are no vacuum leaks The recommended vacuum reading at sea level should be 25 lbs of vacuum 15 Service PRUD PKV101 W j l j T L gr m a e HIL 9 Syr INDUS THES TH MABE EN JEPEN CONNECTIONS CONNECTION DIA seers LA us A HEAD j t IMPORTANT ENGINE INFORMATION ENGINE FAMILY YFNXS 0254GA EMISSION REGULATIONS FOR mra Ore dete na TE S OHE Always refer to the ID tag when ordering parts for the pump The engine has a separate ID tag as well Refer to the engine tag when ordering engine parts Service PKV101 1 Drain any water from the reservoir and remove the 4 bolts that hold the outer casing to the pump back plate 2 Pull the cover away from the back plate keeping tipped back 3 Note position of volute slot and outer case locating tab This tab and slot holds the volute in the correct posi tion This must be positioned correctly during re assembly 4 Remove volute from the outer pump housing check ing for cracks or any other damage that may have oc curred 247 Service PKV101 5 Turn the volute over and check the O ring for nicks or cracks
12. 8 If the seal seems to be stuck squirt some liquid soap on the seal This will loosen it from the black outer rubber seal Using one or two screwdrivers pry the seal outward It may become necessary to remove the pump backplate when the seal is stuck See step 22 for removal of backplate 19 This is what the seal will look like when removed 20 Make sure never to use the back side of a seal when reinstalling The back side of the seal will usually have some colored marks indicating it is the wrong way 33 Service Centrifugal Pumps PKX 21 This is a good time to check the condition of the o ring that seals the outer housing to the back plate Check for nicks cracks and replace if necessary with new 22 It may become necessary to remove the back plate for servicing the engine Use an Allen wrench to remove the 4 bolts that attach it to the engine 23 Lift the back plate out of the way and inspect for dam age 24 If it becomes necessary to remove the engine from the frame remove the four bolts that hold it to the base plate of the pump frame 34 Service Centrifugal Pumps PKX 25 When reassembling the back plate to the engine make sure the weep hole is facing towards the bottom of frame The weep hole is to prevent water from entering the engine should a mechanical seal fail 26 Install the pump back plate onto the engine Install with one bolt to hold its position 27 Place a small a
13. ab pointing upward showing correct placement of gasket Torque to PKX201 3 to 5 ft Ibs PKX301 5 to 6 ft Ibs 41 Service Trash Pumps PKX PKX201T PKX301T M S H pr S Tee By i aa Sa ae sei o a tt ma Re N ss Terapi e TK E gt ae pate aoe CE ON O0 d e L L S E L ra m j oo _ _ lt F LFT Kr mm C3 Cr rm l IT was ON Always refer to the pump ID tag when ordering parts for the pump The engine has a separate ID tag as well Refer to the engine tag when ordering engine parts 42 Service Trash Pumps PKX 1 Drain any water from the reservoir by loosening the drain plug Loosen the 4 knobs that hold the outer pump housing to the back plate of the pump Use the special wrench provided with pump 2 Push the 4 knobs to the side and remove the outer pump housing from the pump back plate 3 Inspect the volute and outer case for cracks and bent castings Also inspect wear plate any uneven wear marks For removal of volute and wear plate from outer pump housing see steps 34 to 48 4 Remove plug on back plate housing for access to impeller Use a soft rod such as aluminum or brass and a hammer to loosen the impeller Hit counter clockwise until loose hee Service Trash Pumps PKX 5 Turn the impeller counter clockwise by hand until free from crankshaft Be prepared to cat
14. aft making sure it is flush with the back plate Note If shims are not properly installed onto crankshaft the impeller will not fit flush to backing plate If this condition occures remove impeller and push the shims onto crankshaft further making sure the sims are not bent out of shape 35 To inure the impeller is installed correctly place the vo lute against the back plate While holding the volute tight against the back plate with one hand check the clearance between the volute and impeller with a feeler gauge If the clearance is larger than 0 040 thousands of an inch then another shim must be added The recommended clearance is 0 020 to 0 040 thou sands of an inch 36 If shims need to be added or subtracted then re move the volute and impeller taking note of how many shims were added or subtracted Re install impeller and check again After proper clearance is obtained install impeller once again 95 Service PKV101 37 Tighten impeller with rubber mallet by hitting on one of vanes until snug 38 Install the volute into the outer pump housing making sure to put the volute slot into the tab that is em bossed in the outer cover Check the outer o ring condition as noted earlier 39 Re install the cover and volute onto the back plate with the four bolts 40 Tighten all bolts and fill with prime water The proper torque value for these bolts is 9 to 11 ft lbs Check engine oil and test for prope
15. ary to remove the engine from the frame remove the four bolts that hold it to the base plate of the pump frame 80 Service High Pressure Pumps PKX 25 When reassembling the back plate to the engine make sure the weep hole is facing towards the bottom of frame The weep hole is to prevent water from entering engine should a mechanical seal wear out 26 Install the pump back plate onto the engine Install with one bolt to hold into position 27 Place a small amount of thread lock sealer on the tip of the bolts before reinstallation Note only use Allen head bolts and special sealing wahsers Washer should fit snug around bolt Inspect for cracks in the sealing surfaces of the washers Replace with new if needed Note Threadlocker Blue or Purplefrom Permatex is recommended It is a light or medium strength product and service removable 28 The four bolts should be tightened snugly by hand Tighten diagonally to ensure even installation 81 Service High Pressure Pumps PKX 29 Using a torque wrench with a special Allen socket torque the bolts to a specified value of 12 to 15 ft lbs 30 Place a small amount of liquid detergent around the seal and rubber holder to ease in installation 31 Push the seal on with two finger or better yet use your two thumbs Making sure it is seating correctly Note If the backplate is removed for whatever reason it would help to install the seal before in
16. asting to the outer pump housing 48 Lift the outer cover and gasket from the pump housing Note position of gasket Check gasket for cracks nicks or other areas that might cause a air leak vB Service semi Trash Pumps PKX 49 There is a correct way and a wrong to install the inlet gasket Make sure that the gasket does not have casting marks facing outward 50 This picture shows correct way to install gasket Make sure gasket is flat against the outer housing when reinstalling cover Align holes and thread the three bolts into the nozzle and cover 51 After reinstalling bolts torque to the specified torque value Note the gasket tab that sticks upward showing correct placement of gasket 52 Pull the engine over with rope start to make sure there is no binding of pump components Then fill with gas oil and prime water Place vacuum tester over intake opening and check inches of vacuum The needle should rise to 20 to 25 inches of vacuum within a few seconds If not check for volute to impeller clearance or gasket in pump components that might not be seated correctly 79 Service High Pressure Pumps PKX PKX201H U if me aat DS T ee 2 a M OD E L I CONNECTION DIA DELIVERY VOLUME TOTAL HEAD ON 0a Has a DE IN JAPAN il L l rd Se gt e ro 0 C gt EE E gt p o aE P a A
17. ch impeller when freed from crankshaft Its heavy H 6 Inspect the impeller for cracks and bent blades 7 Count the number of shim s that are located on the crankshaft Remove slowly and make sure to replace with the same number when reassembling 8 Itis possible that the shim s get stuck in the impel ler Use a screwdriver to pry out and inspect The shim s should not be bent or distorted in any way Replace with new in needed 44 Service Trash Pumps PKX 9 Turn the impeller over and remove the rotating part of the mechanical seal with a small screwdriver Pry on the bottom side and lift upward until removed from im peller 10 There is a wrong side to the rotating seal The white or colored marks will face inward or towards the inlet nozzle side of the pump 11 Sometimes it helps to put a little dish washing soap on shaft to help remove seal This prevents the sealing lip from possibly tearing when removing 12 Using two screwdrivers remove the seal by prying side to side until it is free It may become necessary to remove pump back plate to remove seal If this becomes the case then follow the directions in the fol lowing steps 45 Service Trash Pumps PKX 13 Pull the seal off the crankshaft and inspect for cracks burn marks and overall condition H 14 This is what a new seal will look like when taken out of box Compare it to the seal removed 15 Should it becom
18. ck for leaks 44 If it becomes necessary to remove the discharge noz zle the following procedure is recommended Loosen and remove the 4 bolts that hold the nozzle housing to the outer casing 45 Remove the discharge nozzle and inspect the gasket and nozzle for cracks 46 When replacing the gasket make sure the gasket is flat and not kinked The gasket does not have a speci fied side for placing on the pump housing 39 Service Centrifugal Pumps PKX 47 Re install discharge nozzle and torque to specified recommendations Torque to PKX201 3 to 5 ft Ibs PKX301 4 to 6 ft Ibs 48 If it becomes necessary to remove the inlet nozzle the following procedures are recommended First loosen the three bolts that hold the casting to the outer pump housing 49 Next lift the outer cover and gasket from the pump housing Note the position of the gasket Check gas ket for cracks nicks or other areas that might cause an air leak 50 There is a correct way and a wrong to reinstall the in let gasket Make sure that the gasket does not have casting marks facing outward 40 Service Centrifugal Pumps PKX 51 This picture shows correct way to install the gasket Make sure the gasket is flat against the outer housing when reinstalling cover Align holes and thread the three bolts into the nozzle and cover 52 After reinstalling bolts torque to the specified torque value Note The gasket t
19. ck plate 4 Remove the outer pump housing to pump back plate gasket This will be a good time to check the gasket for cracks tears and overall condition Replace if neces sary Service PTG109 5 Loosen the impeller by hitting on one of the blades ina counter clockwise position with a rubber mallet 6 Turn the impeller by hand in a counter clockwise posi tion until free from the crankshaft of the engine 7 Pull the impeller away from the pump back plate and make sure that any shim s that might be positioned on the crankshaft or the impeller be saved and counted 8 Pull the engine away from the frame Service PTG109 9 For engine service work or seal replacement the pump back plate will need to be removed Loosen and remove the four bolts with a allen socket or wrench 10 Pull the pump back plate away from the engine 11 The engine in now separated from the pump compo nents for service 12 To remove the stationary seal from the back plate it will be necessary to turn the pump back plate face down on the workbench Take a 3 4 inch socket and position it into the cavity behind the seal Service PTG109 13 Hit the backside of the socket until the seal drops to the workbench below 14 This is what the seal will look like when in new condi tion The sealing face will not have gouges cracks chips or burnt edges Replace if any of the previous conditions apply 15 To remove
20. ckwise position until tight 34 The casting marks on the pump back plate indicate where the volute must be placed Make sure that the volute is placed correctly inside these marks 35 After installing the rubber gasket on the face of the volute place the volute on the pump back plate Tip the unit back slightly to hold it in position 36 Make sure there is enough clearance between the volute and impeller use a feeler gauge to check the gap While holding the volute tightly against the pump back plate insert different size feeler gauge blades until the correct reading is obtained The recommended clearance is 0 024 to 0 039 thousands of an inch 249s Service PTG109 37 Place the outer cover over the pump back plate It might make it easier if the pump is tipped back and the volute is in position Do not forget the outer pump housing to back plate gasket 38 Tighten the four bolts snugly The reccommended tightening torque is 9 to 11 ft lbs 39 Should it become necessary to remove the intake nozzle remove the three bolts that hold it in position 40 Watch the position of the gasket and nozzle when removing from the pump housing Also note the correct position of the gasket tab which should be facing upward 14 Service PTG109 41 This picture shows the correct placement of the gasket to the intake nozzle housing 42 Tighten the three outer bolts making sure not to over tighten The gasket
21. e Allen head bolts 35 After the bolts have been removed tap with a rubber mallet to free the volute from the housing 36 Carefully remove the volute from the housing by pulling up 51 Service Trash Pumps PKX 37 This is good time to check the O ring that seals the volute to the from pump housing Check for nicks cracks and tearing Replace if necessary H 38 If the wear plate needs to be removed loosen and remove the three bolts that hold the wear plate to the volute housing 39 Remove the wear plate and inspect its condition The surface should be even and not have gouges or uneven wear 40 This is also a good time to check the condition of the outer pump housing O ring Check for nicks tears and gouging 52 Service Trash Pumps PKX 41 This is what a new wear plate will look like Compare it to the one that was taken out 42 Install the wear plate in the reverse order that is was taken out 43 Apply a light or medium duty thread locker to the wear plate bolts before tightening This should be a service replaceable thread locker as mentioned ealier 44 Tighten the three bolts that hold the wear plate to the volute B Service Trash Pumps PKX 45 Position the volute back onto the front pump housing Note position when installing as it is important which way volute discharge faces See step 3 for the correct volute position as is installed on front pump housi
22. e necessary to remove the pump back plate then loosen and remove the four bolts that hold it to the engine These are special bolts with spe cial washers Make sure to replace with same part numbers if needed 16 Loosen the two bolts that hold back plate to the frame and prepare to tilt the engine back slightly for removal of back plate housing 46 Service Trash Pumps PKX 17 Lift the engine and back plate high enough to clear the bolts from the frame mounts 18 Pull the back plate housing from the engine It may be come necessary to tap of the back plate slightly with a rubber mallet 19 Should it become necessary to remove the engine for service then remove the two bolts that hold it to the engine vibration mounts 20 When replacing back plate on engine not the weep hole on the backside of pump back plate housing The weep hole must not be blocked with dirt or other obstruction This weep hole prevents water from en tering engine should a mechanical seal fail will pump ing water vee Service Trash Pumps PKX 21 Replace back plate housing and hold in position il 22 Loosely start one bolt to hold in position 23 Apply a light or medium duty thread locker to the bolts This would be a service replaceable type of thread locker Permatex purple or blue brand 24 Torque back plate bolts to a specified value of 13 to 15 ft Ibs 48 Service Trash Pumps PKX 25 Afte
23. e sealing lip from tearing 16 Inspect the outer rotating seal surface for cracks nicks or burn marks 20 Service PKV101 17 Carefully pry the stationary seal outward using two screwdrivers if necessary Note if the seal is stuck in casing it may become necessary to squirt a small amount of liquid soap and water on sealing surface to loosen seal It also may become necessary to re move the back plate to push the seal out when prying from the front does not work 18 Inspect both halfs of the seals for imperfections and replace as necessary 19 If it becomes necessary to remove the frame and back plate from the engine for engine service remove the two bolts that hold the frame to the bottom of back plate 20 Remove the four bolts that hold the back plate to the engine 91 Service PKV101 21 The engine is now free from the pump components for easier servicing if necessary 22 When reinstalling the back plate make sure that the weep hole points downward 23 Place a small amount of thread lock sealer on the tip of the bolts before reinstallation Note Thread locker Blue or Purple from Permatex is recommended It is a light or medium strength and service removable 24 Reinstall and hand tighten the bolts that hold the back plate to the engine Inspect the sealilng washers that are attached to the bolts Replace as necessary if cracked or worn 29 Service PKV101 25 Tor
24. e will help re move the seals without bending or distortion 16 After removing the rotating seal inspect the surfaces closely No cracks chips or uneven wear should show If pump was run without water the surface of the seals will have a worn and burnt appearance B Service High Pressure Pumps PKX 17 Use a small screwdriver to pry between the ceramic seal and the black rubber seal that holds it in place 18 If the seal seems to be stuck squirt some liquid soap on the seal This will loosen it from the black outer rubber seal Using one or two screwdrivers pry the seal outward It may become necessary to remove the pump backplate when the seal is stuck See step 22 for removal of backplate 19 This is what the seal will look like when removed 20 Make sure never to use the back side of a seal when re installing The back side of the seal will usually have some colored marks indicating it is the wrong way 279 Service High Pressure Pumps PKX 21 This is a good time to check the condition of the O ring that seals the outer housing to the back plate Check for nicks cracks and replace if necessary with new 22 If it becomes necessary to remove the back plate for servicing the engine follow the procdures in steps 22 29 First use an Allen wrench to remove the 4 bolts that attach it to the engine 23 Lift the back plate out of the way and inspect for damage 24 If it becomes necess
25. er does not drop off quickly when reaching the end of the threads Use two hands if necessary Watch for loose parts such as the shims S Service High Pressure Pumps PKX 9 Inspect the impeller for defects 10 Remove the spring from the crankshaft Note It can be replaced in either direction 11 Remove the shim s from the crankshaft Count the number that is used and replace with the same amount Should the impeller or volute be replaced with new it will become necessary to re shim according the re shimming procedure noted later in these instructions 12 When the shim s get stuck inside the impeller Carefully pry the shim s out with a small screwdriver lf shim s get bent or are flattened beyond use re place with new one s a7 7s Service High Pressure Pumps PKX 13 This is what the shims will look like if in good condition 14 Before trying to pull the rotating seal half carbon side off the crankshaft it might become necessary to clean the crankshaft with an emery cloth Apply liquid detergent to the crankshaft as well as on the seal This will help prevent the sealing lip from tearing when removed 15 Using a pliers carefully pull the rotating half carbon side off the crankshaft Squeezing to hard will ruin the seal A better way to remove the seals would be this procedure loosen the backplate bolts step 22 and pull the backplate forward The pulling force of the entire backplat
26. l they way If the impeller is not threaded to the full extend the impeller face could strike against the inside of the volute 35 To make sure the impeller is installed correctly hold the volute against the back plate and check the clearance with a feeler gauge If the clearance is larger than 0 040 thousands of an inch then another shim must be added If the clearance is 0 020 or less and the pump grinds and turns over hard it is possible that a shim needs to be removed 36 Re tighten the impeller with a hard rubber mallet hit ting the blades in a clockwise position It should be tight enough that you should not be able to turn it loose by hand 97 Service Centrifugal Pumps PKX 39 Re install the volute into the outer case making sure the slot in the volute is resting on the casting molded into the outer case 40 It is important that the volute slot matches with the cast in notch in the outer pump case Note See arrow 41 Replace the cover and volute onto the pump back plate Install the four outer pump case bolts 42 Tighten and torque the four bolts to PKX201 9 to 11 ft lbs PKX301 16 to 20 ft lbs 38 Service Centrifugal Pumps PKX 43 Once the case is torqued down pull the recoil starter to check that pump and engine turn over freely If OK then re fill with prime water Next check the engine oil and start the engine Apply vacuum pressure plate tes ter per service manual and che
27. ld it to the pump housing Torque the bolts to the specified value of PKX201T 3 to 4 ft Ibs PKX301T 4 to 6 ft Ibs Should it become necessary to remove the top pump housing cover follow the listed procedure Remove the four bolts that hold the cover in position and lift cover off 56 Trash Pumps PKX Service Trash Pumps PKX 57 Check the gasket for tears cracks or twists Replace if necessary 58 Install the four bolts that hold the top cover to the pump housing and torque to specified value of 16 to 20 ft Ibs 59 Should it become necessary to remove the intake nozzle for service then loosen the four bolts that hold it to the pump housing 60 Lift the intake nozzle away from the pump housing noting the position of the gasket e575 Service Trash Pumps PKX 61 The picture show the correct way to install the intake nozzle gasket H 62 Apply a thread sealant the the six cover bolts as in step 54 After lightly tightening the six bolts that hold the intake nozzle to the pump housing torque to the specified value of 4 to 6 ft Ibs 63 Before running check the oil and pull the engine over with the recoil rope to make sure nothing is binding in the pump 64 Fill the with prime water start the engine After warm up run engine at full throttle and check the vacuum with the vacuum tester to make sure no leaks have developed A vacuum of 20 to 25 lbs at sea level should be read
28. mount of thread lock sealer on the tip of the bolts before reinstallation This will prevent the bolts from loosening Note Only use Allen head bolts and special sealing washers Washers should fit snug around the bolt Inspect for cracks in the sealing surface Replace with new if needed Note Threadlocker Blue from Permatex is recommended It is medium strength and service removable 28 The four bolts should be tightened snugly by hand Tighten diagonally to ensure even installation 35 Service Centrifugal Pumps PKX 29 Using a torque wrench with a special Allen socket torque the bolts to a specified value of 12 to 15 ft Ibs 30 Push the seal on with two fingers or use your two thumbs Making sure it is seating correctly Note If the backplate is removed for whatever reason it would help to install the seal before installing the backplate onto the engine 31 Reinstall the rotating half of the mechanical seal Note Placing a small amount of soapy water on the sealing lip will aid in reinstallation and keep the seal from tearing 32 Re install the spring in either direction 2665 Service Centrifugal Pumps PKX 33 Re install the shim s using the same number as was taken off If new components such as impeller or volute was used it may become necessary to re shim with new shims for proper clearance 34 Hand tighten the impeller onto the crankshaft Make sure it is threaded on al
29. ng 46 Apply thread lock compound to the bolts before installing Using Permatex brand such as the blue or purple is recommened These models are service replaceable 47 Torque to bolts to the specified value of 12 to 15 ft Ibs 48 The volute and front pump housing are now ready to be installed onto pump back plate 54 Service Trash Pumps PKX 49 Install on back plate and loosely tighten the four knobs making sure the O ring is seated correctly 50 Tighten the four knobs with the special tool that is provided with the pump Tighten very snugly 51 Should it become necessary to remove the discharge nozzle then loosen the four bolts that hold it to the pump housing 52 Lift the discharge nozzle off the housing watching the position of the gasket Check for cracks tears or improper fit 55 S 53 The picture shows the correct position of the discharge H 54 55 56 ervice nozzle The elongated portion of the discharge nozzle will be on the bottom Apply a high temperature thread sealant such as Permatex High Temperature Thread Sealant to the 4 bolts that hold the discharge nozzle to the pump housing This will prevent leakage due to vibration temperature cycling and extreme pressure This type of sealant protects against rust corrosion and galling of threads It is service replaceable After replacing discharge nozzle loosely and evenly tighten the four bolts that ho
30. ould be tight enough that you should not be able to turn it loose by hand 38 Re install the volute into the outer case making sure the slot is resting on the casting molded into the outer case 39 It is important that the volute slot matches with the cast in notch in the outer pump housing 40 Replace the cover and volute onto the pump back plate Install the four outer pump case bolts 70 Service semi Trash Pumps PKX 41 Tighten and torque the four bolts to a minimum torque of 200kg cm 42 Once the case is torqued down pull the recoil starter to check that pump and engine turn over freely If OK then re fill with prime water Next check the engine oil and start the engine Apply vacuum pressure plate tester per service manual and check for leaks 43 If it becomes necessary to remove the discharge nozzle the following procedure is recommended Loosen and remove the 4 bolts that hold the nozzle housing to the outer casing 44 Remove the discharge nozzle and inspect the gasket and nozzle for cracks rs E Service Semi Trash Pumps PKX 45 When replacing the gasket make sure the gasket is flat and not kinked The gasket does not have a specified side to place on pump housing 46 Re install discharge nozzle and torque to specified recommendations 47 If it becomes necessary to remove the inlet nozzle the following procedures are recommended Loosen the three bolts that hold the c
31. p case See arrow 39 Re install the volute into the outer case making sure the slot in the volute is resting on the casting molded into the outer case 40 Replace the cover and volute onto the pump back plate Install the four outer pump case bolts 84 Service High Pressure Pumps PKX 41 Tighten and torque the four bolts to a torque of 22 to 25 ft Ibs 42 Once the case is torqued down pull the recoil starter to check that pump and engine turn over freely If OK then re fill with prime water Next check the engine oil and start the engine Apply vacuum pressure plate tester Reading should be between 20 to 25 lbs of vacuum at sea level 43 If it becomes necessary to remove the discharge nozzle the following procedure is recommended Loosen and remove the 4 bolts that hold the nozzle housing to the outer casing 44 Remove the discharge nozzle and inspect the gasket for tears or breaks Also check the nozzle casting for cracks 85 Service High Pressure Pumps PKX 45 When replacing the gasket make sure the gasket is flat and not kinked The gasket does not have a specified side to place on pump housing 46 Re install discharge nozzle and torque to 4 5 to 6 ft Ibs 47 f it becomes necessary to remove the inlet nozzle the following procedures are recommended Loosen the three bolts that hold the casting to the outer pump housing 48 Lift the outer cover and gasket from the
32. que the 4 bolts to the specified value The recommended torque is 7 9 ft lbs 26 Position the frame under the back plate for reinstalla tion 27 Install and tighten the two bolts that hold the frame to the back plate 28 Squirt a small amount of liquid detergent on the seal and crankshaft before trying to reinstall The detergent acts as a libricant for the rubber seal 299 Service PKV101 29 The seal will have some colored marks indicating that this is the back side Do not install towards the rotating seal The marks should face the engine 30 Push the mechanical seal into the cavity making sure it is seated properly and even Using your two thumbs works great If the backplate was removed then in stall the seal into the backplate before putting on crankshaft Note Lubricating with a small amount of soap detergent and water will ease installation significantly 31 Re install the other half of the seal by pushing tight against the other half Note Lubricating with a small amount of soap detergent and water will ease installation 32 Re install the spring It can be installed in either direc tion 94 Service PKV101 33 Re install the shim s making sure you replaced the same number that came installed with the pump If a new component such as a impeller or volute was installed refer to the section on proper shimming 34 Screw and snug the impeller hand tight on the crank sh
33. r the back plate has been tightened replace the two bolts that hold the pump housing to the frame 26 When replacing the mechanical seal Putting some liquid detergent on the seal and crankshaft will ease installation 27 Push the seal into place Using two thumbs will also make it easier If the pump back plate was removed it will be easier to install the seal before mounting the back plate to the engine 28 Replace the correct amount of shim s As noted earlier it will be necessary to replace with the same amount that was taken off 49 Service Trash Pumps PKX 29 Before placing the rotating seal into the impeller it will help by putting some liquid detergent of the seal This will ease in installation H 30 Install the seal into the backside of the impeller making sure that the outer seal is not kinked and placed on straight 31 This is a good time to check the condition of the volute to back plate housing O ring Check for cracks nicks or tears 32 Turn the impeller on by hand in a clockwise position until tight 50 Service Trash Pumps PKX 33 To insure the impeller is tight Hit on one of the bladed in a clockwise position till good resistance is felt 34 Should it become necessary to remove the volute from front pump housing or replace the wear plate follow the next steps in removing and replacing Loosen the 3 bolts that hold the volute to the front pump housing These ar
34. r vacuum with vac uum plate tester The vacuum guage should read 25 lbs of pressure Note See test procedures under separate heading JOG Service PKV101 41 Should it become necessary to remove the inlet nozzle and gasket follow these steps Remove the three bolts that hold the inlet nozzle to the outer pump case 42 Inspect the check valve gasket noting that there is a correct way to install it 43 Picture show the correct installation of the check valve gasket on the inlet nozzle When reinstalling inlet nozzle it is important not to over tighten The correct torque value is 2 to 3 ft Ibs 44 The picture shows the correct position of the gasket tab facing upwards 2 OF Service Centrifugal Pumps PKX PKX 201 Centrifugal PKX301 Centrifugal _connecnonma 7 gt a DELIVERY VOLUME 158 aa mm LISTA HEAD f i ES RES 29 FUN HEAVY INDUSTRIES m T 21 N MADE IN JAPAN fee BK xan pnaz0 K SERNOS050I0I7 ON 00894 ON YIS gt lt mo lane ca lt gt a Lam ca _ co aLr k J mm coo O _ 2 gt _ on Mm Always refer to the ID tag when ordering parts for the pump The engine has a separate ID tag as well Refer to the engine tag when ordering engine parts 28 Service Centrifugal Pumps PKX 1 Drain water from the reservoir and remove the 4 bolts that hold the outer casing to the pump back plate
35. reomved if engine work is necessary It will pop off with a soft rubber mallet if stuck on 24 The engine is held on with four bolts Loosen the f our bolts and remove from frame if engine work is needed Go Service semi Trash Pumps PKX 25 When reinstalling the smaller adapter plate make sure the weep hole faces downward The weep hole is to prevent water from entering the engine should the seal wear out 26 The next step after placing the small adapter plate on the engine is to mount the large adapter plate Note the weep hole position as well keeping it pointing downward Use one bolt to hold on temporarily 27 Place a small amount of thread locking compound on the tip of the mounting bolts when reinstalling Note make sure to replace with special supplied bolts and washer attached These are special bolts that are used for sealing pump to engine 28 Tighten snuggly with hex head allen wrench watching that the adapter plate align correctly with the back plate 67 Service semi Trash Pumps PKX 29 Using a torque wrench with a special allen head socket torque the bolts to a specified value of 12 to 15 ft Ibs 30 Place a small amount of liquid detergent and water on the crankshaft and inner seal This will make the installation of the seal easier 31 Push the seal into the cavity with your two thumbs and seat it snuggly into position It might be easier as noted ealier to position the
36. seal into the backplate when the backplate is removed from engine 32 Reinstall the shim s using the same number as was taken off in previous steps If new components such as impeller or volute was used it may become necessary to re shim with new shims for proper volute to impeller clearance Check the section on How to Shim Semi Trash Pumps in the Service Manual 68 Service semi Trash Pumps PKX 33 Pour a little liquid detergent on the backside of the impeller before trying to install the rotating seal 34 Push seal into cavity with one or two thumbs making sure the seal is seated correctly 35 Reinstall the impeller and hand tighten on the crank shaft Make sure it is threaded on all the way If impeller is not threaded on the full depth the impeller face could strike against the inside of the volute 36 To make sure the impeller is installed correctly hold the volute against the backplate and check the ay l aga oie clearance with a feeler guage If the clearance is a R 5 larger that 0 040 in then another shim must be sre A E Te nass added If there is less than 0 020 in of clearance between the volute and impeller then it is possible a shim would need to be removed asl Note make sure impeller is threaded tightly against backing plate 69 Service Semi Trash Pumps PKX 37 Remove the volute and re tighten the impeller by hit ting the blades in a clockwise direction It sh
37. stalling the backplate onto the engine 32 Re install rotating half of mechanical seal Placing a little liquid detergent on the sealing lip will aid in reinstallation and keep the seal from tearing 82 Service High Pressure Pumps PKX 33 Re install the shim s using the same number as was taken off If new components such as impeller or volute was used it may become necessary to re shim with new shims for proper clearance Check the procedure listed in a later step on how to perform this function 34 Re install the spring 35 Hand tighten the impeller onto the crankshaft Make Sure it is threaded on all they way If impeller is not threaded to the full extend the impeller face could strike against the inside of the volute 36 To make sure the impeller is shimmedcorrectly hold the volute against the back plate and check the clearance with a feeler gauge If the clearance is larger than 0 0197in then another shim must be added lf there is less than 0 0078 in between the volute and impeller and the unit does not easily turn over with the rope start then it is possible that a shim needs to be removed 83 Service High Pressure Pumps PKX 37 Re tighten the impeller with a rubber mallet hitting the blades in a clockwise position It should be tight enough that you should not be able to turn it loose by hand 38 It is important that the volute slot matches with the cast in notch in the outer pum
38. y use a flywheel strap when it does become necessary 8 Slowly turn the impeller off the crankshaft Watch that the impeller does not drop off quickly when reaching the end of the threads Use two hands if necessary Watch for loose parts such as the shims oe Service semi Trash Pumps PKX 9 Inspect the impeller for defects 10 Inspect the rotating part of the seal for cracks chips and worn face 11 It many happen that the shim s get stuck inside the impeller When this condition occurs carefully pry the shim s out with a small screwdriver If the shims s get bent or are flattened beyond use replace with new one s 12 Place a small screwdriver under the seal and pry outward Placing some liquid water or detergent on the seal might help in removing it if it appears to stick to the metal ee Service semi Trash Pumps PKX 13 The seal has two sides Make sure that you do not install this side towards the stationary seal in the back plate The colored bars must face the impeller EN 7 a J A Ti 2 SK RIANI K L w Pasay i oes x wes A as Qt la N bined TRE ts k gt or a z we hs f s T C E mT KL pr A sad oa ger igh SA ATR A rg OT eS SO Norge Su Da MOC UY IRE AL So TAREE C V FS 14 Remove the shim s from the crankshaft Count the number that is used and replace with the same amount Should the impeller or volute be replaced as new parts it will become necessary to
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