INSTRUCTION MANUAL

IM010R09

Models 3656 / 3756

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
OWNER’S INFORMATION TABLE OF CONTENTS
Please fill in information and give this booklet to homeowner. SUBJECT PAGE
Warranty information is on page 14. Safety Instructions.......................................................................2
Description and Specifications....................................................2
Model Number: Engineering Data.........................................................................2
Serial Number: Installation...................................................................................2
Dealer: Location...................................................................................2
Close-Coupled Units...............................................................2
Dealer’s Phone No. Frame-Mounted Units.............................................................3
Date of Purchase: Installation Date: SAE Engine Driven Pumps..........................................................3
Coupling Alignment....................................................................6
Frame-Mounted Units Only...................................................6
Piping...........................................................................................6
Suction.....................................................................................6
Discharge.................................................................................6
Wiring and Grounding................................................................7
Rotation.......................................................................................7
Operation....................................................................................7
Maintenance................................................................................7
Disassembly.................................................................................8
Reassembly..................................................................................8
Packed Box Instructions..............................................................9
Troubleshooting.........................................................................10
Repair Parts................................................................................11
Limited Warranty......................................................................14

2
SAFETY INSTRUCTIONS ENGINEERING DATA
TO AVOID SERIOUS OR FATAL PERSONAL INJURY Maximum Liquid Temperature:
OR MAJOR PROPERTY DAMAGE, READ AND 212º F (100º C) – standard seal or packing
FOLLOW ALL SAFETY INSTRUCTIONS IN THE 250º F (120º C) – Optional high temp. seal
MANUAL AND ON THE PUMP. Maximum Working Pressure (Fluid temperature dependant):
– NPT connections, 200 PSI (1379 kPa)
This is a SAFETY ALERT SYMBOL. – 125# ANSI flanged connections, 200 PSI (1379 kPa)
When you see this symbol on the pump or Maximum Suction Pressure: 100 PSI (689.5 kPa)
in the manual, look for one of the following Starts per Hour: 20, evenly distributed
signal words and be alert to the potential for
personal injury or property damage. Group Size Suction Discharge
1½ x 2-6 (H) 2" NPT 1½" NPT
DANGER Warns of hazards that WILL cause serious 1 x 2-7 2" NPT 1" NPT
personal injury, death or major property 2½ x 3-7 3" NPT 2½" NPT
damage. S
3 x 4-7 4" Flange 3" Flange
Warns of hazards that CAN cause serious 1 x 2-8 2" NPT 1" NPT
WARNING
personal injury, death or major property 1½ x 2-8 2" NPT 1½" NPT
damage. 2 x 2-5 2" NPT 2" NPT
2½ x 2½-5 2½" NPT 2½" NPT
CAUTION Warns of hazards that CAN cause personal LH 3 x 3-5 3" NPT 3" NPT
injury or property damage. 4 x 4-5 4" Flange 4" Flange
5 x 5-6 5" Flange 5" Flange
NOTICE: INDICATES SPECIAL INSTRUCTIONS
2½ x 3-8 3" NPT 2½" NPT
WHICH ARE VERY IMPORTANT AND
3 x 4-8 4" Flange 3" Flange
MUST BE FOLLOWED.
4 x 5-8 5" Flange 4" Flange
THIS MANUAL IS INTENDED TO ASSIST IN THE 1½ x 2-10 2" NPT 1½" NPT
INSTALLATION AND OPERATION OF THIS UNIT. 2½ x 3-10 3" Flange 2½" Flange
M
THOROUGHLY REVIEW ALL INSTRUCTIONS AND 3 x 4-10 4" Flange 3" Flange
WARNINGS PRIOR TO PERFORMING ANY WORK 4 x 6-10 6" Flange 4" Flange
ON THIS PUMP. 2½ x 3-13 3" Flange 2½ " Flange
3 x 4-13 4" Flange 3" Flange
MAINTAIN ALL SAFETY DECALS.
4 x 6-13 6" Flange 4" Flange
NOTICE: INSPECT UNIT FOR DAMAGE AND 6 x 8-13 8" Flange 6" Flange
REPORT ALL DAMAGE TO CARRIER L 8 x 10-13 10" Flange 8" Flange
IMMEDIATELY. 4 x 6-16 6" Flange 4" Flange

UNIT NOT DESIGNED FOR USE

WARNING INSTALLATION
WITH HAZARDOUS LIQUIDS OR
FLAMMABLE GASES. LOCATION
• Locate the pump as near liquid source as practical; below
level of liquid for automatic repriming capability.
• Allow adequate space for servicing and ventilation. Protect
Hazardous fluids can the unit from weather and water damage due to rain,
cause fire, burns
or death. flooding or freezing temperatures.
• Protect the pump and piping from freezing temperatures.
DESCRIPTION and SPECIFICATIONS • Allow adequate space around the unit for service and
The series 3656/3756 are single stage, end suction, centrifugal ventilation.
pumps for general liquid transfer, booster applications, irriga-
CLOSE-COUPLED UNITS
tion and general service pumping. Pumps are available in three
different materials of construction: all iron, bronze-fitted and • Units may be installed horizontally, inclined or vertically with
all bronze (“S” group only). the motor above the pump.
Pump impellers are fully enclosed, key driven and held in • The motor feet MUST be bolted to a substantial surface
position by an impeller bolt and washer. Casings are full volute (horizontal or vertical) that is capable of complete and rigid
in design with replaceable wear rings. support for the pump and motor. For L-Group pumps, the
motor adapter feet must also be bolted to the supportive
Dependant on the pump size, the suction and discharge
surface.
connections will be threaded or flanged. Shafts are protected
with stainless steel shaft sleeves. • For vertical operation, the motor should be fitted with a drip
cover or otherwise protected against liquid entering the mo-
Close-coupled units have NEMA standard JM or JP motors
tor (rain, spray, condensation, etc.)
with C-face mounting and key driven shaft extension. SAE
drive units bolt directly to the engine flywheel housing for SAE NOTICE: DO NOT INSTALL WITH MOTOR
sizes 1, 2, 3, 4 or 5. Optional elastomer element couplings BELOW PUMP. ANY LEAKAGE OR
are available for 6½, 7½, 8, 10, 11½ and 14 inch flywheels. CONDENSATION WILL AFFECT
Frame mounted units can be coupled to motors through a THE MOTOR.
spacer coupling, or belt driven.

3
FRAME-MOUNTED UNITS indicated. Maximum working pressure for class 30 cast iron,
• A flat substantial foundation surface MUST be provided to per ANSI B16.1, is 175 PSI.
avoid distortion and/or strain when tightening the founda- Internal combustion engines are variable speed and variable
tion bolts. A rubber mounting is acceptable to reduce noise power machines. The power output depends on the engine
or excessive vibration. speed (RPM) and will be reduced when operating altitude,
• Tighten motor hold-down bolts BEFORE connecting piping and/or the air temperature increases. When driving the pump
to pump. at the RPM required to deliver water into the system piping,
the engine must operate within the Engine Manufacturers
Grout hole Base
Finished grouting
(1/4")
minimum and maximum RPM limits. The power output to
supply the pump power demand must not exceed the continu-
Grout ous power rating of the engine, after derating for all power
(1/2 to 3/4")
Allowance Leveling wedges or shims—left in place consuming engine accessories, and adjustmaner for installation
for leveling
Top of foundation—
site altitude and air temperature.
clean and wet down
DRIVE-TRAIN SIZING (BHP)
Wood
frame Sleeve The BHP Equation is: (Flow x TDH) / 3960 x Eff.)
Note: For internal combustion units the BHP calculation must
be de-rated for the following conditions:
Washer • 20% for continuous duty
Lug • 5% for right-angle drive
• 3% for each 1,000 feet above sea level
Figure 1 • 1% for each 10º F above 60º F.
• It is recommended that the baseplate be grouted to a DRIVE-TRAIN SIZING (TORQUE)
foundation with solid footing. Refer to Figure 1. Other than sizing an engine for BHP, torque calculations also
• Place unit in position on wedges located at four points, two are required for proper sizing. Typically the horsepower and
below approximate center of driver and two below torque rating do not follow the same relationship throughout
approximate center of pump. Adjust wedges to level unit. the usable range of a diesel engine (Figure 2). The equation for
Level or plumb suction and discharge connections. torque (lbs/ft) is (5250 x BHP) / RPM.
• Make sure bedplate is not distorted and final coupling 600 180

alignment can be made within the limits of movement of 178

500
motor and by shimming, if necessary. 176
TORQUE (LBS/FT)

174
• Tighten foundation bolts finger tight and build dam around 400
172
foundation. Pour grout under bedplate making sure the areas

HP
300 170
under the pump and motor feet are filled solid. Allow grout 168
to harden 48 hours before fully tightening foundation bolts. 200
166
• Tighten pump and motor hold-down bolts before aligning 164
100
shaft or connecting the piping to pump. 162

• Allow grout to harden for 48 hours before tightening 4 0

1500 1600 1700 1800 1900 2000 2100 2200
160
2300
foundation bolts. RPM

Figure 2: HP (◆) vs. Torque (■)

SAE – ENGINE DRIVEN PUMPS
The SAE engine drive bearing frame is designed to bolt directly VERIFY MATCH OF PUMP END TO ENGINE
to the flywheel housing for engines with an SAE no. 1, 2, SAE Bracket Size:
3, 4 or 5 mount. The pump shaft extension is sized for use Engine drive pumps are available to fit engines having a stan-
with couplings bolted directly to the flywheel. Goulds Water dard SAE 5 through SAE 1 flywheel housing.
Systems optional couplings are sized for 6½", 7½", 8", 10", and For a new engine, the engine supplier can provide the SAE
14" flywheels. Although other flywheel mount couplings may housing number.
be used, it is recommended that the Goulds Water Systems
coupling be used to ensure long and trouble-free operation For an existing engine, the flywheel housing bore and bolt
from your Goulds Pump. circle can be measured and compared against the standard SAE
housing dimensions listed in Table 1, to identify the housing
REQUIREMENTS FOR PROPER OPERATION SAE number.
Pump End: • Measure the flywheel housing bore (A), and the bolt circle
When delivering the required capacity (GPM) to the system (B), as accurately as possible with a tape measure (to the
piping, the pump must add the amount of Head required nearest 1/32 inch).
by the system at the capacity. The operating head-capacity • Count the number of threaded holes in the flywheel housing
point should be as close as possible to the highest efficiency (C). Test the threaded holes with a bolt, to determine the
line shown on the performance curve, and must be below the thread series.
head-capacity line labeled “maximum” RPM. The maximum • Compare the measured dimensions (A), (B), and (C) against
operaton RPM for the pump is determined by bearing life, or Table 1, to determine the SAE number of the flywheel hous-
in some cases, by the pressure limits of the pump. Suction and ing, to be sure it matches the SAE number of your pump.
discharge openings are NPT tapped for standard pipe, or faced
and drilled per ANSI B16.1, class 125 for standard flanges as

4
 Flywheel
SAE Flywheel Housing Size • Examine shaft spline closely. Use a file, if necessary, to
Housing remove any burrs that would prevent coupling from sliding

Dimensions 1 2 3 4 5 freely onto the shaft.
A 201⁄8 175⁄8 161⁄8 141⁄4 123⁄8 • Lubricate pump shaft spline sparingly with light grease.
B 207⁄8 183⁄8 167⁄8 15 131⁄8 Don’t lubricate straight keyed shaft.
No. 12 12 12 12 8
C
Size 7⁄16-14 3⁄8-16 3⁄8-16 3⁄8-16 3⁄8-16 • Slide the coupling onto shaft until it is stopped against the
shaft (refer to page 5 for straight shaft installation).
Table 1
• Measure the distance from the engine side of the flywheel
coupling adapter ring to the mounting face of the pump
bracket. Refer to Figure 4 below, Dimension “A”.
• Next, measure depth from face of flywheel housing on
engine, to face on flywheel against which coupling will be
bolted. Refer to Figure 4 below, Dimension “B”.
• Pump measurement must be less than engine measurement
or axial interference will result in thrust force on engine
crank shaft bearings. Simply stated, Dimension “A” must be
less than Dimension “B”.
FLYWHEEL COUPLING
Figure 3 • The flywheel coupling transmits power from the engine
flywheel to the pump shaft. The maximum power that a
INSTALLATION coupling can safely handle is shown by a rating number, “R”,
• The pump may be installed horizontally, with the discharge which is listed in the coupling dimensions tables.
rotated to any position allowed by the casing bolt pattern • When selecting a flywheel coupling for a pump and engine,
(13). It is recommended that the discharge be located hori- first determine the power rating that the pump will demand.
zontally, above the suction. On the pump performance curve, find the RPM and BHP
• The casing must be supported on all pumps by a rigid sup- values required to produce the spplication head-capacity
port which is anchored to the unit base or foundation. point.
• For M-Group pumps it is recommended that this support • Divide the BHP by the RPM, then multiply the result times
is bolted to the motor adapter ring using 2 or more of the 100. The result will be the demand number for the pump.
casing bolts (13). It is likely that longer bolts will be required For example, a 20BFSAE1AO can deliver 800 GPM at 270
for the additional support thickness. Use SAE grade 5 bolts, feet Total Head when running at 1800 RPM. The power
torqued as indicated in this manual. required by the pump will be 75 BHP. The demand number
• For L-Group pumps it is recommended that the pump is will be: (75 / 1800) x 100 = 4.16
supported beneath the two feet cast into the motor adapter • Next, select a coupling that can safely transmit the power,
(3). These feet must be bolted to the support. and which will fit the flywheel dimensions. For a coupling to
PUMP TO ENGINE ASSEMBLY (SPLINE COUPLING) be suitable, it must have an “R” rating number GREATER
THAN the pump demand number. In the above example,
Preparation for Assembly of Pump on Engine the minimum coupling “R” number whould be 5.
• Clean face and register fit of flywheel housing and flywheel
as necessary to remove all grease, dirt, or rust (and all traces • Torsional compatibility of the engine, pump, and coupling
of rust preventative) which would interfere with installation is the responsibility of the assembler. Goulds Water Systems
of pump and/or prevent correct alignment. If flywheel is fit- will supply data for the pump and coupling for use by the
ted with a pilot bearing for a transmission shaft, remove and assembler for a torsional analysis.
discard. The pilot bearing is not required for installation of NOTE: If the flywheel is fitted with a pilot bearing pressed
the pump end, and could interfere with the pump shaft. into a bore at the center, remove it to avoid interference with
the pump shaft.

Figure 4 Figure 5
5
FLYWHEEL FOR INDUSTRIAL TYPE OVERCENTER Table IB –
CLUTCHES Wide RPM Range, Elastomer Mounted Hub – Straight Shaft
• Figure 6 shows the hollowed-out appearance of the fly- Flywheel Dimensions Flywheel Coupling
wheels made for use with overcenter type clutch power Clutch D Shaft
take-off assemblies. Size Size
Qty. (UNC)
E BC F G H R* Catalog Spline
Number Dia.
• These flywheels will have a recessed bore machined into the
2.28 CD616
face, and a set of tapped holes, which will be used to attach 6½" 6 5⁄16-18 8½ OD 7.88 3.94 1.19 1.69
the coupling to the flywheel. Dimensions are governed by 3.51 CD625
an SAE standard and are listed in Tables 1A and 1B, Figure 2.28 CD716
7½" 8 5⁄16-18 9½" OD 8.75 3.69 1.19 1.69
3. The “clutch size” shown in the table is the nominal clutch 3.51 CD725
facing diameter for Drive Ring Type Overcenter Clutches. 8" 6 3⁄8-16 103⁄8" OD 9.62 4.81 2.44 2.94
2.28 CD816
OTHER FLYWHEELS 3.51 CD825
2.28 CD1016
• Some engines are fitted with flywheels especially machined
3.51 CD1025
for coupling to other kinds of machinery (electrical gen-
erators, torque converters, etc.), and require nonstandard 10" 8 3⁄8-16 123⁄8" OD 11.62 4.47 2.13 2.75 5.71 CD1030
flywheel couplings. These may be purchased from third party 8.57 CD1050
1.625-
vendors or suppliers. 11.23 CD1080 1.624Ø
2.28 CD1116 3⁄8 x 3⁄16
3.51 CD1125 Keyway
5.71 CD1130
11½" 8 3⁄8-16 137⁄8" OD 13.12 5.06 1.56 2.69 8.57 CD1150
11.23 CD1180
12.62 CD1190
16.85 CD11110H
2.28 CD1416
3.51 CD1425
5.71 CD1430
14" 8 3⁄8-16 183⁄8" OD 17.25 6.63 1.00 2.13 8.57 CD1450
11.23 CD1480
Figure 6 12.62 CD1490
Table IA – 16.85 CD14110H
Wide RPM Range, Elastomer Mounted Hub – Spline Shaft Dimensions in inches
* R = Coupling Rating Max.
Flywheel Dimensions Flywheel Coupling (Spline) Coupling Rating = (Rated horsepower x 100) / Rated RPM
Clutch D Shaft
Size Size E BC F G H R* Catalog Spline • For Goulds Water Systems straight shaft keyed couplings –
Qty. (UNC) Ensure that the coupling hub set screw is backed out enough
Number Dia.
6½" 6 5⁄16-18 8½ OD 7.88 3.94 1.19 1.69 7 A00569C 1 1½" 10T to ensure clearance for the shaft key during assembly.
7½" 8 5⁄16-18 9½" OD 8.75 3.69 1.19 1.69 7 A00569C 2 1½" 10T • Mount the coupling assembly to the engine flywheel using
8" 6 3⁄8-16 103⁄8" OD 9.62 4.81 2.44 2.94 7 A00569C 3 1½" 10T the bolts provided torqued as follows in a crossing sequence:
10" 8 3⁄8-16 123⁄8" OD 11.62 4.47 2.13 2.75 7 A00569C 4 1½" 10T 6½" or 7½" Flywheel – 11 lbs.-ft. (15 N. m)
10" 8 3⁄8-16 123⁄8" OD 11.62 4.47 2.13 2.75 9 A00569C 6 1½" 10T 8", 10" or 11½" Flywheel – 20 lbs.-ft. (27 N.m)
11½" 8 3⁄8-16 137⁄8" OD 13.12 5.06 1.56 2.69 7 A00569C 5 1½" 10T
14" Flywheel – 50 lbs.-ft. (68 N.m)
(For other couplings follow manufacturers
11½" 8 3⁄8-16 137⁄8" OD 13.12 5.06 1.56 2.69 9 A00569C 7 1½" 10T
recommended installation procedure.)
14" 8 ½-13 183⁄8" OD 17.25 6.63 1.00 2.13 9 A00569C 8 1½" 10T
• Place the pump shaft key into the pump shaft (122) and align
* R = Coupling Rating Max.
Coupling Rating = (Rated horsepower x 100) / Rated RPM
the shaft to the coupling. Slide the pump into the coupling
until the engine adapter ring (340) contacts the engine
flywheel housing.
INSTALLATION OF COUPLING ON FLYWHEEL
Flywheel Coupling Overcenter Type:
• These couplings are aligned concentrically with the flywheel
by register fit on the flywheel.
• Be sure to remove all preservatives from the engine’s fly-
wheel.
• Fit the coupling into the flywheel. Align the bolt holes and
engage coupling with register fit on flywheel. Tap coupling
with a soft heavy hammer, if necessary, to be sure that it is
seated flat against flywheel. Secure coupling tightly to fly-
wheel with capscrews and lockwasher.
INSTALLATION OF PUMP ON ENGINE
• Lift pump with suitable lifting apparatus and align pump shaft
with coupling. End of pump shaft has a pilot diameter which
epermits wasy engagement of pump shaft into coupling.
6
• Reach into pump suction opening and rotate impeller slightly • All piping MUST be independently supported and MUST
until the shaft will engage the coupling. Verify that there is NOT place any piping loads on the pump
no gap between bracket and flywheel housing faces. Rotate NOTICE: DO NOT FORCE PIPING INTO PLACE
pump as necessary to align bracket holes with engine. Install AT PUMP SUCTION AND DISCHARGE
capscrews and bolt pump end securely to engine. CONNECTIONS.
NOTE: If any interference, or incompatibility of parts is • All pipe joints MUST be airtight.
detected during installation, DO NOT proceed with
assembly. Direct the problem to your nearest Goulds PIPING – SUCTION
Pumps distributor. • For suction lifts over 10 ft. (3 m) and liquid temperatures
• Mount the pump to the engine using the bolts and lock- over 120° F (49° C), consult pump performance curve for
washers provided, torqued as follows in a crossing sequence: net positive suction head required (NPSHR).
SAE #2, #3, #4, #5 – 20 lbs.-ft. (27 N. m) • If a pipe size larger than pump suction is required, an ec-
SAE #1 – 50 lbs.-ft. (68 N. m) centric pipe reducer, with the straight side up, MUST be
• Install coupling guards (501N). installed at the pump suction.
• Bolt motor adapter (3) to the rigid support described above. • If pump is installed below the liquid source, install a gate
valve in the suction for pump inspection and maintenance.
COUPLING ALIGNMENT NOTICE: DO NOT USE THE GATE VALVE TO
THROTTLE PUMP. THIS MAY CAUSE LOSS
WARNING FAILURE TO DISCONNECT AND OF PRIME, EXCESSIVE TEMPERATURES
LOCKOUT ELECTRICAL POWER AND DAMAGE TO PUMP, VOIDING
BEFORE ATTEMPTING ANY WARRANTY.
MAINTENANCE CAN CAUSE
SEVERE PERSONAL INJURY. • If the pump is installed above the liquid source, the following
MUST be provided:
• To avoid air pockets, no part of the piping should be above
Hazardous machinery
can cause personal the pump suction connection.
injury or death.
• Slope the piping upward from liquid source.
FRAME-MOUNTED UNITS ONLY • Use a foot valve or check valve ONLY if necessary for
• Alignment MUST be checked prior to running. See Figure 7. priming or to hold prime during intermittent duty.
• The suction strainer or suction bell MUST be at least
Parallel 3 times the suction pipe diameter area.
• Insure that the size and minimum submergence over suc-
tion inlet is sufficient to prevent air from entering pump
through a suction vortex. See Figures 8 through 11.

Angular
H min. H min.
---------
D --------- D
Figure 7

---------
---------
• Tighten all hold-down bolts before checking alignment.
• If realignment is necessary, always move the motor. Shim
Figure 8 Figure 9
as required. H
16
H = Min. Submergence in feet

15
• Parallel misalignment, shafts with axis parallel but not 14
13
concentric. Place dial indicator on one hub and rotate this 12
11
hub 360° while taking readings on the outside diameter of 10
9
the other hub. Parallel alignment is achieved when reading is 8
3.0D 7
0.010" (0.254 mm) TIR, or less. min.
6
5
• Angular misalignment, shaft with axis concentric but not par- 1.5D
4
3
allel. Place dial indicator on one hub and rotate this hub 360° min. H min. 2
1
while taking readings on the face of the other hub. Angular D D min. D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 V
alignment is achieved when reading is 0.020" (0.508 2 V = Velocity in feet per second
=GPM x 0.321 GPM x 0.4085
mm) TIR, or less. Area D2
• Final alignment is achieved when parallel and angular re- Figure 10 Figure 11
quirements are satisfied with motor hold-down bolts tight. PIPING – DISCHARGE
NOTICE: ALWAYS RECHECK BOTH ALIGNMENTS • Install a check valve suitable to handle the flow, liquids and
AFTER MAKING ANY MECHANICAL to prevent backflow. After the check valve, install an ap-
ADJUSTMENTS. propriately sized gate valve to be used to regulate the pump
capacity, pump inspection and for maintenance.
PIPING • When required, pipe increaser should be installed between
• Piping should be no smaller than pump’s discharge and the check valve and the pump discharge.
suction connections and kept as short as possible, avoiding
unnecessary fittings to minimize friction losses. See Table 1.

7
WIRING AND GROUNDING WARNING OPERATION AT OR NEAR ZERO
FLOW CAN CAUSE EXTREME HEAT,
WARNING Install, ground and wire according PERSONAL INJURY OR PROPERTY
to local and National Electrical Code DAMAGE.
Requirements.
Install an all leg electrical power
disconnect switch near the pump.
Extreme heat can
Disconnect and lockout electrical cause personal injury
Hazardous voltage power before installing or servicing or property damage.
can shock, burn or
the pump.
cause death.
NOTICE: NO NOT RUN PUMP DRY OR SEAL
Electrical supply MUST match DAMAGE WILL RESULT.
pump’s nameplate specifications. In-
correct voltage can cause fire, damage • After stabilizing the system at normal operating conditions,
motor and void the warranty. check the piping. If necessary, adjust the pipe supports.
Motors without built-in protection MUST be provided • On frame-mounted units, coupling alignment may have
with contactors and thermal overloads for single phase changed due to the temperature differential between pump
motors, or starters with heaters for three phase motors. and motor. Recheck alignment following procedures and
See motor nameplate. hazard warnings in “COUPLING ALIGNMENT” section
• Use only copper wire to motor and ground. The ground of this manual.
wire MUST be at least as large as the wire to the motor.
Wires should be color coded for ease of maintenance. MAINTENANCE
• Follow motor manufacturer’s wiring diagram on the motor
WARNING FAILURE TO DISCONNECT AND
nameplate or terminal cover carefully. LOCKOUT ELECTRICAL POWER
BEFORE ATTEMPTING ANY
WARNING FAILURE TO PERMANENTLY MAINTENANCE CAN CAUSE SHOCK,
GROUND THE PUMP, MOTOR AND
Hazardous CONTROLS BEFORE CONNECTING BURNS OR DEATH.
voltage TO ELECTRICAL POWER CAN CAUSE
SHOCK, BURNS OR DEATH. Hazardous voltage
can shock, burn or
ROTATION cause death.

NOTICE: INCORRECT ROTATION MAY CAUSE CAUTION FAILURE TO RELIEVE SYSTEM

DAMAGE TO THE PUMP AND VOIDS PRESSURE AND DRAIN SYSTEM
THE WARRANTY. BEFORE ATTEMPTING ANY
MAINTENANCE CAN CAUSE
• Correct rotation is right-hand, CLOCKWISE when viewed PROPERTY DAMAGE, PERSONAL
from the motor end. For frame mounted units, switch power INJURY OR DEATH.
on and off quickly to observe rotation. On close coupled
units, remove motor end plug or cover to observe rotation. Hazardous pressure can
cause personal injury,
• To reverse three phase motor rotation, interchange any two property damage or death.

power supply leads. WARNING IF PIPING HAZARDOUS OR TOXIC

FLUIDS, SYSTEM MUST BE FLUSHED
OPERATION PRIOR TO PERFORMING SERVICE.

WARNING DO NOT OPERATE FRAME

MOUNTED OR SAE UNITS WITHOUT
SAFETY GUARDS IN PLACE OR
SEVERE PERSONAL INJURY MAY Hazardous fluids can
cause personal injury
RESULT. or property damage.

Hazardous machinery CLOSE-COUPLED UNITS

can cause personal
injury or death. • Bearings are located in and are part of the motor. For lubrica-
tion information, refer to motor manufacturer’s instructions.
WARNING SPLASHING OR IMMERSING OPEN FRAME-MOUNTED UNITS
DRIP PROOF MOTORS IN FLUID
CAN CAUSE FIRE, SHOCK, BURNS OR • Model 3756 S-group has greased for life bearings.
DEATH. No regreasing is possible or necessary.
• Model 3756 M or L-group bearing frame and SAE drive
bearing frame should be regreased every 2,000 hours or
at a three month interval, whichever occurs first. Use a #2
Hazardous voltage
can shock, burn or sodium or lithium based grease. Fill until grease comes out of
cause death.
relief fittings, or lip seals, then wipe off excess.
• Follow motor or engine and coupling manufacturer’s lubri-
cation instructions.
• Recheck alignment.
8
SEASONAL SERVICE 5. Remove retaining ring (361).
• To REMOVE pump from service, remove drain plug and 6. Use bearing puller or arbor press to remove ball
drain all unprotected piping. bearings (112, 168).
• To RETURN pump to service, replace drain plug using
Teflon™ tape or equivalent on male threads. REASSEMBLY
• Reconnect suction line if removed, examine union and repair • All parts should be cleaned before assembly.
if necessary. NOTICE: O-RING SHOULD BE REPLACED AFTER ANY
• Refer to OPERATION section of manual. DISASSEMBLY OF UNIT.
BEARING FRAME
DISASSEMBLY
1. Replace lip seals if removed.
• Follow ALL warnings and instructions in the “MAINTE-
2. Replace ball bearings if loose, rough or noisy when rotated.
NANCE” section of this manual.
3. Check shaft (122) for runout. Maximum permissible is
• Close-coupled units: Remove motor hold-down bolts.
0.002" (0.05 mm) TIR.
• Frame-mounted units: Remove coupling guard, spacer, cou-
4. Refer to the “MAINTENANCE” section of this manual
pling and frame hold-down bolts.
for M-group bearing frame regreasing instructions.
LIQUID END
LIQUID END
1. Remove casing bolts (13).
1. Inspect shaft removing any debris or burrs.
2. Remove back pull-out assembly from casing (1).
2. Treat shaft with LOCQUIC® Primer “T”, or equivalent,
3. Remove casing wear ring (4) if excessively worn. following manufacturer’s instructions carefully.
NOTICE: DO NOT INSERT SCREWDRIVER BETWEEN 3. When replacing shaft sleeve, spray new shaft sleeve’s bore
IMPELLER VANES TO PREVENT ROTATION. with LOCQUIC® Primer “T”, or equivalent. Let parts dry
4. On close-coupled units, remove motor end plug or cover and then apply LOCTITE® #262 on the same surfaces.
to expose screwdriver slot or flats on end of motor shaft. Slide new sleeve over shaft with a twisting motion, wipe
5. While restraining shaft with an appropriate tool (close- off excess. Let cure according to instructions.
coupled units) or with a strap wrench (frame-mounted NOTICE: MECHANICAL SEAL MUST BE REPLACED
units) remove impeller bolt (6). Impeller bolt may need WHENEVER SEAL HAS BEEN REMOVED.
to be heated with torch to remove. Discard. FOLLOW SEAL MANUFACTURER’S
NOTICE: EXERCISE CAUTION WHEN HANDLING INSTRUCTIONS CAREFULLY. FOR PACKED
HOT IMPELLER BOLT. BOX PUMPS SEE “PACKED BOX
INSTRUCTIONS”.
NOTICE: FOR SAE DRIVE UNITS, REMOVE IMPELLER
NUT SET SCREW (22A) PRIOR TO 4. Replace seal housing wear ring, if removed.
REMOVING IMPELLER NUT (22). IMPELLER 5. For mechanical seal pumps, stationary seal seat may be
SET SCREW AND IMPELLER NUT MAY NEED dipped in water to ease installation. Place stationary seal
TO BE HEATED TO BE REMOVED. seat squarely into seal housing bore. Cover the polished
6. Remove impeller washer (7). face of the seat with a thin piece of cardboard or paper
towel. Press seat firmly into bore using a round piece of
7. Insert two pry bars, 180° apart, between impeller (2) and plastic or wood that disperses the force over the entire
seal housing (3). CAREFULLY pry off impeller. seal face. NOTE: If mechanical seal is supplied with a
8. Remove impeller key (8). spring retainer, remove and discard the retainer.
9. Remove seal housing bolts (14) and seal housing (3) 6. Place adapter, concave face pointing up, over motor
pulling with it the mechanical seal assembly. Discard seal shaft and lower it onto the motor.
assembly and seal housing o-ring (9). For packed box
7. Replace seal housing o-ring. This o-ring may be lubricated
pumps see “PACKED BOX INSTRUCTIONS”.
with water or glycerin to ease in installation. Install seal
10. Remove adapter (108). housing on adapter. Exercise care in that the motor shaft
11. Inspect shaft sleeve (11). If badly scored, remove by does not dislodge or damage seal seat.
heating with torch. Discard. 8. Fully and squarely install the rotary assembly of seal
12. Push out the mechanical seal stationary seat from the against the stationary seat.
seal housing. Discard. NOTICE: REPLACE IMPELLER BOLT AND WASHER
13. On units equipped, remove seal housing wear ring (5) WHENEVER IMPELLER IS REMOVED.
if excessively worn. 9. Install impeller key in shaft keyway. Mount impeller on
DISASSEMBLY OF BEARING FRAME OR shaft and push until it bottoms. Hold in place. For SAE
SAE BEARING FRAME units, apply LOCTITE 271 to the impeller bore, keyway
1. Remove deflector (123) from shaft. and shaft. Mount impeller on shaft and push until it
bottoms. Hold in place.
2. Remove bearing cover (134).
10. Install new impeller washer. Impeller washer not used for
3. Remove shaft assembly from frame. SAE units.
4. Remove lip seals (138, 139) from bearing frame (228) and
bearing cover (134) if worn. Discard.

9
11. Apply LOCTITE® #271 or equivalent, to new impeller bolt 3. Install the two piece Teflon lantern ring supplied as shown
threads and tighten to: in figure 13. Note: two pieces make one ring. Notches on
3
⁄8"-16 bolts 20 lbs.-ft. (27 N. m) ring must face each other, but alignment is not necessary.
½"-13 bolts 38 lbs.-ft. (51 N. m)
Impeller bolt not used for SAE units.
12. For SAE units apply LOCTITE® #271 to the external
threads of the shaft and internal threads of the impeller
nut (22). Tighten impeller nut to the following:
½"-Impeller Nut (SAE M-Group) 80 lbs.-ft. (107 N. m)
¾"-Impeller Nut (SAE L-Group) 100 lbs.-ft. (134 N. m)
13. For SAE units, after impeller nut (22) has been installed,
apply LOCTITE® #271 to set screw (22A). Install impeller
set screw into face of impeller nut (22) and tighten Teflon Lantern Ring
hand-tight. Figure 13
14. Replace casing wear ring, if removed. 4. Install the packing rings and lantern ring in the following
15. Replace casing bolts and tighten, in a crossing sequence, sequence to pack the packed box. Install two rings of
to torque values indicated below: packing, then the lantern ring, followed by the final three
rings of packing. Install each ring separately and firmly
3
⁄8"-16 bolts (bronze casing) 25 lbs.-ft. (34 N. m)
seat. The use of a wooden split bushing is recommended
½"-16 bolts (cast iron casing) 37 lbs.-ft. (50 N.m)
to accomplish this. See Figure 14. Use gland to jack the
½"-13 bolts (cast iron casing) 90 lbs.-ft. (122 N.m)
bushing and ring into the box. Stagger joints in each ring
¾"-10 bolts (cast iron casing) 175 lbs.-ft. (237 N. m)
90°. Make sure the flush tap in the packed box lines up
16. Check reassembled unit for binding by rotating shaft with with the center of the lantern ring. Any extra rings are
appropriate tool from motor end. spares.
17. If rubbing exists, loosen casing bolts and proceed with
tightening sequence again.
WOODEN “SPLIT BUSHING”
18. Replace motor hold-down bolts and motor end plug or
cover on close-coupled units.
19. Replace coupling, spacer, coupling guard and frame GLAND
hold-down bolts on frame-mounted units.
NOTICE: ALWAYS RECHECK BOTH ALIGNMENTS STUFFING
AFTER MAKING ANY ADJUSTMENTS. BOX
20. Refer to the “COUPLING ALIGNMENT” section of SHAFT
this manual to realign shaft.
21. Assembly is complete. Figure 14
5. Tighten gland nuts evenly, but not tight. When the pump
PACKED BOX is started, slowly tighten the gland nuts until the leak rate
1. Make sure stuffing box is free of foreign materials and is between 40 and 60 drops per minute. A grease lubricant
clean before beginning packing of packed box. Refer to can be used when the pumpage contains abrasive particles
Sectional Assembly in the repair parts section. or for a suction lift condition.
2. Take special care during installation of packing rings REMOVAL OF PACKED BOX
because they are die-formed. To install, twist the ring • Follow these steps to remove the packing from the
sideways just enough to fit it around the shaft sleeve. packed box.
DO NOT ATTEMPT TO PULL RINGS STRAIGHT 1. Remove gland assembly.
OUT. See Figure 12.
CORRECT WRONG
2. With a “packing hook” remove packing.
3. Insert a wire hook into the ring on the outer edge to
remove the lantern ring.
4. Clean the packed box.
PRIME SAFE ARRANGEMENT
(Optional – M & L Group Only)
Figure 12 • The Prime Safe arrangement can be provided with grease or
an oiler feed lubrication.
1. The grease gland (24) will have the letters "G" and "O"
stamped on the outside diameter and have two 1⁄8" NPT
connections for mounting a grease feeder or oiler.

10
2. For grease feed applications, the grease gland is assembled TROUBLESHOOTING GUIDE
with the “G” stamp in the 12 o' clock position. The grease
feeder (23) will mount in the grease gland at a 30 degree WARNING DISCONNECT AND LOCKOUT
angle from the horizontal. This is done to gain access to the ELECTRICAL POWER BEFORE
grease fitting located on the grease feeder. The lip seal (26) ATTEMPTING ANY MAINTENANCE.
mounted in the grease gland will be assembled as shown in FAILURE TO DO SO CAN CAUSE A
Figure 15. SHOCK, BURN OR DEATH.
3. For oiler feed applications, the grease gland is assembled
with the “O” stamp in the 12 o' clock position. The two Hazardous voltage
can shock, burn or
1⁄8" NPT connections on the grease gland will be located on
cause death.
the horizontal, which is to ensure proper function of the
oiler. The lip seal (26) is to be mounted in the reverse or SYMPTOM
opposite direction as shown in Figure 10. MOTOR NOT RUNNING
See Probable Cause – 1 through 5
4. The mounting of a grease feeder or oiler may require
additional pipe extensions and/or fittings that will be LITTLE OR NO LIQUID DELIVERED
provided from the factory as needed. See Probable Cause – 6 through 13
5. The grease feeder (23) will come with three springs (blue, EXCESSIVE POWER CONSUMPTION
red and silver). The use of the different springs will be See Probable Cause – 3, 13, 14, 15
varied depending on the operating temperature and the EXCESSIVE NOISE and VIBRATION
lubricant (grease) to be used. See Probable Cause – 3, 6, 7, 10, 12, 14, 16, 17
Grease Feeder Spring Size PROBABLE CAUSE
Operating Temperature No. 1 Grease No. 2 Grease No. 3 Grease 1. Motor thermal protector tripped
2. Open circuit breaker or blown fuse
-10ºF (-23ºC) to 40ºF (4ºC) SILVER RED —
3. Impeller binding
-40ºF (-40ºC) to 110ºF (43ºC) SILVER SILVER RED 4. Motor improperly wired
-110ºF (-79ºC) to 200ºF (93ºC) BLUE SILVER SILVER 5. Defective motor
6. Pump is not primed, air or gases in pumpage
Use SAE 30W oil for oiler application. 7. Discharge, suction plugged or valve closed
8. Incorrect rotation (3 phase only)
9. Low voltage or phase loss
10. Impeller worn or plugged
11. System head too high
12. NPSHA too low – Excessive Suction lift or losses
13. Incorrect impeller diameter
23 14. Discharge head too low – excessive flow rate
15. Fluid viscosity, specific gravity too high
16. Worn bearing
17. Pump, motor or piping loose

26

24

Figure 15

11
REPAIR PARTS SERIES 3656/3756

4 6 7 8 2 5 9 10 3 11

SAE M & L
13
Replaces 6 & 7

23
22A 22
3 10 3
16 17 18
11
12 1 14
19

24

20

21 26

25

Packed Box Arrangement Prime Safe Arrangement (optional – M & L group only)
LIQUID END COMPONENTS LIQUID END COMPONENTS
Item No. Description Material Item No. Description Material
1 Casing 24 Grease gland Aluminum
2 Impeller Cast iron or Sil-brass* 25 Pipe plug Zinc plated steel
3 Adapter 26 Lip seal Buna
4 Wear ring (casing) Cast iron or bronze* * Lead free
5** Wear ring (seal housing) ** Item #5 supplied on S-group model 2½ x 3-7 (7½, 10 and 15 HP) and
M-group (except 3 x 4-10).
6 Impeller bolt AISI Type 300
stainless steel POWER END COMPONENTS (shown on next page)
7 Impeller washer
Item No. Description Material
8 Impeller key Steel
112 Ball bearing (outboard) Steel
9 Seal housing o-ring (optional materials) BUNA-N/EPR/Viton
122 Pump shaft
10 Mechanical seal Consult factory
122A Pump shaft (SAE) AISI 4140 steel
11 Shaft sleeve AISI Type 300
stainless steel 123 V-ring, deflector BUNA-N
12 Drain plug – ¼ or 3⁄8 NPT 134 Bearing cover Cast iron
13 Hex head cap screw (casing to adapter) Zinc plated steel 138 Lip seal (outboard) BUNA-N
14 Hex head cap screw (adapter to motor/frame) 139 Lip seal (inboard)
15 Hex head cap screw (Adapter to seal housing) 168 Ball bearing (inboard) Steel
16 Lantern ring Teflon™ 193 Grease fitting (M & L group)
17 Packing, 5 rings Teflon™ impregnated 327C Screw (cover to adapter) (SAE only) Zinc plated steel
18 Gland AISI 300SS 340 Adapter/engine (SAE only) Cast iron
19 Shaft sleeve 361 Retaining ring Steel
AISI Type 300 370C Hex head cap screw (frame to cover) Zinc plated steel
20 Gland stud stainless steel
21 Gland nut 371C Hex head cap screw (adapter to frame)
(SAE only) NOT SHOWN Steel
22 Impeller nut (SAE only) 304 SS
399 Key, coupling
22A Set screw, impeller nut (SAE only)
501N Cover/adapter (SAE only) Galvanized steel
23 Grease feeder (oiler optional) Polycarbonate

12
3656/3756 POWER FRAMES

112 361 370C 361 370C

168

139 399
399

138
138
123 168 122 134
123 193 122 112 193 134
S-Group Power Frame M-Group Power Frame

123 139 371L 193

361 370C

168

361
139 399 399

327C
138

501N
370C
138
340
123 193 122 112 193 134
168 193 122A 112 134

L-Group Power Frame SAE Power Frame

13