BARNES® - Crane Pumps
Contents
1. eestecess 24 First Stage Impeller e c 25 SUCIO COM E 25 Su aeaa e ctr crc ns sts ge geese 26 Discharge TN TE 27 MOTOR HOUSING EE 28 29 Pin Placement Diagram E 30 Perform Pressure e 31 Keele ebe ioris ir a on E SEET 32 OGP ZAP Exploded TEE 33 PAS E EE 34 NOTES ee 35 Other brand and product names are trademarks or registered trademarks of their respective holders Barnes is a registered trademark of Crane Pumps amp Systems Inc Crane Pumps amp Systems Inc 2004 7 06 Alteration Rights Reserved SAFETY FIRST Please Read This Before Installing Or Operating Pump This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS To help recognize this information observe the following symbols IMPORTANT Warns about hazards that can result in personal injury orlndicates factors concerned with N assembly installation operation or maintenance which could result in damage to the machine or equipment if ignored CAUTION Warns about hazards that can or will cause minor personal injury or property damage if ignored Used with symbols below WARNING Warns about hazards that can or will cause serious personal injury death or major property damage if ignored Used with symbols below Hazardous fluids can Extremely hot Severe cause fire or explo burnes can occur on contact sions burnes or death Ali Gs ae ew o Hazardous fluids can Hazard could result ous2. Examine all seal parts and especially contact faces Inspect seal for signs of wear such as uneven wear tracks on stationary members chips and scratches on either seal face DO NOT interchange seal components replace the complete seal assembly if replacing seal NOTE Seal spring retaining cup may not be used on newer versions dated 04 04 04 13 Motor Housing NOTE Position unit upright using 4 PVC coupler to avoid resting unit on the lower shaft Loosen 5 16 hex bolts and lockwashers from cable clamp on motor housing Remove cord from motor housing by pulling straight up while using a rocking motion Remove retaining snap ring with a medium flat tip screwdriver Using a 1 4 20 bolt thread it into the center of the terminal block Pull straight up with a rocking motion to remove the terminal block Disconnect all wire connections noting where each wire is connected The bottom of the block has a number located next to each pin for reference If pump is equipped with automatic level control remove in Same manner as the power cord 14 Motor Housing con t Remove 5 16 hex head bolts and lockwashers from motor housing and vertically lift motor housing from intermediate coupling Remove square ring from intermediate coupling Inspect square ring for signs of wear and abrasion T9 Motor Remove the four long 1 4 hex head stator bolts and carefully remove the motor stator from the rotor A pai
3. unauthorized access to it If the pump is idle for long periods of time it is advisable to start the pump occasionally by adding water to the basin zf s f s CAUTION Pumps build up heat and pressure WANK j during operation allow time for pumps to cool before handling or servicing WARNING DO NOT pump hazardous materials flammable caustic etc unless the pump is specifically designed and designated to handle them Do not block or restrict discharge hose as discharge hose may whip under pressure WARNING DO NOT wear loose clothing that may become entangled in the impeller or other moving parts WARNING Keep clear of suction and discharge openings DO NOT insert fingers in pump with power connected Make sure lifting handles are securely fastened each time before lifting Do not operate pump without safety devices in place Always replace safety devices that have been removed during service or repair Do not exceed manufacturers recommendation for maximum performance as this could cause the motor to overheat Secure the pump in its operating position so it can not tip over fall or slide Cable should be protected at all times to avoid punctures cut bruises and abrasions inspect frequently Ji t Never handle connected power cords with wet hands To reduce risk of electrical shock all wiring and junction connections should be made per the NEC or CEC and appl
4. 4 D Ji r m RK Pie D MI pe a mee SA ks 07784 af Bd ay j sde te ms La pues r H E m M i BL BR a D LL z E d d E q eh ak M Lf e r WI EI 4 Li LP ae Cresent Wrench e Hammer Brass Flat Punch e 1 2 Wrench Combination End e 2 3 16 Flat Blade Screwdrivers e 1 4 Nut Driver e 1 8 Allen Wrench e 5 16 Allen Wrench Needle Nose Pliers e 4 PVC Coupler e 1 4 20 Bolt Seal Pushers Part No TL 21356 Bullets Thread Protectors Part No TL 21375 Dielectric Cooling Oil 900z e Blue 242 Green 609 Loctite Pressure Gauge Kit Part No 085343 e Megohmmeter amp Multi Meter w Clamp Propane Torch OGP 2HP DISASSEMBLY Visual Inspection of Pump Quick visual inspections can save time A visual Examination of the pump for damage to cords controls or cutter and a thorough electrical check should be performed to determine a pumps condition Cut Cords Check the cord s for any cuts or gouges If there is any noticeable damage do not use the cord remove and install a new cord if applicable Megger the Pump Leads Megohmmeter This test is to determine the resistance of the cord and motor insulation The meter will test zero Q if the insulation is damaged or breaking down thus allowing current to flow through the insulation This test can best be performed if the pump leads are disconnected from the control panel or the junction box
5. on rotor shaft Using an arbor press hold the rotor and press the lower bearing on the rotor shaft apply force to the inner race of the bearing only Install bottom retaining ring on rotor shaft The bearing will be positioned between the retaining rings T cove i Le Ge W WK ios NOTE BEARING MARKINGS MUST BE ON OUTSIDE OF ROTOR 19 Motor Slide motor rotor with bearings into seal plate Set wave spring on top of upper bearing hold in place with small amount of grease Set motor stator over rotor being sure that stator drops flat against boss in coupling Place end bell on top of motor and insert the hex stator bolts in motor and torque to 17 in Ibs NOTE SEE WIRING DIAGRAM ON THE FOLLOWING PAGE IF NEW CAPACITORS ARE BEING INSTALLED 20 Wiring Diagram RUN CAPACITOR ui START CAPACITOR THERMAL PROTECTOR THERMOSTAT Ki WHT CC TERMINAL 4 TERMINAL 1 WHT BLK 8 TERMINAL 5 L1 BLACK L2 WHITE Wiring Diagram For Emerson Electric Motor RUN CAPACITOR y VIOLET 9 BLACK 2 BROWN 10 THERMAL PROTECTOR Jace BLUE 4 START CAPACITOR YELLOW 3 Wiring Diagram For Franklin Electric Motor 21 Seal Clean and oil stationary seal cavity in seal plate Slide seal guide see parts list Seal Tool Kit over motor shaft Lightly oil DO NOt grease outer surface of stationary seal Press stationary seal firmly into seal plate using a seal pusher Make sure the stationary me
6. pressure eruptions or ex Ar Biohazard can cause t ar Ww serious personal injury k WE plosions could cause personal injury or property damage Rotating machinery wer Amputation or severe laceration can result Hazardous voltage can shock burn or cause death Only qualified personnel should install operate and repair pump Any wiring of pumps should be performed by a qualified electrician WARNING To reduce risk of electrical shock pumps and control panels must be properly grounded in accordance with the National Electric Code NEC or the Canadian Electrical Code CEC and all applicable state province local codes and ordinances WARNING To reduce risk of electrical shock always disconnect the pump from the power source before handling or servicing Lock out power and tag Prevent large articles of clothing large amounts of chemicals other materials or substances such as are uncommon in domestic sewage from entering the system During power black outs minimize water consumption at the home s to prevent sewage from backing up into the house Always keep the shut off valve completely open when system is in operation unless advised otherwise by the proper authorities Before removing the pump from the basin be sure to close the shut off valve This prevents backflow from the pressure sewer Keep the control panel locked or confined to prevent
7. BARNES SERVICE MANUAL OGP 2 HP Pump IMPORTANT Read all instructions in this manual before operating pump As a result of Crane Pumps amp Systems Inc constant product improvement program product changes may occur As such Crane Pumps amp Systems reserves the right to change product without prior written notification C RA N E 5 P U M PS amp SYSTE M S Submersible Wastewater Pump Association A Crane Co Company 420 Third Street 83 West Drive Bramton Piqua Ohio 45356 Ontario Canada L6T 2J6 Phone 937 778 8947 Phone 905 457 6223 Fax 937 773 7157 Fax 905 457 2650 www cranepumps com Form No SM115336 Rev B TABLE OF CONTENTS SAFET FIRST eege 3 joe E WE 4 OGP 2HP DISASSEMBLY ccc cccccecccceeecceeeeeeeeeeaeeesseeeesaeeeseeeesseeenaes 5 Visual Inspection OF PUMP coss esca Seat ated uer oe Sac Eege 5 7 CURE REMOVA EE 8 Suction Cover Removal E 9 First Stage Impeller Removal ccccccsececsececececseeecseecseeseaneesaees 9 Unc 10 Oil Removal Pressure Check 11 Second Stage Impeller Removal A 12 Shaft Seal ug dveontetecrwpenpesceds seed ag desussacsdetancnciedecticeapdvesoieuedeusteiacesedesins 13 Viewed HOUSING EE 14 15 Klee WEE 16 ES le Le E 17 Anay o eal EE 18 ElE Ger E EE 19 Bearing to Pump Rotor EE 19 Wee EE 20 UPI I GAN E 21 v E 22 Vag 81 gilt ner 29 on
8. CAUSE THE TERMINAL BLOCK TO i CAUTION MAKE CERTAIN THAT CORD SET IS ATTACHED TO PUMP PERFORMING THE BLOW OUT To check the pump for any seal leaks attach the pressure gauge assembly using pipe sealant Tighten the fitting into the hole Pressurize the gauge to 8 to 10 psi Use a soap solution around the sealed areas and inspect joints for air bubbles If after 5 minutes the pressure is still holding constant and no bubbles are observed slowly bleed the pressure and remove the gauge assembly Replace the pipe plug using sealant If the pressure does not hold then the leak must be located and repaired 10 PSI AIR MEE PRESSURE GAUGE ASSY REMOVE PIPE PLUG Replacing Oil Motor housing Set unit upright and refill with see chart for type and amount new cooling oil Fill to just above the end bell top of the motor as an air space must remain in the top of the motor housing to compensate for oil expansion Apply pipe thread compound to threads of pipe plug and assemble to motor housing NOTE Reference oil chart for suitable replacement oils suPPuER GRADE ounces Be EnemarsEiQO Imperial Oil Voltesso 35 Shell Canada Transformer 10 Diala Oil AX CONTACT CRANE PUMPS amp SYSTEMS FORA TYPICAL MSDS SHEET IF REQIIRED G amp G Oil Circulating 22 96 CAUTION DO NOT OVERFILL OIL OVERFILLING OF MOTOR HOUSING WITH OIL AN 4 CAN CREATE EXCESSIVE AND DANGEROUS
9. HYDRAULIC PRESSURE THAT WILL a DESTROY THE PUMP AND CREATE A HAZARD OVERFILLING OIL VOIDS WARRANTY OIL LEVEL FILL UNTIL END OF MOTOR IS COVERED 32 OGP 2HP Exploded View d d Ny 2 E Ss 4 CH 0 5 33 PARTS KITS Seal Repair Kit P N Overhaul Kit P N Cutter Kit P N 116665 116666 1160604 em zs 6 7 13 15 20 25 33 36 38 Item s 3 5 6 7 9 13 15 20 25 28 29 33 36 38 Item s 5 6 7 9 13 15 36 PARTS LIST 3 3 ue same qms e 110328 Motor oo AU series s oos Swredaing Ring e c esee washer e n 108369 Discharge Flange 1 1 NPT LRL pem seem __ Screw 5 16 18 x 1 25 SS 16 AR LOCTITE RC609 vas uocrme2a 5 16 Flatwasher Seal Silicon Carbide STD P22 Am PermatexSeaient20 28 1 116658 Ball Bearing Upper Not Shown mr I uM Te Eer 32 1 103760 Terminal Block Power Manual 34 IEEBENEL ANNETTE RdHd Screw 10 32 x 37 SS AUF LIEB 1x 2h i nel AU series Le 2 105160 Wire Connector Contact your local Distributor or the Factory for other cord lengths and other optional equipment 35 Notes CRANE PUMPS amp SYSTEMS INC 420 THIRD STREET PIQUA OHIO 45356 U S A
10. To perform this test touch one lead to the green ground Touch the other lead to the black wire Repeat this test with ground to white To pass this test a pump set must have a reading of 5mQ or higher on all leads Note that a 0 reading indicates a dead short N CAUTION After performing a megger test ALWAYS discharge cord set leads to ground Dielectric Withstand Test Hi Pot Test This test ensures that the insulation and or spacings between live and isolated parts is suitable for operating voltage This test is especially useful in detecting inadequate insulation which may not be readily visible such as between windings within a motor or due to some other failure eg Pinched wire stray strands nicked motor insulation This test uses a very high potential usually 1000 volts twice the rated voltage to stress the insulation system of the pump and motor to verify its integrity Because it stresses the insulation it is actually a destructive test and should only be used on a limited basis Repeated testing will cause the insulation to break down and fail Touch the green ground lead from the pump to one of the meter leads and the other meter lead to one of the power leads Repeat this test with all of the power leads N CAUTION After performing a Hi Pot test ALWAYS discharge cord set leads to ground Check the Resistance Multi Meter CAUTION Perform this test with the pump oft This test is to check for open circuits or loo
11. de of the NPT tapped hole should be facing up 2f Motor Housing Lubricate and set square ring into bore on intermediate coupling Install ground wire in end bell if removed Use proper bolt to secure ground lug Place fiberglass sleeve over motor and ground leads if removed Pull wires through opening in top of motor housing while lowering motor housing onto seal plate Connect wires to pins on the bottom of the terminal block See wiring diagram on page 30 28 Motor Housing con t Lubricate o ring and slide terminal block back into housing Make sure terminal block is engaged and install snap ring to retain terminal block Tighten bolts and lock washers into motor housing If there were optional pump features such as a float re install those at this time also Tighten 5 16 hex head bolts and lockwashers into motor housing 29 Pin Placement Diagram lt L1 L2 Z D O BLK WHT COMPRESSION FLANGE G 1 2 TERMINAL BLOCK ALIGNMENT MARK ON CABLE MUST ALIGN WITH THE G 1 2 ALIGNMENT MARK ON TERMINAL BLOCK FOR PROPER ASSEMBLY SINGLE PHASE 240 VOLT AC GRN TERMINAL BLOCK TERMINAL BLOCK Wiring Harness MOTOR LEADS SINGLE PHASE 240 VOLT AC AUF and AUE SERIES 30 Perform Pressure Check NOTE This is to be performed with no oil in housing PRESSURE CHECK WITHOUT THE CORD SET ON MAY
12. icable state or province and local codes Requirements may vary depending on usage and location NI Submersible Pumps are not approved for use in swimming pools recreational water installations decorative fountains or any installation where human contact with the pumped fluid is common gt Do not remove cord and strain relief Do not connect conduit to pump Products Returned Must Be Cleaned Sanitized Or Decontaminated As Necessary Prior To Shipment To Insure That Employees Will Not Be Exposed To Health Hazards In Handling Said Material All Applicable Laws And Regulations Shall Apply ck Bronze brass and bronze brass fitted pumps may contain lead levels higher than considered safe for potable water systems Lead is known to cause cancer and birth defects or other reproductive harm Various government agencies have determined that leaded copper alloys should not be used in potable water applications For non leaded copper alloy materials of construction please contact factory D IMPORTANT Crane Pumps amp Systems Inc is not responsible for losses injury or death resulting from a failure to observe these safety precautions misuse or abuse of pumps or equipment gt TOOL LIST c p v EEL aD D start WAT a i ak A d Be OK ke Je simal X d WE t ka O a KN 2 m me 07 EX LA iR K WR i d galt rua Lei Am L E TM L ERST Ke Rss E sea ale v E H 1 LI
13. mance of the check valve perform a visual inspection of the valve to determine if the ball or flapper is pitted or distorted In addition look in the valve to make certain it is free of obstructions that may cause the valve to not seat properly Moveable Alignment To prevent the moveable from leaking make a visual check from the face of the moveable to the lower pump bracket The face of the moveable needs to be parallel to the lower pump bracket When assembled on the pump the moveable face will be perpendicular to the centerline of the pump discharge INTEGRAL VALVE ALIGNED UPPER MOVEABLE d LOWER GUIDE BRACKET WRONG RIGHT T Cutter Removal CAUTION Sharp edges use caution when removing cutter f NOTE Prior to disassembly mark castings with a permanent marker on all joints to assist in realignment With the pump lying on its side remove the cutter retaining screw and washer The screw has green loctite so apply heat to the screw wedge a flat blade screwdriver between cutter and shredding ring and remove screw Using a flat punch and hammer tap the cutter in the counterclockwise direction and remove Do not attempt to remove the volute before removing the radial cutter Suction Cover Removal Loosen and remove the four 5 16 hex head bolts and lock washers from the rim of the suction cover Remove suction cover and square ring from bottom of volute First Stage Impeller Removal With the
14. mber is in straight Nothing but the seal pusher is to come in contact with seal face N CAUTION DO NOT HAMMER ON THE SEAL PUSHER IT WILL DAMAGE THE SEAL FACE With seal guide over motor shaft lightly oil DO NOT grease guide shaft and inner surface of bellows on rotating seal With lapped surface of rotating member facing inward toward stationary member slide rotating member over guide and onto shaft using seal pusher until lapped faces of the stationary and rotating seal are together Place spring over shaft and the rotating member Make sure it is seated on the retainer and not cocked or resting on bellows tail NOTE DISCARD SEAL SPRING CAP INCLUDED IN REBUILD KIT 22 Impeller Assemble spacer sleeve to second stage impeller by applying green loctite to 1 threads on spacer sleeve and thread onto impeller Assemble impeller and spacer sleeve assembly onto motor shaft with machined step fitting inside I D of seal spring by turning clockwise while holding shaft stationary with a screwdriver Tap impeller with a flat punch and hammer in a clockwise direction while holding the shaft stationary with a screwdriver This will snug the impeller on the shaft CAUTION USE CAUTION NOT TO DAMAGE THE THREADS ON THE SHAFT 23 Volute Lubricate square ring and place on groove in bottom seal plate Place volute on seal plate being careful not to damage square ring Place four 5 16 bolts and washers on and tighten equally
15. pump lying on its side use a hammer and tap on the face of the impeller vanes Then using a flat punch and hammer tap the impeller in a counterclockwise direction and remove A large flat bladed screwdriver may be required to hold the motor shaft while unthreading the impeller uu s a E CR CR WIER Arun Volute Loosen and remove the four 5 16 hex head bolts and lock washers from the volute Remove volute and square ring from pump Loosen and remove the two 5 16 bolts and flat washers from the volute discharge Remove volute discharge flange and o ring Inspect cross over and discharge for signs of accumulation of solids and house hold items Also look for signs of excessive wear in the volute 10 Oil Removal Pressure Check Remove plug from motor housing and drain all oil from motor chamber by setting unit on its side um If cooling oil is not going to be Ar reused or recycled it must be Ki disposed of per local and environmental standars 7 e CAUTION Oil can be under alf M pressure and hot Perform Pressure Check CAUTION Make certain the cord set is attached to pump Performing the pressure check without the cord set on may cause the terminal block to blow out To check the pump for any seal leaks attach the pressure gauge assembly using pipe sealant Tighten the fitting into the hole Pressurize the gauge to 8 to 10 psi Use a soap solution around the sealed a
16. r of screwdrivers may be helpful in removing the motor stator CAUTION USE CARE NOT TO DAMAGE MOTOR WINDINGS WHEN REMOVING MOTOR STATOR Motor rotor and lower bearing can be removed from the seal plate by using an arbor press and lightly pressing on the wet end of rotor shaft Make sure to press straight down on shaft while protecting threads from damage Lower pump end bearing should be a tight slip fit to the seal plate 16 Bearings Remove the bearing from the rotor shaft by removing snap rings from shaft and using a wheel puller or an arbor press Upper rotor bearing may be removed from rotor shaft with a bearing puller NOTE Pictures below show bearing markings on outside of rotor When replacing bearings be careful not to damage the rotor or shaft threads Clean the shaft thoroughly and press bearings on applying force to the inner race of bearings only See drawing below for proper bearing orientation BEARING MARKINGS THIS SIDE PUMP END MOTOR END 17 Stationary Seal Remove the stationary seal from the seal plate by pressing out with a flat tipped screwdriver Examine all seal parts and especially contact faces 18 OGP 2HP ASSEMBLY Bearing to Pump Rotor When replacing the bearing be careful not to damage the rotor or shaft threads Using an arbor press hold the rotor and press the bearing on the rotor shaft applying force to the inner race of the bearing only Install top retaining ring
17. reas and inspect joints for air bubbles If after 5 minutes the pressure is still holding constant and no bubbles are observed slowly bleed the pressure and remove the gauge assembly Replace the pipe plug using sealant If the pressure does not hold then the leak must be located and repaired 10 PSI AIR MEME LL PRESSURE GAUGE ASSY REMOVE PIPE PLUG 11 Second Stage Impeller Removal The impeller and spacer sleeve can be removed by using a 7 8 open end wrench or a cresent wrench and turning counterclockwise while holding the motor shaft stationary with a screwdriver 7 n RH CAUTION Use Caution not to damage threads on shaft NOTE With impeller removed the seal spring is relaxed and some oil may seep from the motor housing Do not store this pump without the impeller in place to hold pressure on the seal spring Do not pressure check motor housing at this time V i i n Inspect spacer sleeve for wear OD The spacer sleeve can be removed by using a 7 8 open end wrench or a cresent wrench while holding impeller stationary The spacer sleeve threads have green loctite so heat must be used to help remove it from the second stage impeller NOTE DO NOT USE EXCESSIVE HEAT IT COULD DAMAGE THE PARTS 12 Shaft Seal CAUTION Handle seal parts and shaft with extreme care Do not scratch or mar lapped or machined surfaces Remove spring and rotating member from shaft
18. se connections and also to determine if the motor windings are good To perform this test touch one meter lead to the white pump lead touch the other meter lead to the black pump lead record the reading Then compare the readings to the readings found on motor winding resistance charts Table 1 Readings should be within 5 of nameplate IF AUF PUMP Tip on off float up while measuring resistance IF AEU PUMP Remove AUE level control and install test plug while performing this test Readings should be as follows Black to White 1 06ohms All figures are approximate variances may occur as results of pump motor manufacturer specs and or direct burial cable of varying lengths If these readings do not correlate then the motor windings or wiring is faulty TABLE 1 Motor Winding Resistance MODEL No VOLT NEMA FULL LOCKED CORD CORD CORD OD CORD WINDING START LOAD ROTOR SIZE TYPE 02 5 LENGTH RESISTANCE CODE AMPS AMPS in mm Ft m MAIN START Sow Winding Resistance 5 Pump Rated For Operation at 10 Voltage at Motor Jammed or Worn Cutter Check the cutter for freedom of movement the cutter should move by hand Also check for excessive wear if there is evidence of this then the worn piece s must be replaced NOTE If the cutter is excessively worn the shredding ring may be reversed Nee CAUTION CUTTER ASSEMBLY MAY BE SHARP S Check Valve Evaluation To check the perfor
19. to 11 ft Ibs NOTE Volute discharge must line up 180 degrees from motor leads 24 First Stage Impeller Check and make sure spacer sleeve extends through second stage and into first stage of volute Visually check first stage impeller mating surface and make sure that it is smooth and flat around the 5 8 threads Then install impeller onto shaft by threading impeller clockwise until it stops against spacer sleeve Use a flat punch and hammer to snug impeller against spacer sleeve Use a large screwdriver to hold shaft Suction Cover Lubricate and set square ring onto pilot bore of the suction cover Place suction cover onto volute while lining up the marks Install the four 5 16 hex head bolts and lockwashers and torque them evenly in a cross pattern to 11 ft Ibs 25 Cutter Screw radial cutter on shaft turning clockwise holding motor shaft stationary with a screwdriver Radial cutter should be flush with shredding ring on suction side to within 020 Replace counter sunk washer and 1 4 allen screw and tighten to 6 5 ft Ibs Use green loctite on threads ke CAUTION CUTTING SURFACES ARE SHARP NOTE Tap the cutter tooth with a flat punch to snug the cutter on the shaft 26 Discharge Flange Install o ring and mount volute discharge flange with 5 16 hex head bolts and flat washers NOTE Check the 1 1 4 NPT threads on the mounting flange and make sure they face the correct direction The chamfered si
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