BARNES® - Crane Pumps
Contents
1. This test can best be performed if the pump leads are disconnected from the control panel or the junction box To perform this test touch one lead to the green ground Touch the other lead to the red wire Repeat this test with ground to black and ground to white To pass this test a cord 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 Hi Pot High Potential Insulator Test if required A Hi Pot test of pump leads is more accurate than a megger test either method will indicate the condition of cord insulation In most cases it is not necessary to do both This test detects non visible insulator failures To perform the HiPot test a 500 VOC Megohmmeter is needed 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 A resistance reading no less than 20mO IS ACCEPTABLE 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 off This test is to check for open circuits or loose connections and also to determine if the motor windings are good To perform this test touch one meter lead to the red pump lead touch the other meter lead to the black pump lead record the reading Then c2. 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 e 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 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 21110 6 Hazardous fluids Hazard could result y 25 ous pressure eruptions or ex 7 WE plosions could cause personal injury or property damage Biohazard can cause serious personal injury Rotating machiner
3. head allen screws The screws are installed with loctite so apply heat to screws before removing and lift the throat out of the body The shredding ring is press fitted to the volute and must be removed with an arbor press 9 E 1 DL j NOTE After a number of years of service or if the shredding ring cutting edges dull the ring can be pressed out of the volute and reversed to utilize the opposite cutting edges To maintain efficient grinder pump operation care should be taken to keep both the radial cutter and shredding ring cutting edges sharp Neither part can be sharpened to renew the cutting ability The radial cutter must be replaced and the shredding ring either reversed or replaced Seal Chamber Place unit on its side with oil fill plug downward remove plug a 3 8 drive socket extension works well and drain all oil from seal chamber checking oil for contamination milky white oil indicates the presence of water Perform Pressure Check NOTE This test is to be performed with NO oil in the housing 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 areas and inspect joints for air bubbles lf after 5
4. 8880 Seal Plate 108879 Intermediate Coupling 4 1 105196 Motor Housing STD 105196HA Motor Housing Option 5 1 082085A Shredding Ring SGVF 082085B Shredding Ring SGVH 070704 Skhd Screw 1 4 20 75 SS ls 108369 Discharge Flange 1 1 4 NPT 082088 Radial Cutter 1 109026B Impeller 5 62 Dia SGVH 109026BTD Impeller 5 18 Dia SGVF 625 01558 O Ring 223 12 4 108886 Stud 5 16 18 x 2 25 SS 067564 Square Ring 1 156 1 Screw 5 16 18 x 1 SS 026322 Lockwasher 5 16 SS 062941 5 16 Flatwasher 15 19 1 Hex Nut 5 16 18 SS 110395 Seal outer C C B STD 003217 Pipe Plug 25 NPT 3 Qts Cooling Oil Mtr Housing 24 029034 1 Qts Cooling Oil Seal Cavity 027269 Square Ring 26 6 1 131 1 Screw 5 16 18 x 1 25 SS 111131 Seal inner C C B STD 061143 Retaining Ring Q10 36 E4 Ball Bearing Motor 31 1 06757286 2HP 240 480 Volt 3 Phase 08570086 2HP 600 Volt 3 Phase 2HP 200 240 Volt 1 Phase 016660 Self Tapping Screw 110397BG 067571BG 2HP 200 Volt 3 Phase Notes 31 CRANE PUMPS 8 SYSTEMS INC 420 THIRD STREET PIQUA OHIO 45356 U S A
5. BARNES SERVICE MANUAL SGV 2 HP Pump THREE BEARING DOUBLE SEAL CENTRIFUGAL GRINDER PUMPS 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 CRAN E PUMPS amp SYSTEMS PumpAssociation 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 SM108091 Rev B 5 Alteration Rights Reserved TABLE OF CONTENTS Jio SGV 2HP Disassembly Visual Inspection or PUMP pp Gp Mec Megger the Pump Leads Megohmmeter Hi Pot High Potential Insulator Test if required Check the Resistance Multi Meter Jammed or Worn Cutter Check Valve Evaluation 5 Moveable Alignment Removal NOLS m Perform Pressure Check Outer Sha
6. ds of pipe plug and assemble to intermediate coupling 28 oM 51 4 5 c V i CJ 6 6 SGV 2HP Exploded View Figure C PARTS KITS Item 5 6 7 13 14 15 19 20 21 25 26 27 32 35 47 Item 5 6 7 13 14 15 19 20 21 23 25 26 27 28 29 32 35 47 55 Item 5 5 6 7 9 15 19 23 Item 5 5 6 7 9 15 19 23 113299 115946 113300 113300B Seal Repair Kit P N Overhaul Kit P N Cutter Kit SGVF P N Cutter Kit SGVH P N PARTS LIST ITEM PART NO DESCRIPTION 105111A Ground Wire Assy 10GA 103586 Terminal Block 1 156 1 Screw 5 16 18 x 75 SS 109492 Cord Set Power 15Ft STD 103582 Compression Flange 014270 Pipe Plug C sunk 3 8 NPT 110660 1 2 x 2 1 2 Nipple 105814 1 2 PVC Pipe Cap 103503 Lifting Handle 105197 Retaining Ring 55 4 105150 Terminal Conn 200 240V 3P 3 625 00163 Terminal Conn 480V 3P 105149A Jumper Wire 200 240 3PH OPTIONAL Cord Set Temp 15FT 49 1 103741 113288 Cord Set Moist amp Temp 15Ft 103582 Compression Flange 1 156 1 Screw 5 16 18 x 75 SS 026322 Lockwasher 5 16 SS 087115 Moisture Sensor Probe 038156 Pan Hd Screw 6 32 x 38 a 105106 Wire Moist Sensor 1 103584 Terminal Block Temp Sensor 113272 Terminal Block Moist amp Temp Contact your local Distributor or the Factory for other impeller sizes seal materials cord lengths and other optional equipment 30 ITEM PART NO DESCRITION 10
7. essure 4111004 j y during operation allow time for pumps to cool before handling or servicing TOOL LIST Cresent Wrench Torque Wrench Hammer Brass Flat Punch 3 8 Ratchet 3 8 Short Extension e 1 2 Wrench Open End 2 3 16 Flat Blade Screwdrivers 1 4 Nut Driver 1 8 Allen Wrench 5 32 Allen Wrench 5 16 Allen Wrench Needle Nose Pliers Inside amp Outside Snap Ring Pliers e 4 PVC Coupler 1 4 20 Bolt Seal Pushers Part No TL 21357 1 Bullets Thread Protectors Part No TL 21381 TL 21375 e Seal Lubricant P 80 Dielectric Cooling Oil Check Chart Blue 242 Green 609 Loctite Pressure Gauge Kit Part No 085343 Megohmmeter amp Multi Meter w Clamp SGV 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 strength resistance of the cord insulation The meter will test zero Q if the cord insulation is damaged or breaking down thus allowing current to flow through the insulation
8. ft RR ER Motor Bearing Inner Seal pp NI Rm SGV 2 HP Assembly cxiitciczesechew sccdvsntevecdanivadscupadanemedonssesssdeaneadenedaxeciedenuveasdndibavees Beanngs to Pump Intermediate Coupling Component Parts pp OU Wiring Schematic Pin Placement pp geal S N E Valute Shredding Ring amp Cutter pp PACING emI tm Emm Pump Exploded M er Parts Kits Parts Other brand and product names trademarks 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 SAFETY FIRST 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 l
9. hredding ring may be reversed Check Valve Evaluation To check the performance of the check valve remove the white PVC cap on the top of the valve Perform a visual inspection of the ball to determine that the ball is not grooved pitted or distorted In addition look in the valve to make certain it is free of obstructions that may cause the valve ball 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 Cutter Removal 5 CAUTION Sharp edges use caution when removing cutter 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 Volute Remove the four nuts and lock washers from the volute studs Remove volute and square ring from pump To remove or reverse the shredding ring first remove the three flat
10. ifting 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 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 applicable 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 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
11. install shredding ring into the volute body with the use of an arbor press Insert throat into body with three flat head Allen screws use green loctite on threads Lubricate square ring and place on groove in bottom seal plate Place volute on seal plate being careful not to damage square ring Place washers and nuts on studs and tighten equally to 11 ft Ibs NOTE Discharge must line up with notch in motor housing y zi 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 washer and screw and tighten Use green loctite on threads 2f NOTE Repeat all electrical checks amp pressure tests prior to replacing oil Replacing Oil Motor housing Set unit upright and refill with see chart for type and amount new cooling oil Fill to 1 above 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 SUPPLIER GRADE Enerpar SE100 Conoco Pale Paraffin 22 Mobile D T E Oil Light imperia Oi Shell Canada Texaco Seal Chamber Set unit on its side with plug opening upward and fill completely with see chart for type and amount new oil Apply pipe thread compound to threa
12. l Plate Lubricate and set square ring in bottom groove of seal plate Guide seal plate over end of rotor shaft install and tighten two washers and bolts to 6 5 05 1 Be sure square ring is in groove on coupling and not twisted 24 Outer 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 member is in straight Nothing but the seal pusher is to come in contact with seal face 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 gt pm 25 Impeller Assemble impeller on motor shaft with machined step fitting inside 1 0 of seal spring by turning clockwise while holding shaft stationary with a screwdriver 26 Valute Shredding Ring amp Cutter Next
13. 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 i 10 PSI AIR M REMOVE PLUG PRESSURE t T GAUGE ASSY SEE PARTS LIST 10 PSI AIR REMOVE PLUG Impeller The impeller can be removed by turning it counterclockwise while holding the motor shaft stationary with a screwdriver CAUTION Use Caution to not damage threads on shaft NOTE With impeller removed the seal spring is relaxed and some oil may seep from the seal chamber Do not store this pump without the impeller in place to hold pressure on the seal spring Do not pressure check seal chamber at this time 10 Outer 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 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 1 Seal Plate Remove two bolts and washers from seal plate Remove seal plate and square ring from intermediate coupling Remove stationary seal by pressing out with flat screwdriver Press out sta
14. ompare the readings to the readings found on motor winding resistance charts Table 1 Readings should be within 35 of nameplate Readings should be as follows 1 Phase motor Approximate Red to Black 7 7 to 8 3 gt Start amp Run Resistance Red to White 6 3 to 7 2 Start Resistance Black to White 1 1 to 1 7 Run Resistance All figures are approximate variances may occur as results of pump motor manufacturer specs and or direct burial cable of varying lengths The totals of the two low figures red to white and black to white should equal the red to black Example Red to Black 8 0 This figure should total the other two readings Red to White 6 Black to White 4 Total 0 these readings do not correlate then the motor windings or wiring is faulty TABLE 1 Motor Winding Resistance MODEL No VOLTS NEMA FULL LOCKED CORD CORD CORD WINDING START LOAD ROTOR SIZE TYPE O D RESISTANCE CODE AMPS AMPS MAIN START seva 2 90 124 sow 5 5 2 600 s 32 124 sow 161 Winding Resistance 35 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 s
15. rops flat against register in coupling Place end bell on top of motor and insert motor bolts in motor and torque to 17 in Ib 21 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 intermediate coupling Connect wires to pins on the bottom of the terminal block 44 NOTE Wiring Digram on next page 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 22 23 Figure B MOISTURE AND TEMPERATURE SENORS OPTIONAL MOISTURE AND TEMPERATURE SENORS FOR SGV2022L OPTIONAL MOIST SENSOR Be JONVHO TEMP SENSOR I TERMINAL BLOCK THERMOSTAT MOIST SENSOR lt 0 c LLI E EXCEPT SGV2022L 00 c 00 Z LLI x 0 o X m D ER 5 lt c Y LLI Lu n THREE PHASE 480 VOLT AC THREE PHASE 200 240 VOLT AC MOTOR LEADS MOTOR LEADS TERMINAL BLOCK THREE PHASE 600 VOLT AC amp 200 VOLT SINGLE PHASE 200 240 VOLT AC MOTOR LEADS MOTOR LEADS ERMINAL BLOCK Pin Placement Diagram Sea
16. tional moisture sensors apply thread compound Permatex to threads on probes and install in intermediate coupling Connect wires to probes with machine screw Note If pumps are not equipped with moisture sensors probes will be replaced by pipe plugs install with permatex 19 Inner Seal CAUTION Handle seal parts and shaft with extreme care Do not scratch or mar lapped N surfaces Clean and oil seal cavities in intermediate coupling Lightly oil DO NOt grease outer surface of stationary member Press stationary member firmly into intermediate coupling using a seal pusher see parts list Seal Tool Kit Nothing but the seal pusher is to come in contact with the seal face Make sure the stationary member is straight Place retaining ring and spring over shaft until seated on shaft shoulder Slide a bullet from tool kit over rotor shaft threads Lightly oil DO NOT grease shaft bullet and inner surface of bellows on rotating member with finished end away from motor slide rotating member over bullet and onto shaft until it engages spring Make sure spring is seated on retainer and not cocked or resting on bellows tail 20 Motor Slide motor rotor with bearings and inner seal into intermediate coupling Insert bearing retaining ring into intermediate coupling 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 d
17. tionary seal using care to not damage seal surfaces 12 Motor Bearing Inner Seal Set unit on its side and remove plug from motor housing drain all oil from motor chamber 18 j CAUTION Oil can be under pressure and hot fi 17 NOTE Perform pressure check on motor housing reference back to page 10 13 Motor Housing NOTE Position unit upright using 4 pvc coupler to avoid resting unit on the lower shaft Loosen cable clamp bolts and lock washers from motor housing Remove cord from motor housing by pulling straight up while using a rocking motion 20 A Remove retaining snap ring with a medium flat tip screwdriver Using 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 temperature moisture sensors remove in Same manner as the power cord 14 Motor Housing con t Remove motor housing bolts and washers 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 stator bolts and carefully remove stator housing from rotor Remove snap ring from intermediate coupling rotor
18. will pull out of intermediate coupling with bearing and rotating member of inner seal attached 16 Bearings From rotor shaft remove rotating member and spring Now bearing can be removed from rotor shaft by removing snap rings from shaft and using a wheel puller or arbor press Upper rotor bearing may be removed from rotor shaft with a bearing puller A p 4 G m io LU en rf lt 2 T 6 2 ue 4 4 A Ns a i y 9 eer LM UM 4 T 8 DA x x 9 E a 4 Y ae T j x j 47 EE LL UE A m AT 4 1 t 4 17 Inner Seal From intermediate coupling press out stationary seal with a flat screwdriver 18 SGV 2 HP Assembly Bearings to Pump Rotor When replacing bearings be careful not to damage the rotor or shaft threads Using an arbor press hold the rotor and press the upper bearing on the rotor shaft applying force to the inner race of the bearing only Install top retaining ring 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 Intermediate Coupling Component Parts pump is equipped with op
19. y Q Amputation or severe Fp 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 unauthorized access to it 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 pr
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