Champion Pump CPG3022 User manual

Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Series: CPG3022, CPG3062,
CPG3032, CPG3042,
CPG5022, CPG5062,
CPG5032, CPG5042,
CPG7532, CPG7542
3, 5 & 7.5HP•3450RPM•60Hz
Submersible Grinder Pump
www.championpump.com
No: CPG357 - 04/15
CPG 3, 5, 7.5HP
Submersible Grinder

2
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
General Safety Information
Other brand and product names are trademarks or registered trademarks of their respective holders.
Alteration Rights Reserved. 1/2010, 2/12
Before installation, read the following
instructions carefully. Failure to follow
instruction and Safety information could
cause serious bodily injury, death and/or
property damage. Each Champion Pump is
individually factory tested to insure proper
performance. Closely following these
instructions will eliminate potential operating
problems, assuring years of trouble-free
service.
“Danger” indicates
an immanent
hazardous situation which, if not avoided,
WILL result in death or serious injury.
“Warning” indicates
an immanent
hazardous situation which, if not avoided,
MAY result in death or serious injury.
“Caution” indicates
an potentially
hazardous situation which, if not avoided,
MAY result in minor or moderate injury.
IMPORTANT - Champion Pump Company
is not responsible for losses, injury or
death resulting from failure to observe
these safety precautions, misuse, abuse or
misapplication of pumps or equipment.
All returned Products
must be Cleaned,
sanitized, Or decontaminated
Prior to shipment, to insure
employees will not be exposed to
health hazards in handling said material.
All applicable laws and regulations shall
apply.
Bronze/brass tted
pumps may contain
levels higher than considered safe for potable
water systems. Government agencies have
determined that leaded copper alloys should
not be used in potable water applications.
Installation, wiring,
and junction
connections must be in accordance with the
National Electric Code and all applicable state
and local codes. Requirements may vary
depending on usage and location.
Installation and
servicing is to be
conducted by qualied personnel only.
Keep clear of suction
and discharge
openings. Do not insert ngers in
pump with power connected.
Always wear eye
protection when
working on pumps. Do not wear loose
clothing that may become entangled in
moving parts
Pumps build up heat
and pressure during
operation. Allow time
for pumps to cool
before handling or
servicing.
This pump is not
intended for use
in swimming pools or water
installations where human
contact with pumped uid. Pumps
when used as a decorative water fountain
pump MUST be used in circuit protected by
a Ground Fault Interrupter.
Risk of electric shock.
To reduce risk of
electric shock, always disconnect
pump from power source before
handling. Lock out power & tag.
Do not us these
pumps in water
over 104˚F. Do not exceed manufactures
recommended maximum performance, as
this could cause the motor to overheat.
Do not lift, carry or
hang pump by the
electrical cables. Damage to the
electrical cables can cause shock,
burnes or death. Never handle
connected power cords with wet hands. Use
appropriate lifting device.
Sump and sewage
pumps often handle
materials which could cause illness or disease.
wear adequate protective clothing when
working on a used pump or piping. Never
enter a basin after it has been used.
Failure to permanently
ground the pump,
motor and controls before
connecting to power can cause
shock, burns or death.
These pumps are NOT
to be installed in
locations classied as hazardous
in accordance with the National
Electric Code, ANSI/NFPA 70.
DO NOT introduced
into any sewer,
either directly, or through a kitchen
waste disposal unit or toilet: Seafood
Shells, Aquarium Gravel, Cat Litter,
Plastic Objects (toys, utensils, etc.),
Sanitary Napkins or Tampons, Diapers,
Rags, Disposable Wipes or Cloth,
Medications, Flammable Material, Oil or
Grease, Strong Chemicals, Gasoline.
IMPORTANT!
Prior to installation, record Model
Number, MFG Date, Amps, Voltage, Phase
and HP, from pump name plate for future
reference. Also record the Voltage and
Current Readings at Startup:
1 Phase Models
Amps: Volts:
3 Phase Models
Amps L1-2: Volts L1-2:
Amps L2-3: Volts L2-3:
Amps L3-1: Volts L3-1:
Model Number: ____________________
MFG Date: ____________
PHASE: ______ HP: _________________

3
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Specications
DISCHARGE 2” NPT Vertical, Bolt-on Flange
LIQUID
TEMPERATURE 104°F (40°C) Intermittent
VOLUTE Cast Iron, Class 30
MOTOR HOUSING Cast Iron, Class 30
SEAL PLATE Cast Iron, Class 30
IMPELLER 12 Vane, Vortex, Bronze
SHREDDING RING Stainless Steel
CUTTER Stainless Steel
SHAFT Stainless Steel
SQUARE RINGS Buna-N
HARDWARE Stainless Steel
PAINT Air dry enamel
SEAL
Tandem Double Mechanical, Oil Filled
Reservoir, Upper -Carbon/Ceramic/Buna-N,
Lower - Silicon Carbide/Silicon Carbide/Viton
Stainless Hardware
UPPER BEARING Single row, Ball, Oil Lubricated
INTERMEDIATE
BEARING Single row, Ball, Oil Lubricated
LOWER BEARING Sleeve, Oil Lubricated
POWER CORD 30 ft. Cord . Pressure grommet for Sealing
and Strain Relief.
MOTOR Oil Filled, Squirrel Cage Induction,
Class F Insulation
SINGLE PHASE
Capacitor Start/Capacitor Run. Requires
overload protection in the control panel,
Requires starter or control panel which
includes capacitors.
THREE PHASE Dual Voltage 230/460. Requires overload
protection in control panel
MOISTURE SENSOR Normally Open (NO). Requires relay in
control panel
TEMPERATURE SENSOR Normally Closed (NC). Requires relay in
control panel
Description
Designed to reduce domestic, commercial, institutional
and light industrial sewage to a nely ground slurry.
ii
Series: CPG3022,
CPG3062, CPG3032,
CPG3042, CPG5022,
CPG5062, CPG5032,
CPG5042, CPG7532,
CPG7542
3, 5 & 7.5HP•3450RPM•60Hz
Submersible Grinder Pump

4
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Specications
MODEL HP Hz Volts/Ph RPM Full Load
Amps
Locked
Rotor Amps
NEMA Start
Code
Cord
Type
Cord
Size
Cord
O.D.
CPG3022* 3 60 230/1 3450 21.7 75.0 G SOW 12/3 .67
CPG3062 3 60 208/3 3450 17.0 65.0 J SOW 10/4 .75
CPG3032 3 60 230/3 3450 14.5 62.0 K SOW 10/4 .75
CPG3042 3 60 460/3 3450 7.2 31.0 K SOW 10/4 .75
CPG5022* 5 60 230/1 3450 39.0 136.0 H SOW 12/3 .67
CPG5062 5 60 208/3 3450 25.0 122.0 K SOW 10/4 .75
CPG5032 5 60 240/3 3450 21.9 120.0 L SOW 10/4 .75
CPG5042 5 60 480/3 3450 11.0 60.0 L SOW 10/4 .75
CPG7532 7.5 60 230/3 3450 22.3 136.0 J SOW 10/4 .75
CPG7542 7.5 60 460/3 3450 11.2 68.0 J SOW 10/4 .75
Moisture & Temperature sensor cable for all other models is 18/5 SOW. 0.47 inches O.D. See page 17 for Relay kits.
(*) IMPORTANT! - These pumps require a control panel with start, run capacitors and relay. Capacitor kits which include Start &
Run capacitors and Start Relay, are available if a Champion control panel is not used, see page 17.
Recommended Breaker & Heater Sizes
MODEL HP Hz Volts/Ph Breaker Size Heater
Size ** Voltage Relay Start Capacitor Run Capacitor
CPG3022* 3 60 230/1 50 AMP K-64 MARS 65 257 mfd - 220 volts 20mfd - 370 volts
CPG3062 3 60 208/3 40 AMP K-56 N/R N/R N/R
CPG3032 3 60 230/3 30 AMP K-54 N/R N/R N/R
CPG3042 3 60 460/3 15 AMP K-41 N/R N/R N/R
CPG5022* 5 60 230/1 80 AMP K-70 MARS 64 189-227 mfd-220 volt 40 mfd - 370 volt
CPG5062 5 60 208/3 50 AMP K-63 N/R N/R N/R
CPG5032 5 60 240/3 50 AMP K-62 N/R N/R N/R
CPG5042 5 60 480/3 20 AMP K-50 N/R N/R N/R
CPG7532 7.5 60 230/3 50 AMP K-67 N/R N/R N/R
CPG7542 7.5 60 460/3 30 AMP K-54 N/R N/R N/R
N/R = Not Required
Winding resistance ± 5% at terminal block. Rated operation at ± 10% voltage at motor.
(**) Recommended heater sizes may very depending on pump station requirements.

5
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Performance

6
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Receiving & Installation
Receiving Inspection
Upon receiving the pump, it should be
inspected for damage or shortages.
If damage has occurred, le a claim
immediately with the company that
delivered the pump. If the manual is
removed from the packaging, do not
lose or misplace.
Storage
Any product that is stored for a period
longer than six (6) months from the
date of purchase should be bench
tested prior to installation. A bench
test consists of, checking the impeller
to assure it is free turning and a run
test to assure the motor (and switch
if provided) operate properly. Do not
pump out of liquid.
Controls
CPG series grinders require a separate
approved pump control device or panel
for automatic operation. Be sure the
electrical specication of the control
selected properly match the electrical
specications of the pump.
Location
The grinder pump is designed to t in
basin or wetwell by using a slide rail
system.
IMPORTANT ! - A CLEARANCE
UNDER THE PUMP FOR
ENTRANCE OF SEWAGE SOLIDS
MUST BE A MINIMUM OF 3
INCHES TO A MAXIMUM OF 4.5
INCHES.
Submergence
The pump should always be operated in
the submerged condition. The minimum
sump liquid level should never be less
than above the pump’s volute (See Figure
1).
Recommended
Submergence Level
Minimum
Submergence Level
Bottom of Feet
5”
Figure 1
Dimensions

7
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Installation
There are several methods of installing
grinder pumps. See contract plans and/
or specication: A slide rail in a package
system or concrete wet well is the most
common, which allows the pump(s)
to be installed or removed without
requiring personnel to enter the wet
well.
The sump or basin shall be sealed
and vented in accordance with local
plumbing codes. This pump is designed
to pump grinder or wastewater,
nonexplosive and noncorrosive liquids
and shall NOT be installed in locations
classied as hazardous in accordance
with the National Electrical Code (NEC)
ANSI/NFPA 70 or Canadian Electric
Code (CEC). The pump should never be
installed in a trench, ditch, or hole with
a dirt bottom. The legs will sink into
the dirt and the suction will become
plugged.
The installation should be at a sucient
depth to ensure that all plumbing is
below the frost line. If this is not feasible,
remove the check valve and size the
basin to accommodate the additional
backow volume.
Discharge Piping
Discharge piping should be as short
as possible and sized no smaller than
the pump discharge. Do not reduce
the discharge pipe size below that
which is provided on the pump. Both
a check valve and a shut-o valve are
recommended for each pump. The
check valve is used to prevent backow
into the sump. The shut-o valve is used
to manually stop system ow during
pump servicing.
Liquid Level Controls
The level control(s) should be mounted
on the discharge piping, a cable rack or
oat pole.
The level control should have adequate
clearance so it cannot hang up in it’s
swing and that the pump is completely
submerged when the level control is in
the “O” mode. By adjusting the cord
tether the control level can be changed.
One cycle of operation should be
observed, so that any potential problems
can be corrected.
It is recommended that the level control
oat should be set to insure that the
liquid in the sump never drops below the
top of the motor housing or a minimum
level of 10 inches above the basin oor.
Electrical Connections
Power cable - The power cable mounted
to the pump must not be modied
in any way except for shortening to a
specic application. Any splice between
the pump and the control panel must
be made in accordance with the electric
codes. It is recommended that a junction
box, if used, be mounted outside the
sump or be of at a minimum Nema 4
construction if located within the wet
well. DO NOT USE THE POWER CABLE
TO LIFT PUMP.
Always rely upon a Certied Electrician
for installation.
Thermal Protection:
The normally closed (N/C) over
temperature sensor is embedded in
the motor windings and will detect
excessive heat in the event an overload
condition occurs. The thermal sensor
will trip when the windings become
too hot and will automatically reset
when the pump motor cools to a safe
temperature. It is recommended that
the thermal sensor be connected in
series to an alarm device to alert that an
overtemperature condition and/or motor
starter coil to stop pump. In the event of
an overtemperature, the source of this
condition should be determined and
repaired immediately.
Thermal protection shall not be used as a
motor overload device. A separate motor
overload device must be provided in
accordance with NEC code.
WARNING! - DO NOT LET
THE PUMP CYCLE OR RUN IF
AN OVERLOAD CONDITION
OCCURS !
If current through the temperature
sensor exceeds the values listed, an
intermediate control circuit relay must be
used to reduce the current or the sensor
will not work properly.
TEMPERATURE SENSOR ELECTRICAL
RATINGS
Volts Continuous
Amperes
Inrush
Amperes
110-120 3.00 30.0
220-240 1.50 15.0
440-480 0.75 7.5
600 0.60 6.0
Moisture Sensor:
To detec any moisture present a normally
open (N/O) probe is installed in the
seal chamber. The probe should be
connected in series to an alarm device
or motor starter coil to alert the operator
that moisture has been detected.
Check the probe leads for continuity, (∞
resistance = no moisture). Also check
the junction box and control panel for
moisture content as this may induce a
false signal. IF MOISTURE DETECTION
OCCURRES, MAINTENANCE SHOULD
BE DONE TO IDENTIFY AND REPAIR.
Wire Size:
If longer power cable is required consult
a qualied electrician for proper wire
size.
Receiving & Installation

8
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Pre-Operation
1. Check Voltage and Phase
Compare the voltage and phase
information stamped on the pump
name plate.
2. Check Pump Rotation - Improper
motor rotation can result in poor
pump performance and can damage
the motor and/or pump. Check
rotation on three phase units by
momentarily applying power and
observe the “kickback”.
Kickback should always be in a
counter-clockwise direction as
viewed from motor end or opposite
to impeller rotation. Incorrect rotation
for Single-Phase pumps is unlikely.
If the rotation is incorrect contact
factory.
3. Name Plate - Record the information
from the pump name plate to
drawing in front of manual for future
reference.
4. Insulation Test - An insulation
(megger) test should be performed
on the motor. Before the pump is put
into service. The resistance values
(ohms) as well as the voltage (volts)
and current (amps) should be
recorded.
5. Pump-Down Test - Be sure pump
has been properly wired, lowered into
the basin, sump or lift station, check
the system by lling with liquid and
allowing the pump to operate through
its pumping cycle. The time needed to
empty the system, or pump-down
time along with the volume of water,
should be recorded.
Maintenance
No lubrication or maintenance is required.
Perform the following checks when pump
is removed from operation or when pump
performance deteriorates:
a). Inspect motor chamber for oil level
and contamination.
b). Inspect impeller and body for
excessive build-up or clogging.
c). Inspect motor and bearings.
d). Inspect seal for wear or leakage.
Servicing
NOTE: Item numbers in ( ) refer to Figures
7 & 8.
Cooling Oil - Anytime the pump is
removed from operation, the cooling oil
in the motor housing should be checked
visually for oil level and contamination.
To check oil, set unit upright. Remove
pipe plug (30) from housing (8). With
a ashlight, visually inspect the oil in
housing (8) to make sure it is clean and
clear, light amber in color and free from
suspended particles. Milky white oil
indicates the presence of water. Oil level
should be just above the motor when
pump is in vertical position.
Oil Testing
• Drain oil into a clean, dry container by
placing pump on it’s side, remove pipe
plug (30), from housing (8).
• Check oil for contamination using an
oil tester with a range to 30 Kilovolts
breakdown.
• If oil is found to be clean and
uncontaminated (measuring above
15 KV. breakdown), rell the housing.
• If oil is found to be dirty or
contaminated (or measures below
15 KV. breakdown), the pump must
be carefully inspected for leaks at the
shaft seal, cable assembly, square ring
and pipe plug, before relling with oil.
Tolocate the leak, perform a pressure
test.
After leak is repaired, dispose of old oil
properly, and rell with new oil.
Pressure Test (If oil has been drained)
Remove pipe plug (30) from housing (8).
Apply pipe sealant to pressure gauge
assembly and tighten into hole. Pressurize
motor housing to 10 P.S.I. Use soap
solution around the sealed areas and
inspect joints for “air bubbles”.
If, after ve minutes, the pressure is still
holding constant, and no“bubbles”are
observed, slowly bleed the pressure and
remove the gauge assembly. Replace
oil. Leek must be located and repaired if
pressure does not hold.
Pressure Test (If oil has NOT been
drained) - Oil should be at normal level.
Remove pipe plug (30) from housing (8).
Apply pipe sealant to pressure gauge
assembly and tighten into hole. Pressurize
motor housing to 10 P.S.I. Use soap
solution around the sealed areas above the
oil level and inspect joints for“air bubbles”.
For sealed areas below oil level, leeks will
seep oil. If, after ve minutes, the pressure
is still holding constant, and no“bubbles”/
oil seepage is observed, slowly bleed the
pressure and remove the gauge assembly.
Replace oil. Leek must be located and
repaired if pressure does not hold.
Installation & Service
Figure 2

9
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Pressure builds up extremely
fast, increase pressure by
“TAPPING” air nozzle. Too much
pressure will damage seal. DO
NOT exceed 10 P.S.I.
Seal Chamber - Set pump on its side
with ll plug (30) downward, remove
plug (30) and drain all oil from seal
chamber. Apply pipe sealant to pressure
gauge assembly and tighten into hole in
intermediate coupling (5). Pressurize seal
chamber to 10 P.S.I. and check for leaks.
Oil Replacement:
Motor Housing - Drain all oil (if not
already done so) from motor housing
and dispose of properly per Local and
Environmental Standards.
Set pump upright and rell with new
cooling oil, see“Cooling Oil” chart. Fill to
just 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 (30) then assemble to motor
housing (8).
Seal Chamber - Drain all oil (if not
already done so) from seal chamber
and dispose of properly per Local and
Environmental Standards. Place pump
on its side with plug (30) upward, and
rell with new oil, see “Cooling Oil” chart.
Apply pipe thread compond to threads
of pipe plug (30) and assemble to
intermediate coupling (5).
DO NOT overll oil. Overlling
of housing with oil can create
excessive and dangerous hydraulic
pressure which can destroy the
pump and create a hazard.
Overlling oil voids warranty.
Cooling Oil
Recommended Supplier/Grade
BP Enerpar SE100
Conoco Pale Parafn 22
Mobile D.T.E. Oil Light
Shell Canada Transformer-10
Texaco Diala-Oil-AX
WARNING ! - Before any service
work is done, disconnect and
lock out electrical power to
pump.
Disassembly
Cutter - Lay pump on its side and remove
the cutter retaining screw (29) and washer
(28). A small amount of heat may be
needed to loosen screw. DO NOT overheat.
Wedge a at screwdriver between cutter
and shredding ring and remove screw.
With a hammer and punch, tap the cutter
(27) counter-clockwise to remove.
CAUTION ! - Cutter edges are
very SHARP. Cutter must be
removed before removing volute.
Volute - Remove hex nuts (25) and
washers (9) from studs (26) and remove
volute (23) and square ring (24) from
pump.
Shredding Ring - To replace or reverse
the shredding ring (20), remove allen
screws (22) and lift throat (21) from volute
(23) then press out using an arbor press.
The shredding ring (20) can be pressed
out and reversed when cutting edges dull.
Impeller - Remove impeller (18) by
turning counter-clockwise while holding
the motor shaft stationary with a
screwdriver. NOTE: Seal spring is relaxed
with impeller removed, some oil may
seep from seal cavity. Do Not store pump
without impeller in place.
Outer Seal - Handle seal parts with care.
Remove seal (34) spring and rotating
member from shaft. Examine all seal
parts. Inspect contact faces for signs of
uneven wear tracks on stationary, chips
and scratches on either seal face. DO
NOT interchange seal components,
replace the entire shaft seal (34).
Seal Plate - Remove cap screws (35) and
washers (38) from seal plate (19). Remove
seal plate (19) and square ring (24) from
intermediate coupling (5). With at
screwdriver, press out seal (34) stationary
member. Inspect square ring (24) for cuts
or abrasions.
Cable Assemblies - Remove Hex plugs
(13B) and (14B), washers (13C) and (14C)
and gromeents (13D) and (14D) from
conduit box (11).
Motor - Remove pipe plug (30) and drain
oil if not already done so. Position pump
upright using blocks or pvc pipe to avoid
resting pump on the shaft. Remove
cap screws (15) and lockwashers (16)
from cable box assembly (11) and slide
conduit box up the cords until motor
lead wires are exposed. Disconnect
connectors (17) from motor leads wires
to remove cable assemblies (13) and (14).
Remove ground screw (31). Remove and
inspect o-ring (12).
Remove cap screws (10) and lockwashers
(9) from motor housing (8). Vertically lift
motor housing (8) from intermediate
coupling (5) along with square ring
(7), replace if cut or damaged. Remove
motor bolts and carefully remove stator
housing from rotor. Remove retaining
ring (2) from intermediate (5) and pull
rotor out with bearing (3) and rotating
member of inner seal.
Service

10
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Inspect motor winding for shorts and
check resistance values. Check rotor for
wear. If rotor or the stator windings are
defective, the complete motor must be
replaced.
Bearings & Inner Seal - Remove seal (4)
rotating member and spring from rotor
shaft. Press stationary from intermediate
(5) with at screwdriver. Examine all seal
parts. Inspect contact faces for signs of
uneven wear tracks on stationary, chips
and scratches on either seal face. DO
NOT interchange seal components,
replace the entire shaft seal (4).
Remove retaining rings (6) from shaft.
Using a wheel puller or arbor press
remove bearing (3) from shaft. Remove
upper motor bearing from shaft with a
bearing puller. (See Figure 3)
Check sleeve bearing (39) for excessive
wear, if replacement is required the
complete intermediate coupling (5)
should be replaced.
Moisture Probes - Remove screws (37)
and wire (33) from probes (36). Remove
probes (36) from intermediate (5).
IMPORTANT! - All parts must be
clean before reassembly.
Handle seal parts with extreme
care. DO NOT damage lapped
surfaces.
Reassembly
Moisture Probes - Apply thread
compound to thread on probes (36) and
install in intermediate (5). Connect wires
(33) with screws (37).
Bearings - Be careful not to damage
the rotor shaft when replacing bearings.
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. Replace upper retaing
ring onto rotor shaft. In the same manner
replace lower bearing (3) onto rotor
shaft. Place lower retaining rings (6) onto
shaft.
Inner Seal - Clean and oil seal cavity
in intermediate coupling (5). Lightly
oil (Do not use grease) outer surface
of stationary member. Press seal’s
(4) stationary member rmly into
intermediate coupling (5), using a seal
tool or pipe.
Nothing should come in contact with the
seal face except the seal tool. Be sure the
stationary is in straight. Place seal’s (4)
retaining ring and spring over shaft until
seated on shaft shoulder. Slide a bullet
tool over rotor shaft threads. Lightly oil
(Do not use grease) shaft, bullet, and
inner surface of bellows on rotating
member, with nished end away from
motor, slide rotating member over bullet
and onto shaft until it engages spring.
Make sure spring is seated in retaining
ring and spring is lined up on rotating
member and not cocked or resting on
bellows tail. (See Figure 3)
Motor - Slide rotor/shaft with bearing
(3) and seal parts (4) into intermediate
coupling (5) until bearing seats into
intermediate coupling. Install retaining
ring (2) into intermediate coupling (5).
Place motor stator over rotor, lining up
motor bolts with holes in intermediate
coupling (5). Place end bell on top of
motor and insert motor bolts and torque
to 17 in-lbs.
Wiring Connections - Set square ring
(7) in grove on intermediate coupling
(5). Pull wires through opening in top of
motor housing (8) while lowering motor
housing onto intermediate coupling (5).
Insert capscrews (10) with lockwasher
(9) through motor housing into
intermediate and tighten. Place square
ring (12) on motor housing (8). Place
conduit box with cables next to motor
housing and make wire connections
(see Figure 4). Connect ground wire (42)
with screw (31) to conduit box (11) if
disconnected.
Check power cable (13) and control cable
(14) for damage and replace complete
conduit box and cable assembly if
required.
Service
Figure 3

11
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
FIGURE 4 - SINGLE PHASE
230 VOLT AC
Power Cable Motor Lead Number
Green (Ground) Green
Black 4 run
Red 8 start
White 5 common
FIGURE 4 - THREE PHASE 208 VOLT AC
Power Cable Motor Lead Number
Green (Ground) Green
Black 1
Red 2
White 3
FIGURE 4 - THREE PHASE 230 VOLT AC
Power Cable Motor Lead Number
Green (Ground) Green
Black 1 & 7
Red 2 & 8
White 3 & 9
T4, T5 & T6 Together
FIGURE 4 - THREE PHASE 460 VOLT AC
Power Cable Motor Lead Number
Green (Ground) Green
Black 1
Red 2
White 3
T4 & T7 Together
T5 & T8 Together
T6 & T9 Together
FIGURE 4
MOISTURE & TEMPERATURE SENSORS
Control Cable Lead Number
Green (Ground) Green
Black P1 (Temp Sensor) In
series with starter coil
White P2 (Temp Sensor) In
series with starter coil
Red W1 (Moisture Sensor)
Orange W2 (Moisture Sensor)
FIGURE 4
1 Phase Capacitor Pack for
Control Panel
Pump Wiring Schematics

12
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Place conduit box (11) on motor housing
(8) and insert capscrews (15) with
washers (16) into motor housing and
torque to 16 ft/lbs.
Cable Assemblies - Power cable, Place
one friction ring (13C), grommet (13D),
one friction ring (13C) and hex plug (13B)
into conduit box (11). Control Cable,
Place one friction ring (14C), grommet
(14D), one friction ring (14C) and hex
plug (14B) into conduit box (11). Torque
hex plugs to 15 ft. lbs. to prevent leakage.
See Figures 7 & 8.
Seal Plate - Lubricate and set square
ring (24) in bottom groove of seal plate
(19). Place seal plate (19) over shaft and
onto intermediate coupling (5), being
sure square ring (24) is not twisted and
in the groove. Place two capscrews (35)
with lockwashers (38) into seal plate and
torque to 6.5 ft/lbs.
Outer Seal - Clean and oil stationary
seal cavity in seal plate (19). Slide seal
guide tool over motor shaft. Lightly oil
(Do not use grease) outer surface of
seal’s (34) stationary member.
Press stationary rmly into seal plate
(19) using a seal pusher tool. Be sure the
stationary member is in straight. Nothing
but the seal tool is to come in contact
with seal face. (See Figure 5)
IMPORTANT ! Do not hammer
on the seal pusher. It will
damage the seal face.
With seal guide tool over motor shaft,
Lightly oil (Do not use grease) guide,
shaft and inner surface of bellows on
rotating seal.
With lapped surface of rotating member
facing inward toward stationary, slide
rotating member over guide and onto
shaft, using seal pusher tool, until lapped
faces of stationary and rotating seal are
together. Place spring over shaft and
rotating member. Be sure it is seated on
the retainer and not cocked or resting on
bellows tail.
Impeller - Place impeller (18) on motor
shaft, with machined step tting inside
the inside diameter of seal spring, by
turning clockwise while holding shaft
stationary with screwdriver.
Shredding Ring - Install shredding ring
(27) into volute with the use of an arbor
press. Assemble throat (21) into volute
(23) with tree allen screws (22).
Volute - Lubricate square ring (24) and
place in groove in bottom of seal plate
(19). Place volute (23) on seal plate (19)
being careful not to damage square ring
(24). Place nuts (25) with lockwashers (9)
onto studs (26) and torque evenly to 11
ft/lbs.
Cutter - Screw radial cutter (27) onto
shaft, turning it clockwise while holding
the shaft stationary with a screwdriver.
The radial cutter (27) should be ush with
shredding ring (20), on suction side to
within ± .020. Place washer (28) on screw
(29), apply green Loctite on threads and
place into shaft and tighten.
Figure 5
Service

13
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Typical Panel Wiring Schematic
Figure 6

14
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Figure 7
Repair Parts For Repair Part Please supply: Model Number and MFG Date as shown on
Name Plate, and Part Description and Part Number as shown on Parts List.

15
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Figure 8
Repair Parts
For Repair Part Please supply: Model Number and MFG Date as shown on
Name Plate, and Part Description and Part Number as shown on Parts List.

16
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Ref. Qty Name Used On Part Number
11
Motor
3 HP 230 Volt 1 Ph PF40040054
5 HP 230 Volt 1 Ph PF40040055
3 HP 230/460 Volt 3 Ph PF40040051
5 HP 230/460 Volt 3 Ph PF40040052
7.5 HP 230/460 Volt 3 Ph PF40040053
22
6Retaining ring PF31010004
31
6Ball bearing, lower PF31020022
41
6Seal, inner C/C/B PF31030136
5 1 Bearing Housing PF03040026
62
6Retaining ring PF31010011
71
6Square ring PF92010087
8 1 Motor housing PF03100011
9 10 Lockwasher, 7/16 Stainless 
10 4 Screw, 7/16-14 x 2.25”Lg., Stainless 
11assy 1Conduit Box & Cable Assembly, 10/4 SOW, 30Ft. 3 Ph PF067585
1Conduit Box & Cable Assembly, 12/3 SOW, 30Ft. 1 Ph PF093284
11 1 * Conduit box
Included
in
Item
#11ASSY
PF03100010
12 1 * O-ring PF92010063
13 1 * Power Cable 10/4 SOW PF31030003
Power Cable 12/3 SOW PF31030014
13B 1 * Hex Plug PF30400903
13C 2 * Friction ring PF91010055
13D 1 * Grommet PF92010001
14 1 * Moisture & Temperture Sensor Cable, 18/5 SOW, 30Ft. PF31030005
14B 1 * Hex plug PF30400901
14C 2 * Friction ring PF91010057
14D 1 * Grommet PF92010005
15 4 Capscrews, 1/4-20 x 1”Lg., Stainless 
16 4 Lockwashers, 1/4” Stainless 
17
8
Wire Connectors
Single Phase 230V
PF940100129 Three Phase 230 V
11 Three Phase 460V
18 1 Impeller
6.46” Dia. STD for 7.5HP PF03140079A
6.25” Dia. STD for 5HP PF03140079B
6.00” Dia ---
5.75” Dia. ---
5.50” Dia. ---
5.25” Dia. ---
5.00” Dia. STD for 3 HP PF03140079C
4.75” Dia. ---
4.50” Dia. ---
4.25” Dia. ---
4.12” Dia. ---
Repair Parts For Repair Part Please supply: Model Number and MFG Date as shown on
Name Plate, and Part Description and Part Number as shown on Parts List.
= Aquire standard hardware locally.
= Cutter Kit
6= Overhaul Kit
= Supplied as individual items
* = Supplied with item #11 Assy

17
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
19 1 Seal plate PF03180028
20 1 6Shredding ring PF31010020
21 1 Throat PF03190021
22 3 Allen Screw, 1/4-20 x .75”Lg, Stainless 
23 1 Volute PF03090083
24 2 6Square ring PF92010081
25 4 Hex nut, 7/16-14 Stainless 
26 4 Stud, 7/16-14 x 3.25”Lg., Stainless 
27 1 6Radial cutter PF31030301
28 1 6Washer, Stainless PF30400426
29 1 6Screw, 3/8-16 x 1.75”Lg., Stainless PF91010398
30 2 Pipe plug, 1/4” NPT 
31 1 * Ground screw, 3/16” x 1/2” 
32 4¾ qts Cooling oil, Motor housing See chart on page 9
1½qts Seal cavity
33 2 Wire Assembly, Moisture Sensor PF31030011
34 1 6Seal, outer S/S/V PF31030137
35 2 Screw, 5/16-18 x 1.25”Lg. Stainless 
36 2 Moisture Sensor Probe PF31160001
37 2 Machine screw, 6-32 x 1/4”Lg., Stainless Moisture sensors 
38 2 Lockwasher, 5/16” Stainless 
39 1 Bearing sleeve Supplied in item #5
40 2 Screw, 7/16-14 x 1.25”Lg., Stainless 
41 1 Lifting bail PF30400843
42 1 * Round terminal, 3/16 PF94010043
Repair Kits
CUTTER KIT - Includes Item numbers: 20, 27, 28, 29 PFGL-CT
6OVERHAUL KIT - Includes Item numbers: 2, 3, 4, 6, 7, 20, 24, 27, 28, 29, 34 PFGL-OHK
Capacitor Pack for, Other than Champion Pump control panel:
P/N: PF73303 - for CPG3022, 230 volt, 1 phase 3 Hp (See page 11 for wiring schematic).
P/N: PF73305 - for CPG5022, 230 volt, 1 phase 5 Hp (See page 11 for wiring schematic).
Recommended Moisture & Temperature Sensor Relays for control panel, (or equal):
P/N: PF0861 - Warrick relay #IDIEO rated for 25 volt amperes, 115 volt input, 500 volt output (one per pump).
P/N: PF0876 - IDEC relay #RH2BUAC120V (one per pump).
Repair Parts
For Repair Part Please supply: Model Number and MFG Date as shown on
Name Plate, and Part Description and Part Number as shown on Parts List.
= Aquire standard hardware locally.
= Cutter Kit
6= Overhaul Kit
= Supplied as individual items
* = Supplied with item #11 Assy

18
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Notes:

19
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
Trouble Shooting Chart
Risk of electric shock. Always disconnect the pump from the power source before handling inspections or repairs.
Symptom Possible Cause(s) Corrective Action
Pump will not run
1. Poor electrical connection, blown fuse, tripped
breaker or other interruption of power;
improper power supply
2. Motor or switch inoperative (go to manual
operation)
2a. Float movement restricted
2b.Switch will not activate pump or is defective
2c. Defective motor
3. Insucient liquid level
1. Check all electrical connections for security.
Have electrician measure current in motor leads,
if current is within ± 20% of locked rotor Amps,
impeller is probably locked. If current is 0,
overload may be tripped. Remove power, allow
pump to cool, then re-check current.
2a. Reposition pump or clean basin as required to
provide adaquate clearance for oat
2b.Disconnect level control. Set ohmmeter for a
low rang, such as 100 ohms full scale and
connect to level control leads. Actuate level
control manually and check to see that
ohmmeter shows zero ohms for closed switch
and full scale for open switch. (Float Switch)
2c. Check winding insulation (Megger Test) and
winding resistance. If check is outside of range,
dry and re-check. If still defective, replace per
service instructions.
3. Make sure liquid level is above the pump
4. Re-check all sizing calculations to determine
proper pump size.
5. Check discharge line for restrictions, including
ice if line passes through or into cold areas.
6. Remove and examine check valve for proper
installation and freedom of operation
7. Open valve
8. Check impeller for freedom of operation,
security and condition. Clean impeller cavity
and inlet of any obstruction
9. Loosen union slightly to allow trapped air to
escape. Verify that turn-o level of switch is set
so that the suction is always ooded. Clean vent
hole
10. Check rotation. If power supply is three phase,
reverse any two of three power supply leads to
ensure proper impeller rotation
11. Repair xtures as required to eliminate leakage
12. Check pump temperature limits and uid
temperature
13. Replace portion of discharge pipe with exible
connector or tighten existing piping.
14. Turn to automatic position
15. Check for leaks around basin inlet and outlets
Pump will not turn o
2a. Float movement restricted
2b.Switch will not activate pump or is defective
4. Ecessive inow or pump not properly sized for
application
9. Pump may be air locked causing pump not to ow
14. H-O-A switch on panel is in“HAND”position
Pump hums but doesn’t run
1. Incorrect low voltage
8. Impeller jammed or loose on shaft, or inlet
plugged
Pump delivers insucient capacity
1. Incorrect low voltage
4. Ecessive inow or pump not properly sized for
application
5. Discharge restricted
6. Check valve partially closed or installed backwards
7. Shut-o valve closed
8. Impeller jammed or loose on shaft, or inlet
plugged
9. Pump may be air locked causing pump not to ow
10. Pump running backwards
Pump cycles too frequently or runs periodically
when xtures are not in use
6. Check valve partially closed or installed backwards
11. Fixtures are leaking
15. Ground water entering basin
Pump shuts o and turns on independent of
switch, (trips thermal overload protector).
CAUTION! Pump may start unexpectedly.
Disconnect power supply.
1. Incorrect low voltage
4. Ecessive inow or pump not properly sized for
application
8. Impeller jammed or loose on shaft, or inlet
plugged
12. Excessive water temperature (internal
protection only)
Pump operates noisily or vibrates excessively
2c. Worn bearings, motor shaft bent
5. Debris in impeller cavity or broken impeller
10. Pumprunning backwards
13. Piping attachments to building structure too
loose or rigid
NOTE: Champion Pump assumes no responsibility for damage or injury due to disassembly in the eld. Disassembly of the pumps or supplied accessories
other than at Champion Pump or its authorized service centers, automatically voids warranty.

20
Champion Pump Company, Inc • P.O. Box 528 • Ashland, OH 44805
Phone [phone] • toll free 800-659-4491 • fax [phone]
LIMITED 1 YEAR WARRANTY
Manufacturer warrants, to the immediate purchaser and subsequent initial owner during the warranty
period, every new pump to be free from defects in material and workmanship under normal use
and service, when properly used and maintained, for a period of eighteen (18) months from date of
manufacture or twelve (12) months from date of installation (which ever comes rst). Failure due to wear
due to excessive abrasives is not covered. The initial owner is the purchaser who rst uses the pump
after its initial installation, or for non-permanent installation, the rst owner who uses the pump. The
date of installation shall be determined by a dated sales receipt noting the model and serial number
of the pump. The dated sales receipt must accompany the returned pump. Product will be repaired,
replaced or remanufactured at Manufacturer’s option. No allowance will be made for shipping charges,
damages, labor or other charges that may occur due to product failure, repair or replacement. This
warranty does not apply to and there shall be no warranty for any material or product that has been
disassembled without prior approval of Manufacturer, subjected to misuse, misapplication, neglect,
alteration, accident or act of God; that has not been installed, operated or maintained in accordance
with Manufacturer’s installation instructions; that has been exposed to outside substances including
but not limited to the following: sand, gravel, cement, mud, tar, hydrocarbons, hydrocarbon derivatives
(oil, gasoline, solvents, etc.), or other abrasive or corrosive substances, wash towels or feminine sanitary
products, etc. in all pumping applications. The warranty set out in the paragraph above is in lieu of all
other warranties expressed or implied; and we do not authorize any representative or other person to
assume for us any other liability in connection with our products. Contact Manufacturer to obtain any
needed repair or replacement of part(s) or additional information pertaining to our warranty.
MANUFACTUREREXPRESSLYDISCLAIMSLIABILITYFORSPECIAL,CONSEQUENTIALORINCIDENTAL
DAMAGES OR BREACH OF EXPRESSED OR IMPLIED WARRANTY; AND ANY IMPLIED WARRANTY
OF FITNESS FOR A PARTICULAR PURPOSE AND OF MERCHANTABILITY SHALL BE LIMITED TO THE
DURATION OF THE EXPRESSED WARRANTY.
Some states do not allow limitations on the duration of an implied warranty, so the above limitation may
not apply to you. Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you. This warranty gives you specic
legal rights and you may also have other rights which vary from state to state.
www.championpump.com