Crane BARNES 4SE Series User manual

INSTALLATION and OPERATION MANUAL
Submersible Sewage Ejector
Form No. 084829-Rev. D
IMPORTANT: Read all instructions in this manual before operating pump.
As a result of Crane Pumps & Systems, Inc., constant product improvement program, product
changes may occur. As such Crane Pumps & Systems, Inc., reserves the right to change product
without prior written notification.
SERIES: 4SE
0.9, 1.4 and 1.9 HP
1750 RPM
BARNES®
420 Third Street/P.O. Box 603 83 West Drive, Brampton
Piqua, Ohio 45356-0603 Ontario, Canada L6T 2J6
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]
www.cranepumps.com
PUMPS & SYSTEMS
A Crane Co. Company
Manual Index
SUPERSEDED
Some parts may NOT
be available

TABLE OF CONTENTS
WARNINGS AND SAFETY PRECAUTIONS........................................................................ 3
A. PUMP SPECIFICATIONS..................................................................................................... 4
B. GENERAL INFORMATION................................................................................................... 5
C. INSTALLATION .................................................................................................................... 5 - 6
ELECTRICAL DATA ............................................................................................................. 7
D. START- UP OPERATION ...................................................................................................... 7
E. PREVENTATIVE MAINTENANCE........................................................................................ 8
F. SERVICE and REPAIR ......................................................................................................... 8 - 12
TROUBLE SHOOTING ......................................................................................................... 13
G. REPLACEMENT PARTS ...................................................................................................... 14
CROSS-SECTION (Fig. 8)................................................................................................... 15
EXPLODED VIEW (Fig. 9) ................................................................................................... 16
PARTS LIST ........................................................................................................................17 - 18
WARRANTY INFORMATION ............................................................................................... 19
WARRANTY
START-UP REPORT
WARRANTY REGISTRATION
SPECIAL TOOLS AND EQUIPMENT
INSULATION TESTER (MEGGER)
DIELECTRIC TESTER
SEAL TOOL KIT ( see parts list)
PRESSURE GAUGE KIT (see parts list)
Other brand and product names are trademarks or registered trademarks of their respective holders.
® Barnes is a registered trademark of Barnes Pumps, Inc.
© Barnes Pumps, Inc. 1994, 1997, 1998, 2002 Alteration Rights Reserved. Printed in U.S.A.
2
Manual Index

SAFETY FIRST!
PLEASE READ THIS BEFORE INSTALLING
OR OPERATING PUMP.
GENERAL
1. Most accidents can be avoided by using COMMON SENSE.
2. Read the operation and maintenance instruction manual supplied with the pump.
3. Do not wear loose clothing that may become entangled in the impeller or other moving parts.
4. Always wear appropriate safety gear, such as safety glasses, when working on the pump or piping.
5. Bronze/brass and bronze/brass fitted pumps may contain lead levels higher than considered safe for potable water
systems. 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.
PUMPS
6. Pumps build up heat and pressure during operation-allow time for pumps to cool before handling or servicing.
7. Only qualified personnel should install, operate and repair pump.
8. Keep clear of suction and discharge openings. DO NOT insert fingers in pump with power connected.
9. Do not pump hazardous materials (flammable, caustic, etc.) unless the pump is specifically designed and designated to
handle them.
10. Do not block or restrict discharge hose, as discharge hose may whip under pressure.
11. Make sure lifting handles are securely fastened each time before lifting.
12. Do not lift pump by the power cord (if applicable).
13. Do not exceed manufacturers recommendation for maximum performance, as this could cause the motor to overheat.
14. Secure the pump in its operating position so it can not tip over, fall or slide.
15. Keep hands and feet away from impeller when power is connected.
16. 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.
17. Do not operate pump without guards and safety devices in place.
18. When towing pump behind a vehicle; make sure hitch is properly attached, always attach safety chains.
19. Always replace safety devices that have been removed during service or repair.
20. Operation against a closed discharge valve will cause premature bearing and seal failure on any pump, and on end suction
and self priming pump the heat build may cause the generation of steam with resulting dangerous pressures. It is
recommended that a high case temperature switch or pressure relief valve be installed on the pump body.
ELECTRICAL
21. To reduce risk of electrical shock, pump must be properly grounded in accordance with the National Electric Code (NEC),
or Canadian Electrical Code (CEC) and all applicable state, province and local codes and ordinances.
22. To reduce risk of electrical shock, always disconnect the pump from the power source before handling or servicing.
23. Any wiring of pumps should be performed by a qualified electrician.
24. Never operate a pump with a power cord that has frayed or brittle insulation.
25. Cable should be protected at all times to avoid punctures, cut, bruises and abrasions - inspect frequently.
26. Never handle connected power cords with wet hands.
27. Never operate a pump with a plug-in type power cord without a ground fault circuit interrupter.
28. Do not remove cord and strain relief. Do not connect conduit to pump.
29. 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. See wiring diagrams in manual.
GAS/DIESEL ENGINE POWER PUMPS & DRIVES ONLY
30. Never operate in an enclosed building or area where exhaust gases can accumulate.
31. Do not breath exhaust fumes when working in the area of the engine. (Exhaust gases are odorless and deadly poison.)
32. Never operate near a building where exhaust gases can seep inside.
33. Never operate in a pit or sump without making provisions for adequate ventilation.
34. Allow exhaust system to cool before touching.
35. Never add fuel to the tank while the engine is running. Stop engine and allow to cool.
36. Do not smoke while refueling the engine.
37. Do not refuel near open flame.
38. Carefully read instruction manuals supplied by engine manufacturer before attempting to assemble, operate or service
the engine or any part. The "WARNING" statements indicate potentially hazardous conditions for operator or equipment.
IMPORTANT! Barnes® Pumps, 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.
3
Manual Index

SECTION: A- PUMP SPECIFICATIONS
DISCHARGE: 3 (76) & 4" (102) 125 lb, Horizontal
LIQUID TEMPERATURE: 104°F (40°C) Continuous.
VOLUTE: Cast Iron ASTM A-48, Class 30.
MOTOR HOUSING: Cast Iron ASTM A-48, Class 30.
SEAL PLATE: Cast Iron ASTM A-48, Class 30.
IMPELLER:
Design: 2 Vane, Open, With Pump Out
Vanes On Back Side. Dynamically
Balanced. ISO G6.3.
Material: Cast Iron ASTM A-48 Class 30.
SHAFT: 416 Stainless Steel
SQUARE RINGS: Buna-N
HARDWARE: 300 Series Stainless Steel
PAINT: Air Dry Enamel.
SEAL:
Design: Single Mechanical, Oil-Filled Reservoir,
Secondary Exclusion Seal.
Material: Rotating Face - Carbon
Stationary Face - Ceramic
Elastomer - Buna-N
Hardware - 300 Series Stainless
CABLE ENTRY: 15ft. (4.5M) Cord (Plug On 115 Volt),
Pressure Grommet For Sealing And
Strain Relief.
SPEED: 1750 RPM (Nominal)
UPPER BEARING:
Design: Sleeve
Lubrication: Oil
Load: Radial
LOWER BEARING:
Design: Single Row, Ball
Lubrication: Oil
Load: Radial & Thrust
MOTOR:
Design: NEMA L-Single Phase, NEMA B-Three
Phase Torque Curve. Completely
Oil-Filled, Squirrel Cage Induction.
Insulation: Class A.
SINGLE PHASE: Permanent Split Capacitor (PSC).
Includes Overload Protection In Motor.
THREE PHASE: Tri Voltage 200-230/460;
Requires Overload Protection to be
Included in Control Panel.
OPTIONAL EQUIPMENT: Seal Material, Impeller Trims, N/C
Temperature Sensor with cable for
3 phase pumps, Additional Cable
CSA Listed on 3 phase pumps.
18.31
(465)
6.06
(154)
12.24
(311)
7.37
(187)
4.87
(124)
9.74
(247)
inches
(mm)
4
Manual Index

SECTION B: GENERAL INFORMATION
B-1) To the Purchaser:
Congratulations! You are the owner of one of the finest pumps
on the market today. Barnes®Pumps are products engineered
and manufactured of high quality components. Over one
hundred years of pump building experience along with a
continuing quality assurance program combine to produce a
pump which will stand up to the toughest applications.
This Barnes Pumps, Inc. manual will provide helpful
information concerning installation, maintenance, and proper
service guidelines.
B-2) Receiving:
Upon receiving the pump, it should be inspected for damage
or shortages. If damage has occurred, file a claim immediately
with the company that delivered the pump. If the manual is
removed from the packaging, do not lose or misplace.
B-3) Storage:
Short Term- Barnes Pumps are manufactured for efficient
performance following short inoperative periods in storage. For
best results, pumps can be retained in storage, as factory
assembled, in a dry atmosphere with constant temperatures
for up to six (6) months.
Long Term- Any length of time exceeding six (6) months, but
not more than twenty-four (24) months. The units should be
stored in a temperature controlled area, a roofed over walled
enclosure that provides protection from the elements (rain,
snow, wind-blown dust, etc.), and whose temperature can be
maintained between +40 deg. F and +120 deg. F. (4.4 - 49°C)
If extended high humidity is expected to be a problem, all
exposed parts should be inspected before storage and all
surfaces that have the paint scratched, damaged, or worn
should be recoated with a water base, air dry enamel paint. All
surfaces should then be sprayed with a rust-inhibiting oil.
Pump should be stored in its original shipping container. On
initial start up, rotate impeller by hand to assure seal and
impeller rotate freely. If it is required that the pump be installed
and tested before the long term storage begins, such
installation will be allowed provided:
1.) The pump is not installed under water for more than
one (1) month.
2.) Immediately upon satisfactory completion of the test,
the pump is removed, thoroughly dried, repacked in the
original shipping container, and placed in a temperature
controlled storage area.
B-4) Service Centers:
For the location of the nearest Barnes Pumps Service Center,
check your Barnes Engineered catalog, your Barnes Pumps,
Inc. representative or Barnes Pumps, Inc. Service Department
in Piqua, Ohio, telephone [phone] or Crane Pumps &
Systems Canada, in Brampton, Ontario,
[phone].
SECTION C: INSTALLATION
C-1) Location:
These pumping units are self-contained and are recommended
for use in a sump, lift station or basin. The sump, lift station or
basin shall be vented in accordance with local plumbing codes.
This pump is designed to pump sewage, effluent, or other
nonexplosive or noncorrosive wastewater. and shall NOT be
installed in locations classified as hazardous in accordance with
the National Electrical Code (NEC), ANSI/NFPA 70 or The
Canadian Electrical Code. Never install the pump in a trench,
ditch or hole with a dirt bottom; the legs will sink into the dirt and
the suction will become plugged.
C-1.1) Submergence:
It is recommended that the pump be operated in the submerged
condition and the sump liquid level should never be less than
dimension "A" in Fig. 1.
C-2) Discharge:
Discharge piping should be as short as possible. Both a check
valve and a shut-off valve are recommended for each pump
being used. The check valve is used to prevent backflow into
the sump. Excessive backflow can cause flooding and/or
damage to the pump. The shut-off valve is used to stop system
flow during pump or check valve servicing.
Barnes Pumps supplies a breakaway fitting discharge system
designed to allow the submersible wastewater pump to be
installed or removed without requiring personnel to enter the
wet well.
Recommended
Submergence
Level
Fig. 1
A= 8"
Minimum
Submergence
Level
Bottom of Feet
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Manual Index

Place the Break Away Fitting (BAF) in position. Temporarily
secure the guide rails in the upper mounting brackets and
locate the base on the bottom of the wet well. Level the base
with grout and/or shims. Install the intermediate support
brackets, if required. Make sure the rails are in a true vertical
position so the pump will clear the access opening and will slide
freely down the rails into place on the discharge stationary
fitting. Once the rails are in proper alignment, bolt the base into
the floor of the station and connect the discharge pipe to the
elbow.
Connect the movable portion and other supplied fittings of the
BAF onto the pump and lower into wet well. See the Break
Away Fitting manual for more information.
C-3) Liquid Level Controls:
The level controls are to be supported by a mounting bracket
that is attached to the sump wall, cover or junction box. Cord
grips are used to hold the cords in place on the mounting
bracket. The control level can be changed by loosening the grip
and adjusting the cord length as per the plans and
specifications. Be certain that the level controls cannot hang
up or foul in it’s swing and that the pump is completely
submerged when the level control is in the "Off" mode.
C-4) Electrical Connections:
C-4.1) Power Cable:
The cord assembly mounted to the pump must not be modified
in any way except for shortening to a specific application. Any
splice between the pump and the control panel must be made
in accordance with all applicable electric codes. It is
recommended that a junction box, if used, be mounted outside
the sump or be of at least Nema 4 (EEMAC-4) construction if
located within the wet well. Do not use the power cable to lift
pump. NOTE: THE WHITE WIRE IS NOT A NEUTRAL OR
GROUND LEAD, BUT A POWER CARRYING CONDUCTOR.
C-4.2) Control Cable:
The cord assembly mounted to the pump must not be modified
in any way except for shortening to a specific application. Any
splice between the pump and the control panel must be made
in accordance with all applicable electric codes. It is
recommended that a junction box, if used, be mounted outside
the sump or be of at least Nema 4 (EEMAC-4) construction if
located within the wet well. Do not use the control cable to
lift pump. NOTE: THE WHITE WIRE IS NOT A NEUTRAL OR
GROUND LEAD, BUT A POWER CARRYING CONDUCTOR.
C-4.3) Overload Protection :
C-4.3-1) Three Phase (Optional)- The normally closed (N/C)
thermal 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 itself 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 the
operator of an overload condition, and/or the motor starter coil
to stop the pump. In the event of an overload, the source of this
condition should be determined and rectified immediately.
DO NOT LET THE PUMP CYCLE OR RUN IF AN OVERLOAD
CONDITION OCCURS !
C-4.3-2) Single Phase - The type of in-winding overload
protector used is referred to as an inherent overheating
protector and operates on the combined effect of temperature
and current. This means that the overload protector will trip out
and shut the pump off if the windings become too hot, or the
load current passing through them becomes too high. It will
then automatically reset and start the pump up after the motor
cools to a safe temperature. In the event of an overload, the
source of this condition should be determined and rectified
immediately.
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
C-4.4) Wire Size:
Consult a qualified electrician for proper wire size if additional
power cable length is required. See table for electrical
information.
6
Manual Index

SECTION: D START-UP OPERATION
D-1) Check Voltage and Phase:
Before operating pump, compare the voltage and phase information
stamped on the pump identification plate to the available power.
D-2) Check Pump Rotation:
Before putting pump into service for the first time, the motor rotation
must be checked. Improper motor rotation can result in poor pump
performance and can damage the motor and/or pump. To check the
rotation, suspend the pump freely, momentarily apply power and
observe the "kickback". "Kickback" should always be in a
counter-clockwise direction as viewed from the top of the pump motor
housing.
D-2.1) Incorrect Rotation for Three-Phase Pumps:
In the event that the rotation is incorrect for a three-phase installation,
interchange any two power cable leads at the control box. DO NOT
change leads in the cable housing in the motor. Recheck the
"kickback" rotation again by momentarily applying power.
D-2.2) Incorrect Rotation for Single-Phase Pumps:
In the unlikely event that the rotation is incorrect for a single phase
pump, contact a Barnes Pumps Service Center.
D-3) Start-Up Report:
Included at the end of this manual are two start-up report sheets, these
sheets are to be completed as applicable. Return one copy to Barnes
Pumps, Inc. and store the second in the control panel or with the pump
manual if no control panel is used. It is important to record this data
at initial start-up since it will be useful to refer to should servicing the
pump be required in the future.
D-3.1) Identification Plate:
Record the numbers from the pump identification plate on both
START-UP REPORTS provided at the end of the manual for future
reference.
D-3.2) Insulation Test:
Before the pump is put into service, an insulation (megger) test should
be performed on the motor. The resistance values (ohms) as well as
the voltage (volts) and current (amps) should be recorded on the
start-up report.
D-3.3) Pump-Down Test:
After the pump has been properly wired and lowered into the basin,
sump or lift station, it is advisable to check the system by filling 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 on the start-up report.
Winding Resistance ±5%
Standard Units:
Optional - Temperature sensor cable for 3 phase models is 14/2 SOW-A, 0.530 O.D., CSA Listed
CSA Listed Units:
Optional - CSA Listed Power Cable for 3 Phase Models is 14/4 SOW-A, 0.600 O.D.
MODEL
NO.
HP VOLT PH RPM
(NOM)
NEMA
START
CODE
FULL
LOAD
AMPS
LOCKED
ROTOR
AMPS
CORD
SIZE
CORD
TYPE
CORD
O.D.
EMERSON
WINDING
RESISTANCE
MAIN--START
G.E.
WINDING
RESISTANCE
MAIN--START
4SE914L 0.9 115 1 1750 A 11.6 18.4 14/3 SJTOW-A 0.390 1.18 --14.25 1.34 -- 16.88
4SE924L 0.9 230 1 1750 A 5.8 10.5 14/3 SJTOW-A 0.390 4.67 -- 10.72 4.15 -- 11.84
4SE994L 0.9 200-230 3 1750 A/B 3.9/3.4 6.8/7.8 14/4 SO 0.600 13.87 -- 14.06 --
4SE944L 0.9 460 3 1750 B 1.7 3.9 14/4 SO 0.600 55.48 -- 56.24 --
4SE954L 0.9 575 3 1750 B 1.3 3.1 14/4 SO 0.600 86.68 -- 89.51 --
4SE1424L 1.4 230 1 1750 A 7.0 13.3 14/3 SJTOW-A 0.390 4.04 -- 6.49
4SE1494L 1.4 200-230 3 1750 A/B 5.2/4.5 10.4/12.0 14/4 SO 0.600 8.18 -- 8.43 --
4SE1444L 1.4 460 3 1750 B 2.3 6.0 14/4 SO 0.600 32.72 -- 33.72 --
4SE1454L 1.4 575 3 1750 B 1.8 4.8 14/4 SO 0.600 51.12 -- 52.95 --
4SE1924L 1.9 230 1 1750 A 11.0 17.5 14/3 SJTOW-A 0.390 2.24 -- 9.24 2.32 -- 9.22
4SE1994L 1.9 200-230 3 1750 A/B 6.9/6.0 13.9/16.0 14/4 SO 0.600 6.00 -- 6.10 --
4SE1944L 1.9 460 3 1750 B 3.0 8.0 14/4 SO 0.600 24.00 -- 24.40 --
4SE1954L 1.9 575 3 1750 B 2.4 6.4 14/4 SO 0.600 37.56 -- 38.57 --
7
Manual Index

SECTION E: PREVENTATIVE MAINTENANCE
As the motor is oil filled, no lubrication or other maintenance is
required, and generally Barnes Pumps will give very reliable
service and can be expected to operate for years on normal
sewage pumping without failing. However as with any
mechanical piece of equipment a preventive maintenance
program is recommended and suggested to include the
following checks:
1) Inspect motor chamber for oil level and contamination
and repair as required per section F-1.
2) Inspect impeller and body for excessive build-up or
clogging and repair as required per section F-2.
3) Inspect motor, bearings and shaft seal for wear or
leakage, replace as required per section F-3.
SECTION F: SERVICE AND REPAIR
NOTE: All item numbers in ( ) refer to Figures 8 & 9.
WARNING !
ELECTRICAL POWER TO THE PUMP MOTORS MUST
BE DISCONNECTED AND LOCKED OUT TO PREVENT
ANY DANGEROUS ELECTRICAL HAZARDS OR
PERSONNEL DANGER BEFORE ANY SERVICE WORK
IS DONE TO THE PUMP.
CAUTION !
OPERATING PUMP BUILDS UP HEAT AND
PRESSURE; ALLOW TIME FOR PUMP TO COOL TO
ROOM TEMPERATURE BEFORE HANDLING OR
SERVICING.
F-1) Lubrication:
Anytime the pump is removed from operation the cooling oil in
the motor housing (3), must be checked visually for oil level
and contamination.
F-1.1) Checking Oil:
Motor Housing- To check oil, set unit upright. Remove Pipe
Plug (2) or (36) from motor housing (3) With a flashlight,
visually inspect the oil in the motor housing (3) to make sure it
is clean, clear and that oil level is above all internal
componentry.
F-1.2) Testing Oil:
1. Place pump on it’s side, remove Pipe Plug (2) or (36) from
motor housing (3) and drain oil into a clean, dry container.
2. Check oil for contamination using an oil tester with a range
to 30 Kilovolts breakdown.
3. If oil is found to be clean and uncontaminated (measure
above 15 KV. breakdown), refill the motor housing as
per section F-1.3.
4. If oil is found to be dirty or contaminated (or measures
below 15 KV. breakdown), the the pump must be carefully
inspected for leaks at the shaft seal (9), Gland nut (28b)
and (39b if equipped), O-ring (24), Gasket (13), pipe plugs
(2) or (36) before refilling with oil. To locate the leak,
perform a pressure test as per section F-1.4. After leak is
repaired, refill with new oil as per section F-1.3.
F-1.3) Replacing Oil:
Motor Housing- Drain all oil from motor housing and dispose
of properly. Refill with (see parts list for amount) new cooling
oil as per Table 1. An air space must remain in the top of the
motor housing to compensate for oil expansion (see Fig. 8).
Set unit upright and fill only until the motor, as viewed through
the pipe plug opening, is just covered and no more. Apply pipe
sealant to pipe plug (2) or (36) and install in motor housing (3).
WARNING !
DO NOT OVERFILL OIL
OVERFILLING OF MOTOR HOUSING WITH OIL CAN
CREATE EXCESSIVE AND DANGEROUS HYDRAULIC
PRESSURE WHICH CAN DESTROY THE PUMP AND
CREATE A HAZARD. OVERFILLING OIL VOIDS
WARRANTY.
F-1.4) Pressure Test:
Motor Housing- Before checking the pump for leaks around
the shaft seal, square rings, and cord inlet, the oil level should
be full as described in section F-1.3. Remove pipe plug (2) or
(36) from motor housing (3). Apply pipe sealant to pressure
gauge assembly and tighten into pipe plug hole (see Fig. 2).
Pressurize motor housing to 10 P.S.I. Use a soap solution
around the sealed areas and inspect joints for "air bubbles". If,
after five 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 a sealant. If
the pressure does not hold, then the leak must be located.
10 PSI AIR ⇒ Remove Pipe Plug
PRESSURE GAUGE
ASSEMBLY
(See Parts List)
Fig. 2
8
Manual Index

CAUTION !
ALWAYS WEAR EYE PROTECTION WHEN WORKING
ON PUMPS.
CAUTION !
PRESSURE BUILDS UP EXTREMELY FAST,
INCREASE PRESSURE BY "TAPPING" AIR NOZZLE.
TOO MUCH PRESSURE WILL DAMAGE SEAL. DO NOT
EXCEED 10 P.S.I. IN MOTOR HOUSING.
TABLE 1 - COOLING OIL - Dielectric
SUPPLIER GRADE
BP Enerpar SE100
Conoco Pale Paraffin 22
Mobile D.T.E. Oil Light
G & G Oil Circulating 22
Imperial Oil Voltesso-35
Shell Canada Transformer-10
Texaco Diala-Oil-AX
Woco Premium 100
F-2) Impeller, Volute and Exclusion Seal Service:
F-2.1) Disassembly and Inspection:
To clean out volute (10), disconnect power, remove cap
screws (11) and lockwashers (12), vertically lift motor and seal
assembly from body (10). Clean out body if necessary. Clean
and examine impeller (16) for pitting or wear, replace if
required. Inspect Gasket (13) and replace if cut or damaged.
If impeller (16) requires replacing, place a flat screwdriver in
the slot of the end of the shaft to hold the shaft stationary while
unscrewing the impeller (16). Once impeller (16) is removed,
remove spacer (25) and exclusion seal (19) if damaged or cut.
F-2.2) Reassembly:
Position exclusion seal (19) on shaft until it seats against the
stationary portion of seal (9). Place spacer (25) on shaft until
it seats against exclusion seal (19). To install impeller (16),
clean the threads with loctite cleaner and screw impeller (16)
onto the shaft hand tight. Rotate impeller to check for binding.
Position gasket (13) on volute flange and position impeller and
motor housing assembly on volute (10). Apply thread locking
compound to cap screw (11) and position lockwasher (12) on
cap screw (11) and screw into volute (10). Torque to 8 ft. lbs.
Check for free rotation of motor and impeller.
F-3) Motor, Bearing and Seal Service
F-3.1) Disassembly and Inspection:
To examine or replace the motor (5), bearing (8) and shaft seal
(9), disassemble volute and impeller as outlined in paragraph
F-2.1. Drain oil from motor as outlined in paragraph F-1.3.
Position unit upright, using blocks to avoid resting unit on shaft.
Remove gland nut (28b), friction rings (28c) and grommet
(28d) from motor housing (3). If pump is equipped with
temperature sensor, also remove gland nut (39b), friction rings
(39c) and grommet (39d), from motor housing (3) (see Figure
6). Remove socket head cap screws (23) and lift motor housing
(3) from lower end bell (22). Slide motor housing (3) up cable(s)
(28), and (39) if pump is equipped with temperature sensor,
until wire connectors and ground screw is exposed. Remove
cable lead wires from motor lead wires and temperature sensor
wires ( if equipped) from control cable, by disconnecting wire
connectors (4) and ground screw (27) from motor (5). The
wiring connections should be noted to insure correct
connections when reassembling.
MOTOR END
(INBOARD END)
PUMP END
(OUTBOARD END)
SEAL ASSEMBLY
(9)
CONDUIT BUSHING (6)
WASHER (7)
RETAINING RING (9d)
SPRING (9C)
ROTATING MEMBER (9b)
STATIONARY (9a)
EXCLUSION SEAL (19)
Fig. 3
SPACER (25)
LOWER END BELL (22)
9
Manual Index

Motor- Remove the motor bolts and lift motor stator from motor
rotor and lower end bell (22). Unscrew conduit bushing (6) from
lower end bell (22) and lift motor rotor, shaft, bearing (8),
rotating portion of seal (9), washer (7) and conduit bushing (6)
from lower end bell (22).
Inspect windings for shorts and check resistance values.
Check rotor for wear, if rotor or the stator windings are
defective, the complete motor must be replaced.
To test the temperature sensor (if equipped), check the
continuity between the black and white wires. If found to be
defective contact a motor service station or Barnes Pumps’
Service Department. Check motor capacitor (32) on single
phase units and replace if defective.
CAUTION !
HANDLE SEAL PARTS WITH EXTREME CARE. DO NOT
SCRATCH OR MAR LAPPED SURFACES.
Seal- Remove rotating member (9a), spring (9c) and retaining
ring (9d) from shaft. (see Figure 3) Examine all seal parts and
especially contact faces. Inspect seal for signs of wear such as
uneven wear pattern on stationary members, chips and
scratches on either seal face. DO NOT interchange seal
components, replace the entire shaft seal (9). If replacing seal,
remove stationary (9a) from lower end bell (22) by prying out
with flat screwdriver.
Bearing- Examine bearing (8) and replace if required. If
replacement is required, remove bearing (8) from motor shaft
using a wheel puller. Washer (7) and conduit bushing (6) can
now be removed from motor shaft.
IMPORTANT !
ALL PARTS MUST BE CLEAN BEFORE REASSEMBLY.
F-3.2) Reassembly:
Bearing- When replacing bearing, be careful not to damage
the rotor or shaft threads. Clean the shaft thoroughly. Slide
conduit bushing (6) and washer (7) over motor shaft. Apply
adhesive compound to the shaft and press bearing (8) on the
motor shaft, position squarely onto shaft applying force to the
inner race of the bearing only, until bearing seats against
shoulder of the shaft.
Seal- Clean and oil seal cavity in lower end bell (22). Press
stationary member (9a) firmly into lower end bell (22), using a
seal pusher (see parts list - seal tool kit), nothing but the seal
pusher is to come in contact with seal face (see Figure 4). Make
sure the stationary member is in straight.
IMPORTANT !
DO NOT HAMMER ON THE SEAL PUSHER- IT WILL
DAMAGE THE SEAL FACE.
Slide retaining ring (9d) over shaft and let rest on bearing (8).
Place spring (9c) over shaft and let rest on retaining ring (9d).
Lightly oil ( DO NOT use grease) shaft, bullet and inner surface
of bellows on rotating member (9b), (see Figure 5), with lapped
surface of rotating member (9b) facing outward, slide over
bullet and onto shaft using seal pusher, making sure spring (9c)
is seated in retaining ring (9d) and spring (9c) is lined up on
rotating member (9b) and not cocked or resting on bellows tail.
IMPORTANT !
IT IS EXTREMELY IMPORTANT TO KEEP SEAL FACES
CLEAN DURING ASSEMBLY. DIRT PARTICLES
LODGED BETWEEN THESE FACES WILL CAUSE THE
SEAL TO LEAK.
Motor- Slide motor rotor with conduit bushing (6), washer (7),
bearing (8) and seal parts (9b, c, d) into lower end bell (22) until
bearing (8) seats in lower end bell (22). Center washer (7) on
bearing (8) and tighten conduit bushing (6) on lower end bell
(22).
Lower motor stator over rotor until seated in lower end bell (22),
while aligning holes for motor bolts. Insert motor bolts and
torque to 17 inch pounds. If pump is a single phase unit place
bracket (31) on one of the motor bolts. Insert capacitor (32) in
bracket (31), attach motor leads with flag terminals to capacitor
and place terminal boot (33) over terminals.
LOWER END BELL (22)
SEAL PUSHER
STATIONARY MEMBER (9A),
POLISHED FACE OUT.
Fig. 4
Motor & Lower End Bell Assy.
Stationary (9a) Bullet
Rotating Member (9b) Seal Pusher
Fig. 5
10
Manual Index