Pentair Pool Products Delta D2CX20-21 Troubleshooting guide

23833A596 1
Submersible Centrifugal
Grinder Pump
Installation & Service Manual
with Parts List
NOTE! To the installer: Please make sure you provide
this manual to the owner of the pumping equipment or
to the responsible party who maintains the system.
D2CX20-21

23833A5962
MUST BE INSTALLED BY EXPERIENCED
PROFESSIONALS ONLY
CAUTION: READTHESE SAFETYWARNINGS FIRST
BEFORE INSTALLATION, SERVICING OR OPERAT-
ING ANY PUMP. THESE INSTRUCTIONS ARE
WRITTENWITHTHE UNDERSTANDINGTHATTHE
INDIVIDUALS) HAVE EXPERIENCE IN BUILDING
WETWELLS AND INSTALLING BASINS, GRINDER
PUMPS AND PUMPING EQUIPMENT.
NOTE: ModelswithThird Party approval(s) are clearly
markedonindividualpumpnameplates.
WARNING! RISK OF ELECTRICAL SHOCK. TO
REDUCE RISK OF ELECTRICAL SHOCK, SEE
INSTRUCTIONMANUAL FOR INSTALLATION.
DO NOT REMOVE CORD AND STRAIN RELIEF.
ALLTHREE PHASE PUMPS MUST BE INSTALLED
WITHMAGNETICSTARTERSHAVINGTHREELEG
OVERLOADPROTECTIONINACCORDANCEWITH
THENATIONALELECTRICCODE. FORDUPLEX
INSTALLATIONS,BOTHPUMP MOTORSMUSTHAVE
SEPARATEOVERLOAD PROTECTION.
WARNING! ONLY QUALIFIED PERSONS SHALL
CONDUCT SERVICES AND INSTALLATIONS OF
THIS PUMP. THE PUMP MUST BEWIRED BY A
QUALIFIED ELECTRICIAN.
PUMPSWITH SEAL LEAK DETECTORS, MUST BE
CONNECTEDTOTHEPROPERCONTROLCIR-
CUITRY. SEEINSTRUCTIONS MANUAL.
DANGER! HAZARDOUS MOVING PARTS. TO
REDUCERISKOFINJURYDISCONNECTPOWER
BEFORE SERVICING. NEVER PUT FINGERS NEAR
GRINDERIMPELLERORINPUMPINLETWEN
PUMPCORDISCONNECTEDORPUMPISOPERAT-
ING.
FOR USEWITH MAXIMUM 140°F LIQUID. ACCEPT-
ABLEFOROUTDOORUSE.
DANGER! INTHE INITIAL INSTALLATION,BE-
FORE SEWAGE IS ADMITTEDTOTHE BASIN,
THERE IS NO DANGER ON ENTERINGTHE BASIN,
BUT AFTER SEWAGE HAS BEEN INTHE BASIN
THERE IS DANGER. SEWAGEWATER GIVES OFF
METHANE AND HYDROGEN SULFIDE GASSES,
BOTH OFWHICH ARE HIGHLY POISONOUS. A
BREATHING DEVICE MAY BE REQUIRED. NEVER
ENTER BASIN UNLESS COVER IS OPEN AND AN
OUTSIDE BLOWER IS USED.TO FORCE FRESH AIR
INTOTHE BASIN. ALSO,THEWORKER INTHE
BASIN MUSTWEAR A HARNESS ATTACHEDTOTHE
SURFACE SOTHAT HE CAN BE PULLED OUT IN
CASE OF ASPHYXIATION. NEVERWORK ALONE!
WARNING! DONOTEXCEEDWORKINGLOAD
LIMIT OF LIFTING ROPE OR CHAIN. DO NOT USE
LIFTINGROPEORCHAINWHEREFAILURE COULD
RESULT IN LOSS OF LIFE.
EXAMINE ALL LIFTING DEVICES, ROPE OR CHAIN
FOR DAMAGE BEFORE AND AFTER EACH LIFT.
DO NOT USE ANY LIFTING DEVICESTHAT ARE NOT
RATEDFORANDDESIGNEDTOLIFTTHEWEIGHTS
INVOLVEDWITHTHESE PUMPS.
DO NOT INSTALL OR REMOVE PUMPWITH
PERSON(S) IN BASIN.
GENERAL
1. Most accidents can be avoided by using COMMON
SENSE.
2. Readtheoperationand maintenance instructions
manualsuppliedwiththepump.
3. DO NOT wearlooseclothing that can become
entangled in the impeller or other moving parts.
4. This pump is designed to handle materials which
could cause illness or disease through direct
exposure.
Wearanduseprotectiveclothingwhenworkingonthe
pumporpiping.
ELECTRICAL
1. To reduce the risk of electrical shock,pump
must be properly ground in accordance with the
National Electric Code and all applicable state
and local codes and ordinances.
2. To reduce risk of electrical shock, disconnect the
pumpfromthepower source before handling or
servicing.
3. Any wiring to be done on pumps should be done by
aqualifiedelectrician.
4. NEVER operate a pump with a power cord that has
frayedor brittle insulation.
5. NEVER let cords or plugs lay in water.
6. NEVER handleconnectedpowercordswithwet
hands.
SAFETY CAUTIONS AND WARNINGS

23833A596 3
PUMP
1. Pumpbuildsupheat and pressure during opera-
tion, allow time for pump to cool before handling or
servicing.
2. Onlyqualifiedpersonnelshouldinstall,operateor
repairpump.
3. Keep clear of suction and discharge openings. DO
NOT insert fingers in pump with powerconnected.
4. DO NOT pumphazardousmaterialnotrecom-
mended for pump (flammable, caustic, etc.).
5. Make sure lifting devices are securely fastened
each time before lifting pump.
6. DO NOT LIFT PUMP BYTHE POWER CORD.
7. DO NOT exceedmanufacturer’srecommendation
for maximum performance, as this could cause the
motortooverheat.
8. Secure the pump in its operating position so it
cannot tip over, fall or slide.
9. Keep hands andfeetaway from impellerwhen
powerisconnected.
10. Submersiblegrinderpumpsare notapproved for
useinswimmingpools,recreationalwaterinstalla-
tions, decorative fountains or any installation where
human contact with the pumped fluid is common.
11. DO NOT pump without safety devices in place.
12. For hazardous locations, use pumps that are listed
and classified for such locations.
13. DO NOT usenon-explosionproofratedpumpsin
locationsconsideredhazardousinaccordance with
theNationalElectrical Code,ANSI/NFPA70-1993.
14. Basin must be vented in accordance with the local
plumbingcodes.
IMPORTANT: Manufacturer is not responsible for
losses, injury or death resulting from failure to observe
these safety precautions, misuse or abuse of pumps
orequipment.
CONTROLPANELS
All control panels used on these grinders are UL listed
and CSA certified. Control panels mounted directly to
the basin used outdoors are UL listed and CSA
certifiedwaterproof.
If intrinsically safe controls used in hazardous loca-
tionsarerequired,manufacturercanfurnish a UL listed
or CSA certified panel. Otherwise the installer must
obtainasourceforthepanelrequired.
LEVEL SENSING CONTROLS
Intrinsically-safetypefloatcontrolsarerecommended
forallapplicationsand required for explosion-proof
service. An intrinsically safe control panel relay will
limit the current and voltage to the level controls. A
Delta control panel can be supplied with this type
circuitry.
The float level controls maintain the basin sewage water
levelbycontrolling pump turn-on and turn-off level.
1. The lower turn-off control should be set so that the
pump stops at approximately the top of the pump.
2. Theupperturn-oncontrolshouldbesetabovethe
lower turn-off control. The exact height between the
two controls is determined by the number of pump
starts desired and the depth of the basin. A maxi-
mum of 10 starts per hour should not be exceeded.
3. The override control is set at a specified height
abovetheupperturn-on control.
4. The alarm control is set about 6” to 12” above the
overridecontrol.
5. No control should be set above the inlet invert.
JUNCTIONBOXES
If a junction box is used in a hazardous location, it must
beanexplosion-proof approved type withexplosion-proof
cord connectors. Wires from the junction box must pass
throughanexplosion-proofsealconnector.
CAUTION: No persons should be in the basin when
pump is lowered into position! DO NOT lift pump in a
manner where any failure could result in loss of life.
AIRVENTING
Air tends to trap in the pump volute when water raises in
the sump or when the pump is lowered into water after
service. To vent off this air, a small hole is drilled into
the pump volute. Be sure this vent hole is clean after
any service work on pump.
PUMP MODELS —This grinder pump is made in one
model only for use with single phase and three phase
power. Motor rating is 2 HP, 3540 RPM, 60 Hz. Also
can be used for 50 Hz. operation. Single phase is for
230 volt.
PACKAGING — Each pump is packaged with 15 feet of
power cord in a carton that is marked with Model
NumberandEngineeringNumber. Longer cordsare
available for special jobs.
INSTRUCTIONS — Instructions cover only the pump
unit. Separate instructions for the electrical control panel
and basin packaged system are included with these
items.
CAUTION: PUMP IS NOTTO BE DISASSEMBLED IN
THE FIELD EXCEPT AT CERTIFIED SERVICE STA-
TIONS OR AT FACTORY. WARRANTY ISVOID IF
PUMP IS TAKEN APART FOR ANY REASON EXCEPT
TOREPLACEGRINDERIMPELLERAND GRINDER
RINGWHICHIS COVEREDINTHESEINSTRUCTIONS.
PUMP CAUTIONS AND WARNINGS

23833A5964
DESCRIPTION OF PUMP —This pump is intended to
grindandpumpallnormalsewage for home or commer-
cial use. It will also handle reasonable quantities of
disposablediapers,sanitarynapkins,papertowels,
rubber material, wood, plastic, string, cigarette butts
andothermaterialnotnormallyfoundinsewage.
Pump is of heavy duty construction and submersible
typeforlonglifewhenpumpinggroundsewage. Motor
is capacitor start, capacitor run for single phase.
Capacitors and start relay are mounted in electrical
controlbox.
Pump has two oil-filled chambers: (1) the motor and
ball bearings and (2) the seal chamber - for long life and
best heat transfer.
The lower seal above the pump impeller acts as a
buffer for upper seal that holds oil in the motor chamber.
If lower seal leaks for any reason, water enters the seal
chamber. If motor has the seal leak detector, the
electrode will contact the water and close the circuit to
the red seal light in the control panel indicting motor
must be serviced before upper seal fails.
A heat sensor is attached to stator winding to sense
any abnormal heat. If motor temperature for any cause
rises above 221°F the pump is immediately stopped
and will not restart until motor cools to a safe tempera-
ture.
PUMP CORDS — Each pump has two cords. The
power cord contains 4 conductors and the control cord
has 5 conductors. The larger of the two cords is the
power cord and smaller cord is the control cord.
The power cord for single phase uses the color coding
for start and main windings and connects to control box
terminalstripblack(common),white(run),andred
(start). The green wire is always ground and connects
to ground terminal in control box. For three phase the
same 4 conductor color coded cords are used, the
black, white and red can be connected to any of the
three phase terminals in the control box.
The smaller control cord uses black and white leads for
heat sensor and connects to terminal strip in control
box. The red and orange wires connect to seal failure
terminalsincontrolboxandthegreenorgroundlead
connects to ground terminal in control box.
IMPORTANT — Ground wires must be connected in the
control box to grounding bar, which is connected to a
goodoutsideground. MOTORIS NOTSAFE UNLESS
GROUNDED.
INSPECTING PUMP — Before making any piping or
electrical connections check pump for any shipping
damage and turn grinder impeller to be sure it is free.
DONOTTURN IMPELLERWITH FINGERSAS
EDGES ARE SHARP, use socket wrench in the
impellerscrew.
CAUTION: After pump is installed NEVERWORK ON
MOTORORGRINDERUNITWITHOUTDISCONNECT-
INGMOTOR LEADWIRES FROMCONTROLPANEL.
DONOT RELYONOPENINGCIRCUIT BREAKER
ONLY.
INSTALLING PUMP IN BASIN — Complete installation
and piping instructions are included with the basin
package.
To check rotation turn Hand-Off-Auto switch to OFF
position and turn on circuit breaker. Quickly turn H-O-A
switch to HAND position, then OFF. Note grinder
impellerrotation. Impellermustrotatecounterclock-
wise. If rotation is wrong, change any two line leads to
motor at control box terminal. Recheck for proper
rotation. CAUTION: KEEPHANDSCOMPLETELY
AWAY FROMGRINDERIMPELLERWHENMAKING
THISCHECK.
Where pump is installed remote from control box in
outside installation a different method is used.
Set the pump in the basin and run in some water so
pump can operate. Turn H-O-A switch to hand position
and let pump pull water down in basin. When water
reaches the bottom of pump, rotation of the water can
be observed. Water should rotate in a clockwise
direction if pump rotation is correct. If not correct
rotation, interchange any two line leads to motor at
controlpanel.
When replacing a pump with a new unit, rotation must
be checked.
PUMP INSTALLATION

23833A596 5
Fig. 1
PUMP PARTS LIST
Ref
No. Part No. Description Qty.
1 22407C100 Cord Cap 1
3 12672A001 Connector 7
4 10649A102 Tube, Plastic 2
5 19100A012 Cap Screw, 5/16"-18 x1 1/4" Lg. 8
6 05876A122 Gasket, Rubber Tetraseal 1
7 21570B100 Cap, Upper Bearing 1
8 05876A123 Gasket, Rubber Tetraseal 1
9 05022A092 Pipe Plug, 1/4" NPT, Hex HD. 2
10 05434A043 Screw, Mach., #10-24 x1/2" Lg. 1
11 06107A015 Lock Washer, #10 1
12 07597A017 Screw, Mach., Flat Hd. 2
13 21571D100 Housing, Motor 1
14 11009A003K Oil, Transformer 1.06
15 19331A005 Washer, Spring 2
16 08565A013 Bearing, Ball 1
17 11816A006 Ring Retaining 1
18 21572C100 Rotor, w/Shaft 1
19 21573C100 Stator 1
20 08565A018 Bearing, Ball 1
21 21574D100 Housing, Upper Seal 1
22 21576A010 Seal, 7/8" Shaft 2
23 12558A006 Ring Retaining 1
25 22578A004A Electrode 2
26 05876A125 Gasket, Rubber Tetraseal 2
27 22579A000 Ferrule, Rubber 1
28 21577A000 Plug, Special 1
29 21578C100 Housing, Lower Seal 1
33 22581A001 Gasket, Vellumoid 1
34 21580D102 Casing, Volute 1
35 21581C500 Impeller, Pump 1
36 21582B000 Impeller, Grinding 1
37 07597A018 Mach. Screw, 1/4"-20 x1" Lg. 1
39 21583A000 Retainer, Impeller 1
40 21584B000K Flange, w/Shredding Ring 1
41 19099A012 Cap Screw, Hex 1/4"-20 x1" Lg. 3
55 05013A039 Set Screw, 1/4"-20 x3/8" Lg. 2
12A 06106A008 Cap Screw, 5/16"-18 x1" Lg. 8

23833A5966
REPLACINGPARTS AND
COMPLETE DISMANTLING OF PUMP
StandardTools Required:
1. Allen head socket set
2. Standard socket wrench set
3. Setofopenend wrenches.
4. Plastic hammer
5. Vise grip pliers
6. Largescrewdriverwith heavy handle
7. Wirebrush
8. Three-corneredfile
9. Flat file
10. Snap ring pliers for outside snap ring
11. Crimpingpliersforelectrical connectors
12. Arborpress
13. Loctite#271
14. Submersiblemotoroil
IMPORTANT— Beforeanyrepairwork is done on
pump it should be sandblasted, if possible, to
remove any deposits. After cleaning, pump should
besubmergedinastrong“clorox”solutionforone
hourbeforehandling pump.
CAUTION: DISCONNECT ALL POWER AND
CONTROLWIRESTO MOTOR AT CONTROL
PANEL BEFORE STARTING DISASSEMBLY
OPERATIONS. NEVER RELY ON OPENING
CIRCUITBREAKER ONLY.
DISASSEMBLY OF SHREDDING RING AND
GRINDER IMPELLER
1. Hold impeller from moving by placing small allen
wrenchorscrewdriverinshreddingring slot and
removesocketheadscrewandwasherfrom
pump shaft. See Figure 2.
2. Removethreescrewsfrom grinder ring flange.
Grinder ring is pressed into flange for easy
removal. SeeFigure 3.
3. Thread two screws into tapped back-off holes in
flange and evenly tighten screws to back
grindingringoutofpumphousing.
4. Place large flat blade screwdriver into slot in
shaft.
5. Bumpimpellervanecounterclockwisewith
plastichammertoloosenimpellerand continue
to unscrew impeller from shaft. See Figure 4.
Fig.2
Fig.3
Fig.4
REPLACING PARTS AND DISMANTLING PUMP

23833A596 7
6. Usewirebrushandthoroughlycleanany
depositfrompassageabove grinder impeller
and in cavity for grinder ring. See Figure 5.
7. Replacenewgrinder impeller,usescrewdriver
in slot while turning on impeller, until hand
tight, with screwdriver still in shaft slot bump
with plastic hammer. See Figure 6.
8. Replace new grinder ringandplate. Useoilon
ring for easy fit.
9. Toprovideproper alignment use three sections
of an old ½” tape measure as shims 120
degrees apart and then tighten bolts. Be sure
topull screws down evenly applying pressure
on all three screws. DO NOTTIGHTEN ONE
SCREWCLEAR DOWNBEFORE ADJUST-
ING OTHER SCREWS. See Figure 7.
10. Replaceholdingscrew andwasher,usesmall
amount of Loctite #271 screw. See Figure 8
11. Bump set screw wrench with plastic hammer
to tighten, working against small allen wrench
orscrewdriverinshredding ring.
12. Check freedom ofrotation using fingeron
impeller vanes. Pump should turn free with
slight drag due to seals. Use caution to avoid
injuryfromshreddingring while turning grinding
impeller.
13. As a final check, measure distance from end
of ring to bottom of impeller vanes. This
should be 3/32” to 1/8”. If distance is only 1/16” or
less it will indicate pump impeller has partially
unscrewedwhengrinder impellerwasre-
moved. See Figures 9 and 10. If this is the
case, pump case will have to be removed to
tighten pump impeller. These steps will be
given in the following instructions. In rare
cases if the impeller is jammed so tight it can’t
be removed by the steps given it will be
necessary to remove the motor housing so
that the motor rotor can be gripped to break
loosethegrinder impeller. SeeFigure11.
Fig.5
Fig.6
Fig.7

23833A5968
Fig.10
Fig.8
Fig.9
Fig.11
Fig.12
Fig.13

23833A596 9
REPLACING LOWER SEAL
1. Usesteps1through5forremovinggrinder
ring and grinderimpeller.
2. Before removing any other parts use a mark-
ing pen to mark joining parts so that they can
bereplacedinsamepositionasremoved.
SeeFigure12.
3. Remove oil fill plug slowly from seal chamber
as pressure may have built up in this cavity,
and pour out oil. See Figures 13 & 14.
4. Remove volute case bolts and pull off volute
casing. Plastic hammer can be used to bump
on casing discharge to loosen. Place gasket
in oil to prevent drying out.
5. Insert large flat blade screwdriver in slot
providedinpumpshaftandholdimpellerhub
withvise grip pliers. Turn impeller counter-
clockwise to loosen. It may be necessary to
give pliers a sharp blow with plastic hammer to
loosenimpeller. SeeFigure 15. Turn counter-
clockwise to loosen.
6. Use wire brush and putty knife and clean
castingbeforeremovingseal.
7. Remove Allen socket head screws from seal
plate. See Figure 16.
8. Pry carbon portion of seal from shaft by using
flat blade screwdrivers on each side of shaft.
DO NOT SCRATCH SHAFT. It does not
matter if carbon cracks as it may be replaced
with new part. See Figure 17.
9. Removeceramicsealfaceandrubberretain-
ing boot by prying seal out with flat blade
screwdrivers. (Seal can be pressed out with a
screwdriver from the opposite side.) Be
careful not to scratch bronze bushing. Dam-
age to seal is not important, as a new part
must be installed. See Figure 18.
10. Thoroughlycleaninsideofseal chamber and
pocket where new seal is to be installed. See
Figure 19. Use rags and solvent cleaner.
11. Use care to avoid touching sealing faces with
hands,useprotectivecardboardcirclepro-
vided with seal, while handling. Use an artists
brush to coat bottom outside portion of rubber
retainingbootwithconservativeapplicationof
STP or equivalent lubrication to ease installa-
tion. See Figure 20.
Fig.14
Fig.15
Fig.16

23833A59610
Fig.17
Fig.18
Fig.19 Fig.22
Fig.21
Fig.20

23833A596 11
12. Place seal in seal cavity loosely and using
cardboardprotectoruseboththumbstopress
seal into seal plate. The cardboard protector can
be moved about to insure seal is pressed in
evenly. See Figure 21.
13. Wettingfingerandtouching centerofcardboard
protector will allow it to be easily removed.
14. Coatlower rubbershaft boot portion ofcarbon
half of rotary seal with conservative application
of STP or equivalent lubricant. Next immerse
seal in small container ofTransformer Oil (small
babyfoodjarrecommended). See Figure 22.
Firmly press seal on shaft using thumbs.
Observe that carbon seal is firmly in contact
with ceramic portion of seal, and that carbon
portion has not slipped out of its metal holder.
See figure 23. Install spring for lower seal only.
NOTE: Discard spring retaining ringprovided
with the seal, as a groove is machined in the
back side of the bronze impeller to locate and
retain this seal spring.
15. Replace impeller andtighten with visegrip
pliers, holding shaft with large flat blade screw-
driver.
16. File off any burrs made on impeller neck with
vise grip pliers. See figure 24.
17. Cleancasingthoroughlywith wirebrushand
wash out with solvent. Be sure the discharge
port and small weep hole in the volute case is
clean and free of any deposits. See Figure 25.
18. Replace volute case being careful to have
gasket in place. Line up with center marks
madebeforedismantlingpump. SeeFigure26.
19. Replacegrinderringand impelleras described
under“ReplacingGrinder Ring &GrinderImpel-
ler”.
20. Air test repaired pump with approximately 6 lbs.
ofairpressureusingpipingwithpressure gauge
and air valve stem. Submerse in water and after
evacuating air from volute case observe for
leaks, remove and dry off pump.
21. Refill seal chamber withTransformer Oil. See
Figure 27. Fill until oil is ¾” below top of oil plug
boss. See Figure 28.
22. Cleanoilplugwith wirebrush, reapplyTeflon
tape and reinstall oil plug.
23. In rare case when impeller is locked too tight to
remove as described, it may be necessary to lift
off the motor housing so that rotor can be held
whileimpellerisremoved.
Fig.23
Fig.24
Fig.25

23833A59612
Fig.26
Fig.27
Fig.28
Fig.29
Fig.30
Fig.31

23833A596 13
REPLACING UPPER SEAL
To replace upper seal it is necessary to completely
dismantle the pump. Usually if upper seal is out, the
motor stator will be ruined with water, so it will also be
necessaryto be replaced.
1. Remove oil fill plugs slowly and drain oil from
motor and seal chamber. See Figures 29, 30 and
31.
2. Removemotorendcapscrewsandthreadinto
tapped back-off holes to force cap from motor
housing. SeeFigure32
3. Lift cap and remove lead from ground screw. See
Figure33
4. Cut off all motor leads ¾” down from the connec-
tor on the stator side, this way the cap and cord
assembly and the connectors can be checked for
continuity. See Figures 34 and 35.
5. Remove socket type flat head screws from
bearingcapandthreadintotappedback-offholes
to force cap from housing. See Figure 36.
6. Remove bolts from motor stator housing and lift
off casting. Please Note: Bearing housing
contains two finger spring washers which may fall
out of casting when removed. The red and the
orange seal failure wires will pull out of hole in
stator. See Figure 37.
7. Therotorisnowexposedandtheredand orange
sealfailure wires are exposed. Rotor can now be
heldforremovinggrinder impeller and pump
impellerasdescribedbefore.
8. To remove upper seal use snap ring pliers and
remove snap ring that holds upper seal in place.
SeeFigure38.
9. After snap ring is removed, bump on end of shaft
with plastic hammer to force shaft through upper
sealandtopushlowerballbearingfromhousing.
SeeFigure39.
10. Push old seal out of housing. Clean thoroughly
and press in new seal seat as described in the
first section steps 8 thru 14.
11. Replaceballbearingsifworn or rustedfrom water
beinginmotor.
12. Use arbor press to push off bearings. Use flat
steel bars to get under bearing. See Figure 40.
13. In replacing bearingsalways presson inner face
ofbearing.
Fig.32
Fig.33
Fig.34

23833A59614
Fig.35
Fig.36
Fig.37
Fig.38
Fig.39
Fig.40

23833A596 15
14. Replaceredandorange seal failurewires if
necessary. Loosen nut in seal chamber to
removewire.
15. Put in new seal failure wires and adjust so that
the probe portion of the seal leak wires are
staggered, the end of the longest wire being up
¼” from the machined face of the casting. See
Figure 41. Position shorter lead above the first
so probes do not touch. See drawing front cover.
Retighten seal nut. Be sure rubber seal ring is in
place to seal wire. See Figure 42.
16. Usingfinepicturehangingwirepull seal failure
wireupthroughstatorhole beforereplacing stator.
See Figure 43. The stator is pressed into housing
at the factory and is shipped as a unit. Do not try
to replace stator in housing in the field, they must
be replaced as a unit.
17. Using Allen wrench or small screwdriver in bolt
holes to hold parts in place, position upper
bearingcastingupside-down and runwiresdown
through holes in segmented casting. Next apply
STP or equivalent to bearing cup liberally and
insert the first finger spring washer flat side down.
Apply more STP and insert second finger spring
washer flat side down, to make paired finger
washers. Apply STP again to hold washers in
place when casting is turned over and installed
on top of rotor. Bearing housing will be held off of
statorhousingapproximately1/16”and will depress
totouchstator housing when pusheddownward.
See Figures 44, 45 and 46.
Fig.41
Fig.42
Fig.43
Fig.4
Fig.5

23833A59616
18. Reassemble all parts as taken apart. BE SURE
NEW O-RINGS ARE IN PLACE BEFORE
BOLTING PARTSTOGETHER. If necessary to
replace cords use cap with cords potted in. In
emergency, cut cord can be spliced and taped.
Reconnectall motor lead wires to power cord with
pressuretype insulated connectors. Crimp tight
with crimping pliers that will not penetrate the
insulationof the connector.
19. Reinstall cap and cord assembly. Run OHM
Meter resistance test at this time to check
windings and test for grounding. Test seals with
airpressureasdescribedearlier.
20. Fill motor chamberand seal chamberwith
submersible oil. Fill top motor chamber to bottom
of seal plug threads and fill seal chamber to
within ¾” of top of plug fill boss.
IMPORTANT — AFTER ALL ASSEMBLY AND
REPLACEMENT OF PARTS BE SURE PUMP
TURNS FREE BY HAND. PUMP MUST NOT BIND
INANYPOSITIONORROTATION.
ELECTRICAL CONTROL BOX —Allinstructions
andwiringdiagramsforconnectingpumptocontrol
box are included with the control box.
CHECK LIST TO DETERMINE
MOTORTROUBLE
Checking For Moisture in Motor:
Use ohmmeter and set on highest scale. Readings on
thelargepowercordbetweenanyoftheconductors
red, black, white to green conductor or motor shell
shouldbemorethan500,000ohms. Motorprobablywill
run with a lower reading, but if pump is out of service
andreadingisbelow500,000ohmsthe motor housing
and stator should be removed and baked in a drying
oven at 220°F.to dry out winding. If winding cannot be
dried out it must be replaced.
Both motor housing and stator must be replaced as a
unit as stator is pressed in at the factory and cannot be
removed in the field.
ResistanceofWindings:
Every motor winding ha a fixed resistance and winding
must check close to the values given to operate
properly. This winding resistance also shows if motor is
connectedforvoltagebeingused.
Use ohmmeter for this test and set on scale to read
directly in ohms.
Black To Black To
White Red
Main Start White to
MotorType &Voltage Winding Winding Red
Single Phase, 230V 1.56 7.84 9.40
Winding ResistanceValues in Ohms
Full Load Amp Readings for Motors
MotorType Volts Amps Locked Rotor Amps
Single Phase 230 12 41.0
If amp readings are higher than listed, it indicates
voltagemay be higher or lower than normalor that
pumpgrinder may be clogged with trash causing extra
loadonmotor.
Fig.46
MOTORTROUBLE

23833A596 17
TROUBLE CHECK LIST
Troubles listed below are generally not caused by the pump. Other trouble can occur from faulty control box
operation. These will be listed with the control box instructions.
CONDITION
Pump runs but does not pump
liquid from basin.
Red light comes on at control
box
Overloadtripsandalarm
buzzer or flashing red light
comes on due to high water
level in basin
Yellow run light stays on
continuously
PROBABLE CAUSE
1. Pump impeller may be air locked, this occasionally occurs on a new
installation. Remove pump and clean volute case weep hole and
reinstall pump allowing 2 to 3 minutes for air to weep from pump.
2. Remove pump and guides from wet well, and test in 5 gallon bucket
after checking weep hole again. If pump still does not pump, disas-
semble check valve and check to insure that check valve flapper has
not adhered to sealing face. This condition results from assembled
basin units setting in the sun before installation. NOTE: Check valve
boltsshouldhaveLoctite242orequivalentappliedbeforereassembly
of check valves.
3. If pump will pump water from bucket, try in wet well again. If it still will
not pump, the following problems may exist:
a) BallValve - GateValve may be in off position.
b) Discharge pipingobstructed
c) Valve at street or in main line may be off — redundant check valve
inbackwards.
d) Tapat forcemain obstructed — hole not drilledthrough enough —
pipes pushed into tee too far.
4. If pump has been installed for some time an does not pump, it may be
cloggedatgrinderinlet.
5. Discharge head may be too high. Check elevation. Maximum pump
head at zero flow is 105 feet. See pump curve.
6. If above checks do not locate trouble, motor rotor may be loose on
shaft which allows motor to run but will not turn impeller or only at low
RPM.
1. This indicates some water has leaked past the lower seal and has
enteredthesealchamberandmadecontactwiththeelectrode probe.
Pump must be removed from basin within approximately two (2) weeks
for replacement of lower seal. This preventative repair will save an
expensive motor.
1. Push in red reset button to reset overload. If overload trips again after
short run, pump has some damage and must be removed from basin
for checking.
2. Troublemay be from clogged grinder causing motor to overload or
could be from failed motor.
3. Trouble may be from faulty component in control box. Always check
controlboxbeforeremovingpump.
1. Indicates H-O-A switch be in the hand position.
2. Level control switch may have failed causing pump to continue to
operatewhenwaterisbelow lower float.
3. Grinder assembly may be partially clogged causing pump to operate at
very reduced capacity.
4. Check valve may be clogged causing low pump flow. Gate valve or
street valve may be in off position.
5. Pump may be air locked.
TROUBLESHOOTING

23833A59618
Circuitbreakertrips
Pump is noisy and pump rate
is low
Greaseandsolidshave
accumulatedaroundpump
and will not pump out of
basin
1. Resetbreakerbypushingcleardownonhandlethenbackto“ON”
position. If breaker trips again in few seconds it indicates excessive load
probably caused by a short in the motor or control box. Check out
instructions given with control box before pulling pump.
2. If this condition happens after an electrical storm, motor or control box
maybedamagedbylightning.
3. Resistance reading of the motor with lead wires disconnected from the
control box can determine if trouble is in motor or control box.
1. Grinder assembly may be partially clogged with some foreign objects
causingnoiseandoverload on the motor.
2. Grinderimpellermayberubbingongrinderringduetobentshaftor
misalignment.
1. Water shut-off level may be set too high or volume of pumping cycle may
be too great allowing solids to settle out of suspension. Set pump shut-
off level at the pumps widest part where volute case mates with seal
chamber - to 1”below. See Figure 47. Set water level control (float or
weight)tofollowingapprox.levels:
2 ft. dia. basin 12” - 14”
3 ft. dia. basin 6” - 8”
4 ft. dia. basin 6” - 7”
abovepumpshut-off.
2. Run pump on hand operation for several minutes with small amount of
water running into basin to clean oout solids and grease. This allows
pump to break suction and surge which will break up the solids. If level
switch lower weight or float is set properly this condition generally will not
occur.
3. Where all type switches are installed trash may have accumulated
around lower weight causing pump to turn off too soon. Clean trash from
weightandsuspensioncable.
Fig.47

23833A596 19
MOTORWIRING DIAGRAM
NOTE: ProbetestresistorisusedonD2CX20-21 ULexplosion-proof only.

23833A59620
PUMP DIMENSIONS