Power-flo PFG2002HV Troubleshooting guide

Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
ISP No: PFGrinder - 9/09
INSTALLATION, SERVICE & PARTS MANUAL
Power Flo Pumps & Systems 877 24PUMPS www poweropumps com
Series:
PFG2002HV & HH
PFG2022HV & HH
PFG2062HV & HH
PFG2032HV & HH
PFG2042HV & HH
Double Seal
2 HP • 3450 RPM • 60 Hz
Submersible Grinder Pump
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
2
General Safety Information
Model Number
MFG Date
AMPS VOLTAGE
PHASE
60 Hz HP
877-24 PUMPS
www.powerflopumps.com
C US
® Power-Flo is a registered trademark of Power-Flo Technologies Inc.
Other brand and product names are trademarks or registered trademarks of their respective holders.
Alteration Rights Reserved. 11/2007 - 3/08, 9/08, 6/09, 9/09
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 3 Phase Models
Amps: Amps L1-2: Volts L1-2:
Volts: Amps L2-3: Volts L2-3:
Amps L3-1: Volts L3-1:
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
Power-Flo pump is individually factory
tested to insure proper performance.
Closely following these instructions will
eliminate potential operating problems,
assuring years of trouble-free service.
ALL RETURNED
PRODUCTS MUST BE
CLEANED, SANITIZED,
OR RECONTAMINATED
PRIOR TO SHIPMENT,
TO INSURE EMPLOYEES WILL NOT
BE EXPOSED TO HEALTH HAZARDS
IN HANDLING SAID MATERIAL.
ALL APPLICABLE LAWS AND
REGULATIONS SHALL APPLY.
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.
• Risk of electric shock. To reduce risk of
electric shock, always disconnect pump
from power source before handling.
Lock out power & tag.
• Installation must be in accordance
with the National Electric Code and all
applicable state and local codes.
• Installation and servicing is to be
conducted by qualied personnel.
• These pumps are NOT to be installed
in locations classied as hazardous in
accordance with the National Electric
Code, ANSI/NFPA 70.
• 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 use power cord to lift pump.
Protect cable from cuts and punctures.
Do not handle power cable with wet
hands.
• Do not us these pumps in water over
145˚F. Consult Power-Flo for high
temperature pump models.
• 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 any
body of water with human
contact. Pumps when used as a
decorative water fountain
pump MUST be used in circuit
protected by a Ground Fault
Interrupter.
• 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.
PFG - HH & HV 2HP Submersible Grinder Pumps
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
3
Specications
C US
Description
Designed to reduce domestic, commercial, institutional
and light industrial sewage to a nely ground slurry.
Series: PFG2002HV & HH
PFG2022HV & HH
PFG2062HV & HH
PFG2032HV & HH
PFG2042HV & HH
2 HP • 3450 RPM • 60 Hz
Submersible Grinder Pump
DISCHARGE 1-1/4” NPT Vertical, Bolt-on Flange
LIQUID
TEMPERATURE 160°F 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 Powder Coated - Industrial Grade
SEAL Tandem Double Mechanical,
Carbon/Ceramic/Buna-N
UPPER BEARING Single row, Ball, Oil Lubricated
INTERMEDIATE
BEARING Single row, Ball, Oil Lubricated
LOWER BEARING Sleeve, Oil Lubricated
POWER CORD
PFG Series: 20 ft. Custom Molded, Fast
Disconnect, for Sealing and Strain Relief.
CSA approved, 12/4 Type SOW
MOTOR Oil Filled, Squirrel Cage Induction,
Class B Insulation
SINGLE PHASE
Capacitor Start/Capacitor Run. Includes
overload protection in the motor. Requires
starter or control panel which includes
capacitors.
THREE PHASE Dual Voltage 230/460.
NOTE: Consult factory before making modications as they may eect CSA
listing.
PFG - HH & HV 2HP Submersible Grinder Pumps
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
4
MODEL HP Hz Volts/Ph RPM Full Load
Amps
Locked
Rotor Amps
NEMA Start
Code
Cord
Type
Cord
Size
Cord
O.D.
High Volume
PFG2002HV* 2 60 200/1 3450 17.0 53.0 F SOW 12/4 .67
PFG2022HV* 2 60 230/1 3450 15.0 53.8 H SOW 12/4 .67
PFG2062HV 2 60 200/3 3450 11.0 42.0 J SOW 12/4 .67
PFG2032HV 2 60 230/3 3450 9.0 36.0 J SOW 12/4 .67
PFG2042HV 2 60 460/3 3450 4.0 18.0 J SOW 12/4 .67
High Head
PFG2002HH* 2 60 200/1 3450 17.0 53.0 F SOW 12/4 .67
PFG2022HH* 2 60 230/1 3450 15.0 53.8 H SOW 12/4 .67
PFG2062HH 2 60 200/3 3450 11.0 42.0 J SOW 12/4 .67
PFG2032HH 2 60 230/3 3450 9.0 36.0 J SOW 12/4 .67
PFG2042HH 2 60 460/3 3450 4.0 18.0 J SOW 12/4 .67
(*) 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 Power-Flo control panel is not used.
See page 13 for wiring schematic.
PF88243 - for 200 volt, 1 phase
PF73306 - for 230 volt, 1 phase
Specications
MODEL HP Volts/Ph BREAKER
SIZE
HEATER
SIZE (**)
VOLTAGE
RELAY
START
CAPACITOR
RUN
CAPACITOR
High Volume
PFG2002HV 2 200/1 30 Amp K-60 MARS 169 150 mfd - 250 volts 20 mfd - 450 volts
PFG2022HV 2 230/1 30 Amp K-57 MARS 169 150 mfd - 250 volts 45 mfd - 450 volts
PFG2062HV 2 200/3 20 Amp K-53 N/R N/R N/R
PFG2032HV 2 230/3 20 Amp K-50 N/R N/R N/R
PFG2042HV 2 460/3 15 Amp K-33 N/R N/R N/R
High Head
PFG2002HH 2 200/1 30 Amp K-60 MARS 169 150 mfd - 250 volts 20 mfd - 450 volts
PFG2022HH 2 230/1 30 Amp K-57 MARS 169 150 mfd - 250 volts 43 mfd - 450 volts
PFG2062HH 2 200/3 20 Amp K-53 N/R N/R N/R
PFG2032HH 2 230/3 20 Amp K-50 N/R N/R N/R
PFG2042HH 2 460/3 15 Amp K-33 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.
PFG - HH & HV 2HP Submersible Grinder Pumps
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5
Performance
PFG-HH, 2HP Submersible Grinder Pumps
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
6
Performance
PFG-HV 2HP Submersible Grinder Pumps
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
7
Dimensions
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
PFG 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 (with legs removed) or
by resting on oor of basin with legs
attached.
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
8”
Figure 1
PFG - HH & HV 2HP Submersible Grinder Pumps
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
8
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
Wire Size:
If longer power cable is required consult
a qualied electrician for proper wire
size.
Receiving & Installation
PFG - HH & HV 2HP Submersible Grinder Pumps
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9
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
8 & 9.
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 (4) from housing (15). With a
ashlight, visually inspect the oil in the
housing (15) 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 (5), from housing (15).
• 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 (4) from housing (15).
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 (4) from housing (15).
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
PFG - HH & HV 2HP Submersible Grinder Pumps
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10
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 (22) downward, remove plug (22)
and drain all oil from seal chamber. Aplly
pipe sealant to pressure gauge assembly
and tighten into hole in intermediate
coupling (21). 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
(4) then assemble to motor housing (15).
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 (22) upward, and rell with new oil,
see “Cooling Oil” chart. Apply pipe thread
compond to threads of pipe plug (22) and
assemble to intermediate coupling (21).
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 (40)
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 (29) counter-clockwise to
remove.
CAUTION ! - Cutter edges are
very SHARP. Cutter must be
removed before removing
volute.
Volute - Remove hex nuts (41) from studs
(34) and remove volute (25) from pump.
Shredding Ring - To replace or reverse
the shredding ring (27) press out using an
arbor press.
Impeller - Remove impeller (30) 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 (33) 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 (33).
Seal Plate - Remove cap screws (32) and
washers (11) from seal plate (31). Remove
seal plate (31) and square ring (24) from
intermediate coupling (21). With at
screwdriver, press out seal (33) stationary
member. Inspect square ring (24) for cuts
or abrasions.
Motor - Remove pipe plug (4) 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 (1) and lockwashers (2) from cable
assembly (3) and remove cable assemble
(3) by pulling straight up. Remove
retaining ring (38). Using a 1/4-20 bolt,
thread bolt into the center of the terminal
block (37) and pull straight up to remove.
Disconnect all wires, noting where each
was connected. There are numbers next
to the pins on the bottom of block, use
these for reference.
Remove cap screws (35) and lockwashers
(11) from motor housing (15). Vertically
lift motor housing (15) from intermediate
coupling (21) along with square ring (20),
replace if cut or damaged. Remove stator
bolts and carefully remove stator housing
from rotor. Pull rotor out with bearing (18)
and rotating member of inner seal.
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.
Service
PFG - HH & HV 2HP Submersible Grinder Pumps
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
11
Bearings & Inner Seal - Remove seal (19)
rotating member and spring from rotor
shaft. Press stationary from intermediate
(21) 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 (19).
Remove retaining ring (39) from shaft.
Using a wheel puller or arbor press
remove bearing (18) from shaft. Remove
upper motor bearing from shaft with a
bearing puller. (See Figure 3)
Check sleeve bearing (23) for excessive
wear, if replacement is required, press
sleeve from intermediate coupling (21).
IMPORTANT! - All parts must be
clean before reassembly.
Handle seal parts with extreme
care. DO NOT damage lapped
surfaces.
Reassembly
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 (18) onto rotor
shaft. Place lower retaining ring (39) onto
shaft.
Inner Seal - Clean and oil seal cavity
in intermediate coupling (21). Lightly
oil (Do not use grease) outer surface
of stationary member. Press seal’s
(19) stationary member rmly into
intermediate coupling (21), 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 (19) 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
(18) and seal parts (19) into intermediate
coupling (21) until bearing seats into
intermediate coupling. Install retaining
ring (39) into intermediate coupling (21).
Place motor stator over rotor, lining up
motor bolts with holes in intermediate
coupling (21). Place end bell on top of
motor and insert motor bolts and torque
to 17 in-lbs.
Set square ring (20) in grove on
intermediate coupling (21). Attach
ground wire (36) to end bell if removed.
Pull wires through opening in top of
motor housing (15) while lowering motor
housing onto intermediate coupling
(21). Connect wires to pins on bottom
of terminal block (37) as noted at
disassembly and/or see wiring digrams in
Figure 7.
Lubricate o-ring (9) with dielectric oil
and slide terminal block (37) back into
housing (15). Be sure terminal block is
engaged and install retaining ring (38).
Place cap screws (35) with lockwashers
(11) through housing (15) into
intermediate coupling (21) and tighten.
(See Figure 4)
Service
Figure 3
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12
Power Cable Connection - Check power
cord (3) for cracks or damage and replace
if required. Insert female end of cord
plug into housing bore aligning timing
mark with hole in terminal block (37)
see Figure (5). Compress cord plug with
compression ange by tightening cap
screws (1) with lock washers (2) into the
housing (15). Torque to 132 in-lbs.
Seal Plate - Lubricate and set square
ring (24) in bottom groove of seal plate
(31). Place seal plate (31) over shaft and
onto intermediate coupling (21), being
sure square ring (24) is not twisted and
in the groove. Place two capscrews (32)
with lockwashers (11) into seal plate and
torque to 6.5 ft/lbs.
Outer Seal - Clean and oil stationary
seal cavity in seal plate (31). Slide seal
guide tool over motor shaft. Lightly
oil (Do not use grease) outer surface
of seal’s (33) stationary member. Press
stationary rmly into seal plate (31) 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 6)
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 (30) 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.
Volute - Place volute (25) on seal plate
(31). Place nuts (41) with lockwashers
(11) onto studs (34) and torque evenly to
11 ft/lbs.
Note: Discharge must line up with notch
in motor housing.
Cutter - Screw radial cutter (29) onto
shaft, turning it clockwise while holding
the shaft stationary with a screwdriver.
The radial cutter (29) should be ush with
shredding ring (27), on suction side to
within ± .020. Place washer (28) on screw
(40), apply green Loctite on threads and
place into shaft and tighten.
Figure 5
Service
Figure 6
PFG - HH & HV 2HP Submersible Grinder Pumps
Figure 4
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
13
Figure 7 - 200/240 Volt, 3Phase
Figure 7 - 460 Volt, 3Phase
Figure 7 - 200/230 Volt, 1Phase
Pump Wiring Schematics
PFG - HH & HV 2HP Submersible Grinder Pumps
1Phase Capacitor & Relay Pack
For Control Panels:
2HP, 200 V, 1 Ph - P/N: PF88243
2HP, 230 V, 1PH - P/N: PF73306
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
14
Typical Panel Wiring Schematic
PFG - HH & HV 2HP Submersible Grinder Pumps
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
15
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.
PFG - HH & HV 2HP Submersible Grinder Pumps
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
16
Figure 9
PFG - HH & HV 2HP Submersible Grinder Pumps
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.
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
17
Ref. No. Qty Name Used On Part Number
1 2 Cap Screw 5/16-18 x 3/4” Lg., Stainless 
2 2 Lockwasher 5/16 Stainless 
31
Power Cord, 20 Ft. PF109492
4 1 Pipe Plug Counter Sunk, 3/8” NPT, Stainless 
5 2 Cap Screw 5/16-18 x 1-1/4”Lg., Stainless 
6 2 Washer 5/16” Stainless 
7 1 Discharge Flange PF108369
81
6O-ring PF2-31051-224
9 1 Handle PF103503
10 2 Cap Screw 5/16-18 x 3/4”Lg., Stainless 
11 10 Lockwasher 5/16 Stainless 
12 1 6O-ring PF2-31051-224
15 1 Housing PF105196
17 1 Motor
200/230 Volt 1 Ph PF110397BG
200 Volt, 3 Ph PF067571BG
230/460 Volt, 3 Ph PF067572BG
18 1 6Lower Bearing PF10-36-E4
19 1 6Inner Shaft Seal Carbon/Ceramic/Buna-N PF111131
20 1 6Square Ring PF074498
21 1 Bearing Bracket PF108879
22 1 Pipe Plug, 1/4” NPT 
23 1 Bronze Insert ----
24 1 6Square Ring PF067564
25 1 Volute PF108344
26 3 Pump Leg PF110660
27 1 6Shredding Ring HV PF082085A
HH PF082085B
28 1 6Impeller Washer PF067556
29 1 6Radial Cutter PF082088
30 1 Impeller HV PF109026B
HH PF109026BTD
31 1 Seal Plate PF108880
32 2 Cap Screw 5/16-18 x 1”Lg., Stainless 
33 1 6Outer Shaft Seal Carbon/Ceramic/Buna-N PF110395
34 4 Stud 5/16-18 x 2-1/4” Lg., Stainless 
35 6 Cap Screw 5/16-18 x 1-1/4”Lg., Stainless 
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.
PFG - HH & HV 2HP Submersible Grinder Pumps
= Aquire standard hardware locally.
= Cutter Kit
6= Overhaul Kit
= Supplied as individual items
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
18
PFG - HH & HV 2HP Submersible Grinder Pumps
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.
Ref. No. Qty Name Used On Part Number
36 1 Ground Wire, 10GA. PF105111A
37 1 Terminal Block PF103586
38 1 6Retaining Ring PF105197
39 1 6Retaining Ring PF061143
40 1 6Impeller Screw 1/4-20 x 3/4” Lg., Stainless PF070704
41 4 Hex Nut 5/16-18, Stainless 
Repair Kits
CUTTER KIT - Includes Item numbers: 27, 28, 29, 40 PFG2HV-CT
PFG2HH-CT
6OVERHAUL KIT - Includes Item numbers: 8, 12, 18, 19, 20, 24, 27, 28, 29, 33, 38, 39, 40 PFG2HV-OHK
PFG2HH-OHK
Capacitor Pack for PFG2002HV / HH Panel if other than a Power-Flo panel, 200 volt, 1 phase. PF88243
Capacitor Pack for PFG2022HV / HH Panell if other than a Power-Flo panel, 230 volt, 1 phase. PF73306
= Aquire standard hardware locally.
= Cutter Kit
6= Overhaul Kit
= Supplied as individual items
Notes:
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
19
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
Blown fuse or other interruption of
power; improper voltage.
Switch is unable to move to the “turn ON”position
due to interference with the side of basin or other
obstruction
Insucient liquid level
Defective level control
Check that the unit is securely plugged in. Have an
electrican check all wiring for proper connections
and adequate voltage and capacity.
Position the pump or switch so that it has adequate
clearance for free operation.
Make sure the liquid level is allowed to rise enough
to activate level control(s).
Remove and replace level controls
Pump will not turn o
Discharge is blocked or restricted
Check valve is stuck closed or installed backwards
Gate or ball valve is closed
Total lift is beyond pump’s capability
Pump impeller is jammed or volute casing is pluged
Check the discharge line for foreign material,
including ice if discharge line passes through or
into cold areas
Remove check valve(s) and examine for freedom of
operation and proper installation
Open gate or ball valve
Try to route piping to a lower level.
If not possible, a larger pump may be required.
Consult the factory
Disconnect unit electrically. Remove the pump
from the basin. Detach the pump base and clean
the area around the impeller. Rotate impeller by
hand. Reassemble and reinstall
Pump will not turn o
Level control(s) unable to move to the“turn OFF”
position due to interference with the side of basin
or other obstacle
Defective level control
Posistion the pump or level control so that it has
adequate clearance for free operation
Remove and replace level control
Pump runs periodically when xtures are not in use
Check valve is stuck open or is leaking
Fixtures are leaking
Remove check valve(s) and examine for freedom of
operation and proper installation
Repair xtures as required to eliminate leakage
Pump operates noisily
Debris in the impeller cavity
Damaged impeller
Worn bearings
Piping attachments to building are too rigid
Remove the pump from the basin.
Detach the pump base and clean the area around
the impeller. Reassemble and reinstall
Consult the factory for information regarding
replacement of impeller
Return pump to the factory or authorized repair
station for repair
Replace a portion of the discharge line with rubber
hose or connector
NOTE: Power-Flo Pumps & Systems assumes no responsibility for damage or injury due to disassembly in the eld. Disassembly of the pumps or supplied
accessories other than at Power-Flo Pumps & Systems or its authorized service centers, automatically voids warranty.
Trouble Shooting Chart
PFG - HH & HV 2HP Submersible Grinder Pumps
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Power-Flo Pumps & Systems • 877-24PUMPS • www.poweropumps.com
20
LIMITED 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 at: 1-877-24PUMPS or
www.poweropumps.com, Attention: Customer Service Department, to obtain any needed repair or replacement
of part(s) or additional information pertaining to our warranty.
MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR SPECIAL, CONSEQUENTIAL OR INCIDENTAL
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.
PFG - HH & HV 2HP Submersible Grinder Pumps
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