Barnes 3SE1524L, 3SE1544L, 3SE1594L, 3SE2094L, 3SE2024L Installation And Operation Manual

®

Manual Index

BARNES

INSTALLATION and OPERATION MANUAL

Submersible Sewage Ejector

Series: 3SE-L

1.5 & 2HP
1750RPM, 60Hz

(Single Seal)

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 reserves the right to
change product without prior written noti• cation.

A Crane Co. Company

420 Third Street 83 West Drive, Brampton
Piqua, Ohio 45356 Ontario, Canada L6T 2J6
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]
www.cranepumps.com

Form No. 132724-Rev. C

TABLE OF CONTENTS

A. PUMP SPECIFICATIONS ................................................................... 4

B. GENERAL INFORMATION ................................................................. 5

C. INSTALLATION ................................................................................... 5 - 6

ELECTRICAL DATA ............................................................................ 7

D. START-UP OPERATION ..................................................................... 6

E. PREVENTATIVE MAINTENANCE ...................................................... 6 - 8

F. SERVICE and REPAIR ....................................................................... 8 - 11

G. REPLACEMENT PARTS ..................................................................... 12

TROUBLE SHOOTING ....................................................................... 14

CROSS-SECTION (Figure 11) ............................................................ 15

EXPLODED VIEW (Figure 12) ............................................................ 16

PARTS LIST ....................................................................................... 17 - 18

SAFETY FIRST ................................................................................... 3

WARRANTY ........................................................................................ 19

WARRANTY REGISTRATION ............................................................ 20

RETURNED GOODS POLICY ............................................................ 20

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 Crane Pumps & Systems, Inc
1994, 2002, 3/06, 9/06 Alteration Rights Reserved

2

SAFETY FIRST!

Please Read This Before Installing Or Operating Pump. This
information is provided for SAFETY and to PREVENT
EQUIPMENT PROBLEMS. To help recognize this information,
observe the following symbols:

Do not block or restrict discharge hose, as discharge hose
may whip under pressure.

IMPORTANT! Warns about hazards that can result in
personal injury or Indicates factors concerned with assembly,
installation, operation, or maintenance which could result in
damage to the machine or equipment if ignored.

CAUTION ! Warns about hazards that can or will cause minor personal
injury or property damage if ignored. Used with symbols below.

WARNING ! Warns about hazards that can or will cause serious
personal injury, death, or major property damage if ignored. Used with
symbols below.

Hazardous fl uids can
cause fi re or explo­sions, burnes or death
could result.

Biohazard can cause
serious personal injury.

Rotating machinery
Amputation or severe
laceration can result.

Only qualifi ed personnel should install, operate and repair pump. Any
wiring of pumps should be performed by a qualifi ed electrician.

WARNING ! - To reduce risk of electrical shock, pumps and
control panels must be properly grounded in accordance with
the National Electric Code (NEC) or the Canadian Electrical
Code (CEC) and all applicable state, province, local codes and
ordinances.

WARNING! - To reduce risk of electrical shock, always
disconnect the pump from the power source before handling
or servicing. Lock out power and tag.

WARNING! 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.

CAUTION ! Never operate a pump with a plug-in type
power cord without a ground fault circuit interrupter.

Extremely hot - Severe
burnes can occur on contact.

Hazardous fl uids can Hazard­ous pressure, eruptions or ex­plosions could cause personal
injury or property damage.

Hazardous voltage can
shock, burn or cause death.

WARNING! - DO NOT wear loose clothing that may
become entangled in the impeller or other moving parts.

WARNING! - Keep clear of suction and discharge openings.
DO NOT insert fi ngers in pump with power connected.

Always wear eye protection when working on pumps.

Make sure lifting handles are securely fastened each time
before lifting. DO NOT operate pump without safety devices
in place. Always replace safety devices that have been
removed during service or repair. Secure the pump in its
operating position so it can not tip over, fall or slide.

DO NOT exceed manufacturers recommendation for
maximum performance, as this could cause the motor to
overheat.

DO NOT remove cord and strain relief. Do not connect
conduit to pump.

WARNING! Cable should be protected at all times to avoid
punctures, cut, bruises and abrasions - inspect frequently.
Never handle connected power cords with wet hands.

WARNING! 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.

WARNING! Submersible Pumps are not approved for use in
swimming pools, recreational water installations, decorative
fountains or any installation where human contact with the
pumped fl uid is common.

WARNING! Products Returned Must Be Cleaned, Sanitized,
Or Decontaminated As Necessary Prior To Shipment, To
Insure That Employees Will Not Be Exposed To Health
Hazards In Handling Said Material. All Applicable Laws And
Regulations Shall Apply.

Bronze/brass and bronze/brass fi tted pumps may contain
lead levels higher than considered safe for potable water
systems. Lead is known to cause cancer and birth defects or
other reproductive harm. Various government agencies 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.

CAUTION! Pumps build up heat and pressure
during operation-allow time for pumps to cool
before handling or servicing.

WARNING! - DO NOT pump hazardous materials
(fl ammable, caustic, etc.) unless the pump is specifi cally
designed and designated to handle them.

IMPORTANT! - Crane Pumps & Systems, Inc. is not
responsible for losses, injury, or death resulting from a failure
to observe these safety precautions, misuse or abuse of pumps
or equipment.

3

SECTION: A - PUMP SPECIFICATIONS:

DISCHARGE .................. 3” NPT, Vertical

L

IQUID TEMPERATURE .. 104°F (40°C) Continuous

MOTOR HOUSING ........ Cast Iron ASTM, Class 30

VOLUTE ......................... Cast Iron ASTM, Class 30

SEAL PLATE .................. Cast Iron ASTM, Class 30

IMPELLER:

Design ...........2 Vane, Open with Pump out vanes

on Back side. Dynamically
balanced, ISO G6.3

Material ........ Cast Iron, Class 30

SHAFT ............................ 416 Stainless Steel

SQUARE RINGS ............ Buna-N

HARDWARE ................... 300 Series Stainless Steel

PAINT ............................. Air dry enamel, top coat

SEAL Design .......... Single Mechanical in oil ! lled

reservoir

Material ........ Rotating Faces - Carbon

Stationary Faces - Ceramic
Elastomer - Buna-N
Hardware - 300 series stainless steel

CORD ENTRY ................ 30 ft. (9.1m) Cord. Quick connect

custom molded for sealing and strain
relief

SPEED ........................... 1750RPM, 60Hz (nominal)

UPPER BEARING:

1.5 & 2HP ..... Single Row, Ball, Oil Lubricated

Load ............. Radial

LOWER BEARING:

Design .......... Single Row, Ball, Oil Lubricated

Load ............. Radial & Thrust

MOTOR: Design .......... NEMA L, Single phase,

NEMA B, Three Phase Torque Curve,
Oil Filled, Squirrel Cage Induction

Insulation ...... Class B for 1.5 & 2HP

Class F on selected models

SINGLE PHASE ............. Permanent Split Capacitor (PSC)

includes overload protection in motor

THREE PHASE .............. 200-230/460, 60Hz is Tri voltage

motor, 575V. Requires overload
protection to be included in control
panel

OPTIONAL EQUIPMENT ..Seal Material, Impeller Trims,
Additional Cord, Normally Closed Temperature Sensors with
cord for 3 phase pumps (Requires relay in control panel)

inches

(mm)

IMPORTANT !

1.) PUMP MAY BE OPERATED “DRY” FOR EXTENDED PERIODS WITHOUT DAMAGE TO MOTOR AND/OR SEALS.

2.) THIS PUMP IS APPROPRIATE FOR THOSE APPLICATIONS SPECIFIED AS CLASS I DIVISION 2 HAZARDOUS LOCATIONS.

3.) THIS PUMP IS NOT APPROPRIATE FOR THOSE APPLICATIONS SPECIFIED AS CLASS I DIVISION 1 HAZARDOUS LOCATIONS.

4.) INSTALLATIONS SUCH AS DECORATIVE FOUNTAINS OR WATER FEATURES PROVIDED FOR VISUAL ENJOYMENT MUST BE INSTALLED IN

ACCORDANCE WITH THE NATIONAL ELECTRIC CODE ANSI/NFPA 70 AND/OR THE AUTHORITY HAVING JURISDICTION. THIS PUMP IS NOT

INTENDED FOR USE IN SWIMMING POOLS, RECREATIONAL WATER PARKS, OR INSTALLATIONS IN WHICH HUMAN CONTACT WITH PUMPED

MEDIA IS A COMMON OCCURRENCE.

4

SECTION B: GENERAL INFORMATION

B-1) To the Purchaser:

Congratulations!
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
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, fi le 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 effi cient
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 unit 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). 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 Service Center, check
your Barnes representative or Crane Pumps & Systems, Inc.,
Service Department in Piqua, Ohio, telephone [phone]
or Crane Pumps & Systems Canada, in Brampton, Ontario,
[phone].

You are the owner of one of the fi nest pumps

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” (see Figure 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 back­fl ow into the sump. Excessive backfl ow can cause fl ooding
and/or damage to the pump. The shut-off valve is used to
stop system fl ow during pump or check valve servicing.

FIGURE 1

Barnes Pumps offers a Break Away Fitting (BAF) discharge
system designed to allow the submersible wastewater pump
to be installed or removed without requiring personnel to enter
the wet well.

Place the 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 fi tting. Once the rails are in
proper alignment, bolt the base into the fl oor of the station and
connect the discharge pipe to the elbow.

SECTION C: INSTALLATION

C-1) Location:

These pumping units are self-contained and are
recommended for use in a sump, lift station or basin.
sump, lift station or basin shall be vented in accordance
with local plumbing codes. This pump is designed to pump
sewage, effl uent, or other nonexplosive or noncorrosive
wastewater. and shall NOT be installed in locations classifi ed
as Class I Division 1 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.

The

Connect the movable portion and other supplied fi ttings 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
specifi cations. 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.

5

C-4) Electrical Connections:
C-4.1) Power Cable:

T

he cord assembly 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 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-4.4) Wire Size:

Consult a quali• ed electrician for proper wire size if additional
power cable length is required. See table for electrical
information.

SECTION: D START-UP OPERATION

D-1) Check Voltage and Phase:

B

efore operating pump, compare the voltage and phase
information stamped on the pump identi• cation plate to the
available power.

C-4.2) Control Cable:

The cord assembly 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 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 recti• ed
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 recti• ed
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
220-240 1.50 15.0
440-480 0.75 7.5
575-600 0.60 6.0

Inrush

Amperes

D-2) Check Pump Rotation:

Before putting pump into service for the • rst 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 Service Center.

D-3) Identifi cation Plate:

Record the numbers from the pump identi• cation plate for
future reference.

D-3.1) 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.

D-3.2) 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 • 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.

SECTION E: PREVENTATIVE MAINTENANCE

As the motor is oil • lled, no lubrication or other
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:

maintenance

6

MODEL

NO

HP VOLT/PH Hz RPM

(Nom)

NEMA

START

CODE

INSUL.
CLASS

FULL
LOAD
AMPS

LOCKED

ROTOR

AMPS

CORD

SIZE

CORD

TYPE

CORD

O.D

inch (mm)

WINDING RESISTANCE

EMERSON

MAIN-START

G.E.

MAIN-START

3SE1524L 1.5 230/1 60 1750 C F 16.0 44.6 12/3 SOOW / SOW 0.61 (15.5) 1.21 - 2.80 --­3SE1594L 1.5 200-230/3 60 1750 D/G F 13.3/11.6 35.8/41.2 12/4 SOOW / SOW 0.68 (17.4) 2.21 2.23
3SE1544L 1.5 460/3 60 1750 G F 5.8 20.6 14/4 SOOW / SOW 0.57 (14.5) 8.84 8.92
3SE1554L 1.5 575/3 60 1750 G B 4.6 16.4 14/4 SOOW / SOW 0.57 (14.5) 13.79 13.95

3SE2024L 2.0 230/1 60 1750 A F 19.0 44.6 10/3 SOOW / SOW 0.66 (16.8) 1.21 - 2.80 1.35 - 4.20
3SE2094L 2.0 200-230/3 60 1750 B/D F 15.2/13.2 35.8/41.2 12/4 SOOW / SOW 0.68 (17.4) 2.21 2.23
3SE2044L 2.0 460/3 60 1750 D F 6.6 20.6 14/4 SOOW / SOW 0.57 (14.5) 8.84 8.92
3SE2054L 2.0 575/3 60 1750 D B 5.2 16.4 14/4 SOOW / SOW 0.57 (14.5) 13.79 13.95

Winding Resistance ± 5%, measured from terminal block. Pump rated f
OPTIONAL - Temperature sensor cord for 3 phase models are 14-3 / 18-5 SOOW/SOW, 0.53 (13.5mm) / 0.47 (11.9mm) O.D.

or operation at ± 10% voltage at motor

7

1) Inspect motor chamber for oil level and contamina

tion and

repair as required per paragraph F-1.

2) Inspect impeller and body for excessive build-up or clogging
and repair as required per paragraph F-2.

3) Inspect motor and bearings and replace as required per
paragraph F-3.

4) Inspect seal for wear or leakage and repair as required per
paragraph F-4.

SECTION F: SERVICE AND REPAIR

NOTE: All item numbers in ( ) refer to Figures 11 & 12.

F-1) Lubrication:

Anytime the pump is removed from operation, the cooling oil
in the motor housing (5) should be checked visually for oil
level and contamination.

F-1.1) Checking Oil:
Motor Housing - To check oil, set unit upright. Remove pipe

plug (19) from housing (5). With a ! ashlight, visually inspect
the oil in the motor housing (5) 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 a vertical position.

F-1.2) Testing Oil:

1. Place pump on it’s side, remove pipe plug (19), from motor
housing (5) 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), re" ll the motor housing as per
paragraph 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 (31), cable assemblies
(30) and (32 if used), square ring (8) and pipe plug (19)
before re" lling with oil. To locate the leak, perform
a pressure test as per paragraph F-1.3. After leak is
repaired, re" ll with new oil as per paragraph F-1.4.

pressure and remove the gauge assembly. If the pressure
does not hold, then the leak must be located and repaired.

WARNING ! - Pressure builds up due to heat.

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.

FIGURE 2

F-1.4) Replacing Oil:
Motor Housing- Set unit upright and re" ll with new cooling

oil as per Table 1 (see parts list for amount). Fill to just above
motor as an air space must remain in the top of the motor
housing to compensate for oil expansion (see Figure 2, 11 or

12). Apply pipe thread compound to threads of pipe plug (19)
then assemble to motor housing (5).

IMPORTANT! - For single phase units, oil level
should be below capacitor.

F-1.3) Pressure Test:
Pumps that have had the oil drained from the Motor
Housing - Apply pipe sealant to pressure gauge assembly

and tighten into pipe plug hole (See Figure 2). 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 as described in
paragraph F-1.4. If the pressure does not hold, then the leak
must be located and repaired.

Pumps that have NOT had the oil drained from the Motor
Housing - The pressure test may be done with the oil at its

normal level. Remove pipe plug (19) from motor housing (5).
Apply pipe sealant to pressure gauge assembly and tighten
into hole (see Figure 2). 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
the oil level, leaks will seep oil.
If, after " ve minutes, the pressure is still holding constant,
and no “bubbles”/oil seepage is observed, slowly bleed the

WARNING ! - DO NOT over" ll oil.
Over" lling of motor housing with oil
can create excessive and dangerous
hydraulic pressure which can destroy the
pump and create a hazard. Over" lling oil
voids warranty.

TABLE 1 - COOLING OIL - Dielectric

SUPPLIER GRADE

Sohio / Standard SE 40, Energol HL22 or HL32

Shell Turbo Oil 32

Texaco Rando HD32, 522

Sun Petroleum Supar 110, Sunvis 816WR, 911

or 916

Mobile D.T.E. Oil Light or Rubrex 200

G&G Circu Oil 22

Allegheny Petroleum Altrapar 22

Woco Premium 100

8

F-2) Impeller and Volute Service:
F

-2.1) Disassembly and Inspection:

To clean out volute (24) or replace impeller (29), disconnect
power, remove screws (12), and lockwashers (11), vertically
lift motor and seal plate assembly from volute (24). Clean
out volute if necessary. Clean and examine impeller (29), for
pitting or wear and replace if required, inspect gasket (10)
and replace if cut or damaged. If the impeller (29) needs

replacing, remove nut (3), place a • at screwdriver in the
slot of the end of the shaft to hold the shaft stationary while
unscrewing the impeller (29). (See Figure 11 or 12)

F-2.2) Reassembly:

To install impeller (29), screw impeller onto the shaft hand tight.
Clean the threads with Loctite cleaner. Apply thread locking
compound to shaft threads and install nut (3). Torque to 40
ft. lbs. Rotate impeller to check for binding. Position gasket
(10) on volute • ange and position impeller and motor housing
on volute (24). Position lockwashers (11) on cap screws (12)
and screw into volute (24). Torque to 8 ft. lbs. Check for free
rotation of motor and impeller. (See Figure 11 or 12)

F-3) Motor and Bearing Service:
F-3.1) Disassembly and Inspection:

To examine or replace the motor (20), capacitor (21, single
phase units), and bearing (6), drain oil from motor as outlined
in paragraph F-1.2. Disassemble volute and impeller as
outlined in paragraph F-2.1 and disassemble shaft seal as
outlined in paragraph F-4.1. (See Figure 3, 4, and 11)

and lift motor stator from seal plate (1). Disconnect capacitor
leads from capacitor (21, single phase units). Examine
bearing (6) and replace if required. If replacement is required,
remove bearing (6) from motor shaft using a wheel puller or
arbor press, see Figure 4.

FIGURE 4

Check motor capacitor (21, single phase units) with an

Ohm meter by ! rst grounding the capacitor by placing
a screwdriver across both terminals and then removing
screwdriver. Connect Ohm meter (set on high scale) to
terminals. If needle moves to in! nity (") then drifts back,
the capacitor is good. If needle does not move or moves to
in! nity (") and does not drift back, replace capacitor (21).
To test the temperature sensor (P1 / P2, optional), check for
continuity between the wire leads (see Figure 10). If found
to be defective, contact a motor service station or Barnes
Pumps Service department. 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.

FIGURE 3

Position unit upright, using blocks to avoid resting unit on
shaft. Unscrew cable hex bolts (16) and remove compression

• ange (30a) and power cord (30). Remove snap ring (41) with
a • at head screwdriver. Pull the terminal block (23) out of the
housing (5) using a T-bolt or pair of pliers and a 1/4”-20 screw
in the threads of the terminal block (23). Be sure to leave
slack on the motor leads connected underneath. Use needle
nose pliers to pull each female connector off of the pins on
the underside of the terminal block (23) (see Figure 5). The
unit voltage should be noted. Repeat cable and terminal block
removal procedure for any control cables (32) if equipped.
Remove socket head cap screws (9). Vertically lift the motor
housing (5) from seal plate (1) by lifting handle (17). Inspect
square ring (8) for damage or cuts. Remove the motor bolts

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. Apply
adhesive compound to the shaft and press bearing (6) on the
motor shaft, position squarely onto the shaft applying force to
the inner race of the bearing only, until bearing seats against
the retaining ring (2).

9

POWER CORD (30)

CONTROL CORD (32)

CAP SCREW (16)

LOCKWASHER (11)

COMPRESSION FLANGE (30a)

SNAP RING (41)

O-RING (40)

TERMINAL BLOCK (23)

TERMINAL TERMINAL

FIGURE 5

Motor - Slide lower bearing (6) and motor shaft squarely

into the seal plate (1) until bearing seats on the bottom. Place
stator over rotor, lining up motor bolts with holes in seal plate
(1). Position capacitor (21, single phase units) so that it will
lay on the opposite side of the cable entry bosses of the
motor housing (5). Reconnect capacitor leads. Torque motor
tie bolts to 17 in-lbs. Set square ring (8) in groove on seal
plate (1).

F-3.3) Wiring Connections:

Check power cables (30) and control cable (32, if used), for
cracks or damage and replace if required (see Figure 5).
Make internal wiring connections which are independent of
the terminal block as shown in (Figure 10), using connectors
(14), terminal (15) and wire assemblies (18) as required. Do
not use wire nuts. Slip motor leads and ground wire through
! berglass sleeve. Lower motor housing (5) down onto seal
plate (1) while aligning holes and stringing motor leads
through the cable entry bore(s). (Slipping cords inside a 1 ft.
length of .5” conduit makes this easier). Place socket head
cap screws (9) through seal plate (1) into motor housing (5)
and torque to 60 in-lbs.

CAP SCREW (16)

LOCKWASHER (11)

COMPRESSION FLANGE (32a)

SNAP RING (41)

O-RING (40)

TERMINAL BLOCK (38)

Reconnect motor and optional control leads to the underside
of the terminal block(s) (23), (38 optional) as shown in Figure

5. Note that the pins are numbered underneath the terminal
block. Place o-ring (40) into groove in terminal block and
lubricate with dielectric oil. Press the terminal block (23) (38
optional) into the housing so it seats completely below the
snap ring groove. Place snap ring (41) into groove in cable
entry bore of housing. Repeat terminal block installation for
control cable, if equipped.

F-3.4) Cable Assemblies:

Power/Control Cable- Re! ll the cooling oil as outlined in
paragraph F-1.4. Make wire connections as outlined in
paragraph F-3.3. Insert female end of cable plug into housing
bore aligning timing mark with hole in terminal block (23)
(38 optional) (see Figure 6). Compress cable plug with

compression fl ange (30a)(32a) by tightening cap screws (16)
into the housing (5). Torque to 132 in-lbs.

F-4) Shaft Seal Service:

Important ! - Handle seal parts with extreme care.
DO NOT scratch or mar lapped surfaces.

FIGURE 6

F-4.1) Disassembly and Inspection:

To expose shaft seal (31) for examination disassemble volute
and impeller as outlined in paragraph F-2.1. If further repair
is required remove retaining ring (31d), spring (31c) and
rotating member (31b) from shaft (see Figure 9). 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.

10

Stationary Member (31A)
Polished Face Out

Motor & Bearing Bracket

Rotating Member (31B)

Stationary

Seal Plate (1)

FIGURE 7

Seal Pusher

DO NOT interchange seal components, replace the entire
shaft seal (31). If replacing seal, remove stationary (31a) by

prying out with •

at screw driver.

F-4.2) Reassembly:

Seal - Clean and oil seal cavities in seal plate (1). Lightly oil
(DO NOT use grease) outer surface of stationary member

(31a). Press stationary member (31a) ! rmly into seal plate
(1), 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 7).

Bullet

FIGURE 8

Seal Pusher

Important ! - DO NOT Hammer On The Seal
Pusher- It Will Damage The Seal Face.

Make sure the stationary member is in straight. Slide a bullet
(see parts list-seal tool kit) over motor shaft. Lightly oil (DO
NOT use grease) shaft, bullet and inner surface of bellows on
rotating member (31b) (see Figure 8). With polished surface
of rotating member (31b) facing inward toward stationary
member (31a), slide rotating member (31b) over bullet and
onto shaft, using seal pusher, until polished faces of (31a)
and (31b) are together (see Figure 9).

It is extremely important to keep seal faces clean during
assembly. Dirt particles lodged between these faces will
cause the seal to leak.

Place spring (31c) over shaft and in place on rotating member
(31b), making sure it is seated on retainer and not cocked or
resting on bellows tail. Slide retaining ring (31d) over shaft
and let rest on spring (31c). Assemble impeller and volute
as outlined in paragraph F-2.2. Replace oil as outlined in
paragraph F-1.4.

SEAL ASSEMBLY (31)

FIGURE 9

RETAINING RING (31D)

SEAL PLATE (1)

SPRING (31C)

ROTATING MEMBER (31B)

STATIONARY (31A)

11

SECTION: G REPLACEMENT PARTS

G-1 ORDERING REPLACEMENT PARTS:

W

hen ordering replacement parts, ALWAYS furnish the

following information:

G-2 PART NUMBER:

The part number consists of a six (6) digit number, which
appears in the catalog. A one or two letter suf! x may follow this
number to designate the design con! guration. This number is
used for ordering and obtaining information.

1. Pump serial number and date code. (Paragraph G-4)

2. Pump model number. (Paragraph G-3)

3. Pump part number. (Paragraph G-2)

4. Part description.

5. Item part number.

6. Quantity required.

7. Shipping instructions.

8. Billing Instructions.

2

3

1

G-3 MODEL NUMBER:

This designation consists of numbers and letters which
represent the discharge size, series, horsepower, motor phase
and voltage, speed and pump design. This number is used for
ordering and obtaining information.

G-4 SERIAL NUMBER:

The serial number block will consist of a six digit number,
which is speci! c to each pump and may be preceded by
a alpha character, which indicates the plant location. This
number will also be suf! xed with a four digit number, which
indicates the date the unit was built (Date Code). EXAMPLE:
A012345 0490.

Reference the six digit portion (Serial Number) of this number
when referring to the product.

12

FIGURE 10

13

TROUBLE SHOOTING

CAUTION ! Always disconnect the pump from the electrical power source before handling.

If the system fails to operate properly, carefully read instructions and perform maintenance recommendations.
If operating problems persist, the following chart may be of assistance in identifying and correcting them:

MATCH “CAUSE” NUMBER WITH CORRELATING “CORRECTION” NUMBER.

NOTE: Not all problems and corrections will apply to each pump model.

PROBLEM CAUSE CORRECTION

Pump will not run

Pump will not turn off 2a. Float movement restricted.

Pump hums but does not run 1. Incorrect voltage

Pump delivers insuffi cient capacity 1. Incorrect voltage.

Pump cycles too frequently or runs
periodically when fi xtures are not in use

Pump shuts off and turns on independent of
switch, (trips thermal overload protector).
CAUTION! Pump may start unexpectedly.
Disconnect power supply.

Pump operates noisily or vibrates excessively 2c. Worn bearings, motor shaft bent.

. Poor electrical connection, blown fuse, tripped

1

breaker or other interruption of power, improper
power supply.

2. Motor or switch inoperative (to isolate cause, go
to manual operation of pump).

2a. Float movement restricted.
2b. Switch will not activate pump or is defective.
2c. Defective motor

3. Insuffi cient liquid level.

2b. Switch will not activate pump or is defective.

4. Excessive infl ow or pump not properly sized for
application.

9. Pump may be airlocked

14. H-O-A switch on panel is in “HAND” position

8. Impeller jammed or loose on shaft, worn or
damaged, impeller cavity or inlet plugged.

4. Excessive infl ow or pump not properly sized for
application.

5. Discharge restricted.

6. Check valve stuck closed or installed backwards.

7. Shut-off valve closed.

8. Impeller jammed or loose on shaft, worn or
damaged, impeller cavity or inlet plugged.

9. Pump may be airlocked.

10. Pump running backwards

6. Check valve stuck closed or installed backwards.

11. Fixtures are leaking.

15. Ground water entering basin.

1. Incorrect voltage.

4. Excessive infl ow or pump not properly sized for
application.

8. Impeller jammed, loose on shaft, worn or dam­aged, impeller cavity or inlet plugged.

12. Excessive water temperature.
(internal protection only)

5. Debris in impeller cavity or broken impeller

10. Pump running backwards

13. Piping attachments to buiding structure too
rigid or too loose.

1. Check all electrical connections for security.
Have electrician measure current in motor leads,
if current is within ±20% of locked rotor Amps,
impeller is probably locked. If current is 0,
overload may be tripped. Remove power, allow
pump to cool, then recheck current.
2a. Reposition pump or clean basin as required to
provide adequate clearance for fl oat.
2b. Disconnect level control. Set ohmmeter for
a low range, such as 100 ohms full scale and
connect to level control leads. Actuate level
control manually and check to see that ohmmeter
shows zero ohms for closed switch and full scale
for open switch. (Float Switch).
2c. Check winding insulation (Megger Test) and
winding resistance. If check is outside of range,
dry and recheck. If still defective, replace per
service instructions.

3. Make sure liquid level is at least equal to
suggested turn-on point.

4. Recheck all sizing calculations to determine
proper pump size.

5. Check discharge line for restrictions, including
ice if line passes through or into cold areas.

6. Remove and examine check valve for proper
installation and freedom of operation.

7. Open valve.

8. Check impeller for freedom of operation,
security and condition. Clean impeller and inlet of
any obstruction.

9. Loosen union slightly to allow trapped air to
escape.Verify that turn-off level of switch is set so
that the suction is always fl ooded. Clean vent hole.

10. Check rotation. If power supply is three phase,
reverse any two of three power supply leads to
ensure proper impeller rotation.

11. Repair fi xtures as required to eliminate
leakage.

12. Check pump temperature limits & fl uid
temperature.

13. Replace portion of discharge pipe with fl exible
connector.

14. Turn to automatic position.

15. Check for leaks around basin inlet and outlets.

14

FIGURE 11

15

FIGURE 12

16

PARTS KITS

SEAL

REPAIR KIT: 1.5 & 2.0HP............ P/N 130181

SERVICE: 1.5 & 2.0HP .......................... P/N 130208

(+) 8, 10, 31, 40

(◊) 2

, 3, 6, 8, 10, 14, 15, 18, 25, 31, 34, 35, 40, 41

TOOLS: Seal Pusher........... .................. P/N- TL-21360

Bullet ....................................... P/N- TL-21375

PRESSURE GAUGE KIT ....................... P/N 085343

PARTS LIST - Standard

ITEM QTY PART NO. DESCRIPTION

1 084343 Seal Plate

1

2 1 061143 ◊ Retaining Ring
3 1 038132 ◊ Nut 5/8-18 Stainless
5 1 105196 Motor Housing (Std)
105196HA (Optional) temp. sensor
6 1 039734 ◊ Bearing 1.5 & 2HP
7 1 016660 Screw #8-32, ⅜ lg Stainless
8 1 027269 +◊ Square Ring
9 2 084948 Soc. Hd Screw 1/4-20 x 1-1/4” lg Stainless
10 1 027344 +◊ Gasket
11 8 026322 Lockwasher (Std), 5/16, Stainless
10 026322 (Optional) temp. sensor
12 4 1-140-1 Cap Screw
13 105 oz. 029034 Oil
14 4 105150 ◊ Connector 230V 3 Phase
3 019212 ◊ 460V ONLY
15 3 111951 ◊ Terminal 460V ONLY
16 4 1-156-1 Hex. Hd. Cap Screw (Std), 5/16-18 x 1.00” Lg., Stainless
6 1-156-1 Hex. Hd. Cap Screw (Optional) temp. sensor
17 1 103503 Handle
18 3 105149A ◊ Wire Assemblies (3 Phase) 230V
19 1 014270 Pipe Plug .375” NPT
20 1 084382MA Motor 3SE1524L, 3SE2024L
084383MA 3SE1594L, 3SE1544L
084383MA 3SE2094L, 3SE2044L
092856 3SE1554L, 3SE2054L
21 1 036391 Capacitor (1 phase) 370V, 45MFD
22 1 039858 Capacitor Bracket (1 phase)
23 1 See Table 2 Terminal Block
24 1 084399 Volute
25 1 625-02117 ◊ Sleeve, Fiberglass 230V 1 Phase, 460V 3 Phase, 575V 3 Phase
2 625-02117 230V 3 Phase
29 1 See Table 3 Impeller, Cast Iron
30 1 See Table 2 Power Cable Set
31 1 067562 +◊ Shaft Seal Carbon/Ceramic/Buna-N (STD)
067562SB Tungsten/Tungsten/Buna-N (Optional)
067562SD Silicon/Silicon/Buna-N (Optional)
32 1 See Table 2 Control Cable (Optional) temp. sensor
34 1 105111 ◊ Ground Wire 460V 3 Phase, 575V 3 Phase
1 105111A ◊ 230V 1 Phase
1 105111B ◊ 230V 3 Phase
35 1 105111 ◊ Ground Wire (Optional) temp. sensors
38 1 See Table 2 Terminal Block (Optional) temp. sensors
40 1 2-31051-224 +◊ O-ring (Std)
1 2-31051-224 (Optional) temp. sensor
41 1 105197 ◊ Snap Ring (Std)
1 105197 (Optional) temp. sensor

17

TABLE 2 - POWER & SENSOR CORD SETS

MODEL NO 30 FT. POWER 50 FT. POWER 100 FT. POWER

3SE1524L 109498XC 109498XF 109498XL 103760
3SE1594L 109492XC 109492XF 109492XL 103586
3SE1544L 103742XC 103742XF 103742XL 103583
3SE1554L 103742XC 103742XF 103742XL 103583
3SE2024L 103769XC 103769XF 103769XL 103760
3SE2094L 109492XC 109492XF 109492XL 103586
3SE2044L 103742XC 103742XF 103742XL 103583
3SE2054L 103742XC 103742XF 103742XL 103583

MODEL NO 30 FT. TEMP. SENSOR 50 FT. TEMP. SENSOR 100 FT. TEMP. SENSOR

3SE1524L None None None None
3SE1594L 103741XC 103741XF 103741XL 103584
3SE1544L 113288XC 113288XF 113288XL 113272
3SE1554L 113288XC 113288XF 113288XL 113272
3SE2024L None None None None
3SE2094L 103741XC 103741XF 103741XL 103584
3SE2044L 113288XC 113288XF 113288XL 113272
3SE2054L 113288XC 113288XF 113288XL 113272

TABLE 3 - IMPELLER ITEM #29

TERMINAL BLOCK

POWER

TERMINAL BLOCK

TEMP. SENSOR

DIAMETER 1.5 & 2HP

7.00” 084439

6.88” 084439TA

6.75” 084439TB

6.62” 084439TC

6.50” (STD 2.0 HP) 084439TD

6.38” 084439TE

6.25” 084439TF

6.12” 084439TG

6.00” (STD 1.5 HP) 084439TH

5.88” 084439TJ

5.75” 084439TK

5.62” 084439TL

5.50” 084439TM

5.38” 084439TN

5.25” 084439TP

5.12” 084439TQ

5.00” 084439TR

4.88” 084439TS

4.75” 084439TT

4.62” 084439TU

4.50” 084439TV

18

A Crane Co. Company

Limited 24 Month Warranty

Crane Pumps & Systems warrants that products of our manufacture will be free of defects in material and workmanship
under normal use and service for twenty-four (24) months after manufacture date, when installed and maintained
in accordance with our instructions.This warranty gives you speci• c legal rights, and there may also be other rights
which vary from state to state. In the event the product is covered by the Federal Consumer Product Warranties Law
(1) the duration of any implied warranties associated with the product by virtue of said law is limited to the same
duration as stated herein, (2) this warranty is a LIMITED WARRANTY, and (3) no claims of any nature whatsoever
shall be made against us, until the ultimate consumer, his successor, or assigns, noti• es us in writing of the defect,
and delivers the product and/or defective part(s) freight prepaid to our factory or nearest authorized service station.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply.

THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF ANY AND ALL WARRANTIES WITH RESPECT TO ANY
PRODUCT SHALL BE TO REPLACE OR REPAIR AT OUR ELECTION, F.O.B. POINT OF MANUFACTURE OR
AUTHORIZED REPAIR STATION, SUCH PRODUCTS AND/OR PARTS AS PROVEN DEFECTIVE. THERE SHALL BE
NO FURTHER LIABILITY, WHETHER BASED ON WARRANTY, NEGLIGENCE OR OTHERWISE. Unless expressly

stated otherwise, guarantees in the nature of performance speci• cations furnished in addition to the foregoing material
and workmanship warranties on a product manufactured by us, if any, are subject to laboratory tests corrected for

• eld performance. Any additional guarantees, in the nature of performance speci• cations must be in writing and such
writing must be signed by our authorized representative. Due to inaccuracies in • eld testing if a con! ict arises between
the results of • eld testing conducted by or for user, and laboratory tests corrected for • eld performance, the latter
shall control. RECOMMENDATIONS FOR SPECIAL APPLICATIONS OR THOSE RESULTING FROM SYSTEMS

ANALYSES AND EVALUATIONS WE CONDUCT WILL BE BASED ON OUR BEST AVAILABLE EXPERIENCE AND
PUBLISHED INDUSTRY INFORMATION. SUCH RECOMMENDATIONS DO NOT CONSTITUTE A WARRANTY OF
SATISFACTORY PERFORMANCE AND NO SUCH WARRANTY IS GIVEN.

This warranty shall not apply when damage is caused by (a) improper installation, (b) improper voltage (c) lightning
(d) excessive sand or other abrasive material (e) scale or corrosion build-up due to excessive chemical content. Any
modi• cation of the original equipment will also void the warranty. We will not be responsible for loss, damage or labor
cost due to interruption of service caused by defective parts. Neither will we accept charges incurred by others without
our prior written approval.
This warranty is void if our inspection reveals the product was used in a manner inconsistent with normal industry practice
and\or our speci• c recommendations. The purchaser is responsible for communication of all necessary information
regarding the application and use of the product. UNDER NO CIRCUMSTANCES WILL WE BE RESPONSIBLE FOR

ANY OTHER DIRECT OR CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO TRAVEL EXPENSES,
RENTED EQUIPMENT, OUTSIDE CONTRACTOR FEES, UNAUTHORIZED REPAIR SHOP EXPENSES, LOST
PROFITS, LOST INCOME, LABOR CHARGES, DELAYS IN PRODUCTION, IDLE PRODUCTION, WHICH DAMAGES
ARE CAUSED BY ANY DEFECTS IN MATERIAL AND\OR WORKMANSHIP AND\OR DAMAGE OR DELAYS IN
SHIPMENT. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER EXPRESS OR IMPLIED WARRANTY,
INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

No rights extended under this warranty shall be assigned to any other person, whether by operation of law or otherwise,
without our prior written approval.

420 Third Street 83 West Drive
Piqua, Ohio 45356 Brampton, Ont. Canada L6T 2J6
[phone] [phone]
Fax [phone] Fax [phone]
www.cranepumps.com

19

RETURNED GOODS

RETURN OF MERCHANDISE REQUIRES A “RETURNED GOODS AUTHORIZATION”.

CONTACT YOUR LOCAL CRANE PUMPS & SYSTEMS, INC. DISTRIBUTOR.

Products Returned Must Be Cleaned, Sanitized,
Or Decontaminated As Necessary Prior To Shipment,
To Insure That Employees Will Not Be Exposed To Health
Hazards In Handling Said Material. All Applicable Laws
And Regulations Shall Apply.

IMPORTANT!

WARRANTY REGISTRATION

Your product is covered by the enclosed Warranty.

To complete the Warranty Registration Form go to:

http://www.cranepumps.com/ProductRegistration/

If you have a claim under the provision of the warranty, contact your local

Crane Pumps & Systems, Inc. Distributor.

20