No: ?? ??? ?? Revision 2 2001.

07

Workshop manual

Minex Minette Minor Major Master www.grindex.com

Salvador Senior Sandy Super NEW LINE

Workshop Manual Index

Foreword ______________________________________________ 3
Product description ___________________________________ 4
Technical data ________________________________________ 6
Dismantling ___________________________________________ 8
Draining of oil __________________________________________ 8–9
Diffuser, lower ____________________________________________ 9
Pump housing___________________________________________ 10
Impeller ________________________________________________ 10
Shaft seal, lower _________________________________________ 11
Diffuser, upper __________________________________________ 11
Oil housing bottom _______________________________________ 11
Shaft seal, upper ________________________________________ 12
Bearing holder and rotor ___________________________________ 12
Ball bearings and rotor ____________________________________ 13
Cover, power cable and motor protector ______________________ 14
Main cover, air valve and terminal board ______________________ 15
Stator _________________________________________________ 15
Assembly _____________________________________________ 16
Stator _________________________________________________ 16
Ball bearing and rotor in bearing holder _______________________ 17
Motor unit and upper shaft seal _____________________________ 18
Upper diffuser and oil housing bottom ________________________ 19
Terminal board __________________________________________ 20
Main cover, valve, motor protector and valve cover ______________ 21
Wiring diagram, power cable and cover ____________________ 21–22
Shaft seal, lower _________________________________________ 23
Impeller ________________________________________________ 24
Filling of oil, lower diffuser, outer casing,
bottom plate and discharge connection _______________________ 25
Pump housing, outer casing, stand and discharge connection _____ 26
Fault tracing (Trouble shooting) ______________________ 27
Inspection ____________________________________________ 29
Motor unit and cable ______________________________________ 29
Stator insulation, oil and discharge head ___________________ 29–30
Stator winding, contactor and capacitors ___________________ 30–31
Motor protector SMART ___________________________________ 32
Stator specifications ___________________________________ 30, 33
Tools _________________________________________________ 34

GRINDEX 2
 Workshop Manual Foreword

We hope that you will read carefully through this workshop manual and derive great benefit
from it. It is designed to:
! provide you with detailed information about Grindex dewatering and sludge pumps.
! ensure that the pumps will retain their outstanding reliability by permitting you to carry out
the specified service work and inspections.
! permit you to remedy any operating difficulties quickly and methodically.

The Workshop Manual

! contains a Product description and Technical data.
! describes Dismantling and Assembly completely. If any model of pump deviates from the
uniform design of the rest, this is described separately in conjunction with the general de-
scription.
! describes Fault tracing, Inspection measures and suitable Special tools.
! shows different operations by means of photographs/exploded views. Where there is no ex-
ploded view, reference is made to the appropriate spare parts list for the pump model.

This is how to interpret the data plate

Model Serial No.

Pump type No. Maximum power

MADE IN SWEDEN

MINEX SER. No XXXXXXX

consumption
Rated voltage 1101
TYPE
Rated current Maxumum head
U 380–400 V P max 1.9 kW
Number of phases I 3.9–3.7 A H max 16 m Maximum capacity
and frequency Ø 3~ c/s 50 Hz Q max 700 l/min
Maximum
Direction of ROTATION
START REACTION 20 m submersion depth
impeller rotation
Start reaction

We reserve the right to make changes in design and specification without prior notice.

GRINDEX 3
 Workshop Manual Product description

Grindex submersible, electric dewatering and sludge pumps are designed for continuous
operation. The pumps may run dry. The dewatering pumps are designed to pump a medium
that may contain small particles. The sludge pumps are designed to pump sludge that may
contain coarse solid particles.

APPLICATIONS
Temperature of medium: Max. 40°C (105°F)
pH of medium: Standard pump 5 - 8
Grindex GPC 4 - 9.5
Submersion depth: Max. 20 m. (65 ft.)
Density of medium: Max. 1.1 kg/dm3 (68 lbs/ft3)
The medium to be pumped may contain particles up to a size
corresponding to that of the strainer holes (7 - 12 mm) (9/32 - 1/2 in).
Density of sludge: Max. 2.0 kg/dm3 (125 lbs/ft3)
The sludge to be pumped may contain particles up to the size
corresponding to the through-flow diameter of the pump
(32 - 80 mm) (1 1/4-3 1/8 in).
CAUTION

CAUTION
The pumps should not be used in explosive or fire-risk conditions or for pumping inflamma-
ble liquids.

DESIGN

Hydraulic part
! The impellers in all dewatering and sludge pumps are made of Chromium-alloyed white cast
iron with a hardness of 55±5 Rc
! The impellers in dewatering pumps are of the open, centrifugal type, while those in sludge
pumps are of the vortex type.
! The diffusers in dewatering pumps are lined with nitrile rubber. Polyurethane diffusers can be
supplied for certain models.
! The pump housing of sludge pumps has a wear resistant lining made of polyurethane.

Shaft seal
Lower shaft seal: Duratite - Duratite
Upper shaft seal: Carbon against nitrided steel.

GRINDEX 4
 Workshop Manual Product description

Bearings
Grease-packed ball bearings with C3 clearance of the following type:
Pump Bearing Type
Minex, Major, Master
Salvador, Super Upper bearing Single-row, grooved ball bearing
Minex, Minor, Major, Master
Senior, Sandy, Super Lower bearing Double-row, angular-contact bearing
Minette, Salvador Lower bearing Single-row, grooved ball bearing

SMART – Electronic motor surveillance system

! Rotasense: Permits the pump to start only if the correct phase sequence is
connected
! Phase guard: Permits the pump to work only if all three phases are connected.
! Temperature guard: A temperature guard is incorporated in each winding of both single
and three-phase pumps. This opens at a temperature of 130°C (266°F)
and disconnects the power supply to the contactor’s holding coil.
! Restart protection: Prevents the pump from restarting automatically in the event of a
tripped motor protector.

Motor
Squirrel-cage 2-pole (Senior: 4-pole) asynchronous motor of 50 Hz or 60 Hz. The stator is insu-
lated in accordance with IEC 85 Class F 155°C (312°F).
The difference between the voltage level of the respective phases may not exceed 2% (in ac-
cordance with IEC 34-1). Maximum number of uniformly distributed starts: 15 per hour.
The voltage supplied to the motor may not vary by more than 5% from the rated voltage.

Power cable
In accordance with Class HO7RN-F of the following sizes:
3 x 1.5 mm2 4 x 1.5 mm2
3 x 2.5 mm2 4 x 2.5 mm2
4 x 4 mm2

GRINDEX 5
 Workshop Manual Technical data

Drainage pumps 50 Hz
Minex Minette Minor Major Master
N H N H L N H L
Phase 1 3 1 3 3 3 3 3 3 3 3 3
Rated output, kW 0.9 1.6 1.6 2.0 3.2 2.9 6.1 5.6 5.4 8 8 8
Shaft speed, rpm 2800 2800 2800 2800 2800 2800 2800 2800 2800 2800 2800 2800
Max Power cons., kW 1.2 1.9 2.2 2.7 4.4 4.0 7.6 6.9 6.8 10 10 10
Current A, 110 V 12
“ A, 220 V 5.8 6.8 10 8.3 13 12 22 20 20 28 28 28
“ A, 380 V - 3.9 - 4.8 7.4 6.9 13 12 11 16 16 16
“ A, 400 V - 3.7 - 4.6 7.0 6.6 12 11 11 16 16 16
“ A, 415 V - 3.6 - 4.4 6.8 6.3 12 11 10 15 15 15
“ A, 500 V - 3.0 - 3.6 5.6 5.3 9.7 8.9 8.7 13 13 13
Discharge con., in 2 2 3 3 3 3 4 3 6 4 3 6
Strainer hole Ø mm (in) 7 (9/32) 7.5 (5/16) 8.5 (11/32) 8.5 (11/32) 8.5 (11/32)
Weight, kg (lbs) 17 (37) 25 (55) 39 (86) 45 (99) 45 (99) 50 (110) 56 (123) 60 (132) 61 (135)

Height, mm (in) 520 (20) 535 (21) 650 (26) 650 (26) 720 (28)
Width max., mm (in) 240 (9 1/2) 295 (11) 310 (12) 330 (13) 310 (12) 495 (19) 330 (13) 310 (12) 495 (19)
Strainer bot. Ø mm (in) 195 (8) 240 (9 1/2) 280 (11) 280 (11) 280 (11)
Max H, m 14 16 16.5 18 23 37 25 44 15 27 70 16
Max Q, l/min 570 700 850 1000 1900 950 2400 1200 3900 3300 1100 4500
Max H, ft. 46 52 54 59 75 121 82 144 49 89 230 52
Max Q, Imp. gpm. 125 154 187 220 418 209 528 264 858 726 238 990

Sludge pumps 50 Hz
Salvador Senior Sandy Super
Phase 1 3 3 3 3
Rated output, kW 1.4 2.0 4.1 5.0 5.6
Shaft speed, rpm 2800 2800 1400 2800 2800
Max Power cons., kW 1.9 2.8 5.1 6.5 7.2
Current A, 220 V 8.9 8.5 16 19 21
“ A, 380 V - 4.9 9.5 11 12
“ A, 400 V - 4.7 9.0 11 12
“ A, 415 V - 4.5 8.7 10 11
“ A, 500 V - 3.8 7.2 8.4 9.3
Discharge con., in 3 3 3 3 3
Throughlet Ø. mm (in) 50 (2) 80 (31/8) 46 (1 3/4) 32 (11/4)
Weight, kg (lbs) 27 (60) 55 (121) 55 (121) 55 (121)
Height, mm (in) 645 (25) 740 (29) 740 (29) 740 (29)
Width max ,mm (in) 375 (15) 480 (19) 480 (19) 480 (19)
Max H, m 13.5 15 8.5 24 42
Max Q, l/min 680 820 2000 950 460
Max H, ft. 44 49 28 79 138
Max Q, Imp.gpm. 150 180 440 209 101

GRINDEX 6
 Workshop Manual Technical data

Drainage pumps 60 Hz
Minex Minette Minor Major Master
N H N H L N H L
Phase 1 3 1 3 3 3 3 3 3 3 3 3
Rated output, kW 1.0 1.4 1.9 2.3 3.7 4.1 6.2 5.2 5.9 9.8 9.8 9.8
Shaft speed, rpm 3400 3400 3400 3400 3400 3400 3400 3400 3400 3400 3400 3400
Max Power cons., kW 1.4 2.0 2.6 3.1 4.9 5.3 7.9 6.6 7.5 12 12 12
Current A, 115 V 13
“ A, 220 V 6.6 6.1 12 9.4 14 16 23 19 22 34 34 34
“ A, 230 V 6.3 5.8 12 9.0 14 15 22 18 21 33 33 33
“ A, 440 V - 3.0 - 4.7 7.2 7.9 11 10 11 17 17 17
“ A, 460 V - 2.9 - 4.5 6.9 7.5 11 9.1 10 16 16 16
“ A, 575 V - 2.3 - 3.6 5.5 6.0 8.7 7.3 8.2 13 13 13
Discharge con., in 2 2 3 3 3 3 4 3 6 4 3 6
Strainer hole Ø mm (in) 7 (9/32) 7.5 (5/16) 8.5 (11/32) 8.5 (11/32) 8.5 (11/32)
Weight, kg (lbs) 17 (37) 25 (55) 39 (86) 45 (99) 45 (99) 50 (110) 56 (123) 60 (132) 61 (135)

Height, mm (in) 520 (20) 535 (21) 650 (26) 650 (26) 720 (28)
Width max., mm (in) 240 (9 1/2) 295 (11) 310 (12) 330 (13) 310 (12) 495 (19) 330 (13) 310 (12) 495 (19)
Strainer bot. Ø mm (in) 195 (8) 240 (9 1/2) 280 (11) 280 (11) 280 (11)
Max H, m 15 19 18.5 18.5 23 45 26 51 14.5 30 80 25
Max Q, l/min 480 670 960 1180 2100 900 2500 940 3900 3400 1100 4500
Max H, ft. 49 62 61 61 75 148 85 167 48 98 262 82
Max Q, Imp. gpm. 127 177 254 312 555 238 660 248 1030 903 285 1141

Sludge pumps 60 Hz
Salvador Senior Sandy Super
Phase 1 3 3 3 3
Rated output, kW 2.4 2.4 5.1 5.7 6.1
Shaft speed, rpm 3400 3400 1700 3400 3400
Max Power cons., kW 3.4 3.4 6.2 7.5 8.0
Current A, 220 V 17 10 20 22 23
“ A, 230 V 16 9.5 19 21 22
“ A, 440 V - 5.0 10 11 12
“ A, 460 V - 4.8 9 10 11
“ A, 575 V - 3.8 7.5 8.3 8.9
Discharge con., in 3 3 4 3 3
Throughlet Ø. mm (in) 50 (2) 80 (3 1/8) 46 (1 3/4) 32 (1 1/4)
Weight, kg (lbs) 27 (60) 55 (121) 55 (121) 55 (121)
Height, mm (in) 645 (25) 740 (29) 740 (29) 740 (29)
Width max ,mm (in) 375 (15) 480 (19) 480 (19) 480 (19)
Max H, m 18 18 11.5 24 47
Max Q, l/min 760 850 2150 770 320
Max H, ft. 59 59 38 79 154
Max Q, Imp.gpm. 201 225 568 203 85

GRINDEX 7
 Workshop Manual Dismantling

Draining the oil

– Dewatering pumps
Tighten the service handle (114646) securely
onto the discharge connection attachment points
and place the pump in the fixture (114334), or
lay the pump on a bench.
Unscrew the nuts that retain the strainer bottom.
Remove the strainer bottom and protective
rubber sleeves for the studs. Pull the outer
casing and remove the O-ring that seals between
the cover and outer casing.

Note, on Minex pumps

Unscrew the nuts (45) that retain the lower
diffuser. Remove the lower diffuser (62) and
rubber bushings (44).

Draining
Lay the pump on the bench. Unscrew the oil
plug and remove the O-ring. Turn the pump and
drain the oil.

CAUTION
In the event of water entering the oil housing, excess pressure can build up in the oil
housing. Unscrew the oil plug slowly and carefully. Hold a cloth over the oil plug to avoid
any splashing.

GRINDEX 8
 Workshop Manual Dismantling

Draining the oil – Sludge pumps

Senior, Sandy and Super have the oil plug on
the outside.

Note, on Salvador pumps

Fit the service handle (114646) securely
onto the inspection cover attachment points
and place the pump in the fixture (114334),
or lay the pump on a bench. Unscrew the
nuts (46) and remove the stand (71), pump
casing (70), O-ring (66), outer casing (23)
and the O-ring (22) that seals between the
main cover and the outer casing.

Draining
See “Draining” under the heading “Dewatering
pumps”.

Dismantling the lower diffuser

– Dewatering pumps
Unscrew the nuts that retain the lower diffuser.
Pull the diffuser and remove the rubber blocks.

Note, on Minex pumps

This operation is described under the
heading “Draining the oil – Dewatering
pumps”.

GRINDEX 9
 Workshop Manual Dismantling

Dismantling the pump housing

– Sludge pumps
Unscrew the screws (53) and remove the spring
washers (52). Remove the stand (80). Unscrew
the screws (77) and remove the spring washers
(76). Remove the clamp (74) and discharge
connection (75). Unscrew the nuts (51) and
remove the spring washers (50). Remove the
lower pump housing unit (79), wear lining(78)
and screws (47). Unscrew the nuts (49), remove
the spring washers (48), upper pump housing
unit (72) and wear lining (73). Remove the seals
(45) from the studs (44) and the cylindrical guide
pins (71) from the wear lining(73). Remove the
gasket (46).

Note, on Salvador pumps

The above operation is described under the
heading “Draining the oil – Sludge pumps”.

Dismantling the impeller

Dewatering pumps Sludge pumps

Bend out the lock washer (A) Unscrew the screw (B).
and unscrew the screw (B). This screw is of the self-
locking type and may not
therefore be reused.

CAUTION
Do not use screwdrivers or suchlike to
retain the pump impeller. Small chips may
break off the impeller and injure the eyes.
Use the Grindex tool (114386) designed
for retaining the impeller.
Remove the impeller, shaft key, shims and
guide plate from sludge pumps.

GRINDEX 10
 Workshop Manual Dismantling

Dismantling the lower shaft seal

unit (dewatering and sludge pumps)
Use two screwdrivers to
remove the unit (B, C, D, E)
carefully.

To remove theO-ring (A) from

dewatering pumps: the upper diffuser must
be removed
sludge pumps: the oil-casing bottom
must be removed.

Dismantling the upper diffuser

– Dewatering pumps
Remove the protective washers (H) and unscrew
the screws (G). Remove the upper diffuser (F),
O-ring (E) and thrust plate (D), spring (C) and
spring support (B). Remove the O-ring (A).

Note, on Minex pumps

Unscrew the nuts (110). Remove the studs
(132), upper diffuser (131) and O-ring (120).

Dismantling the oil housing

bottom from sludge pumps
Unscrew the screws (G) and remove the oil
housing bottom (F), O-ring (E), thrust plate (D),
spring (C) and spring support (A). Remove the
O-ring (B).
Senior, Sandy and Super are provided with
threaded holes in the oil housing bottom. If the
oil housing bottom is stuck in position, the screws
(G) may be used in the threaded holes to press
down the oil housing bottom.

GRINDEX 11
 Workshop Manual Dismantling

Dismantling the upper shaft seal

unit
Use a pair of circlip pliers to
remove the circlip (D). Use the
special tool (114627) to pull the
rotating seal ring (C) from the
shaft. Use the same tool to lift
up the sealing ring (B). Remove
the O-ring (A) from the sealing
ring (B).

Note
If the rotating seal ring (C) is stuck in
position, it is advisable to detach both the
stationary and the rotating seal rings (B, C)
with two screwdrivers.
Fit the screwdrivers in the free groove of
the stationary ring (B) and carefully prize it
out from the bearing holder. Then use the
special tool (114627) to pull the two seal
rings from the shaft.

Dismantling the bearing holder with

rotor unit
Lay the pump on a bench. Unscrew the studs
that retain the upper diffuser. Unscrew the
screws, remove the nuts that hold together the
bearing holder and stator housing. Pull the rotor
unit from the stator housing. Remove the O-ring.
If the rotor unit is stuck in position, it is advisable
to use a special tool (114645).

Note, on Minex pumps

The bearing holder and stator housing are
held together by the upper diffuser (see
“Dismantling the upper diffuser”).

GRINDEX 12
 Workshop Manual Dismantling

Removing the upper ball bearing

Use a race puller to remove the upper ball
bearing. (Use tool 114649)

Removing the rotor unit

Place the bearing holder, with the shaft end
pointing upwards, in a press and press out the
rotor unit.

Removing the lower ball bearing

Use a pair of circlip pliers to remove the circlip
(A) and remove the cover plate (B). Use the
special tool (114310) to press the lower ball
bearing (C) out of the bearing holder (E).
Remove the spacer washer (D).

GRINDEX 13
 Workshop Manual Dismantling

Removing the cover

Unscrew the screws that retain the cover.
Disconnect the leads on the motor protector/
contactor and the earth (ground) leads between
the cover and main cover. Remove the O-ring/
gasket between the cover and main cover.

Removing the power cable

Unscrew the screws (A) and remove the cable
clamp (B).
Unscrew the screws (F) that hold the cable entry
flange (E). Slide the cable into the cover and
remove the sealing washer (C), rubber seal (D)
and the second washer (C). Now pull the cable
from the cover.

Removing the contactor and motor

protector (3-phase) and capacitors
and starter relay (single-phase)
Disconnect all the electrical connections.
Remove the contactor/motor protector (3-
phase), capacitors/starter relay (single-phase)
so as to free the main cover.

GRINDEX 14
 Workshop Manual Dismantling

Removing the main cover and air

valve
Unscrew the screws that hold together the main
cover and stator housing (4 x M8 on Minex,
Minette and Salvador pumps, and 2 x M 12
hexagonal socket-head screws on Minor, Major,
Senior, Sandy and Super pumps).
Unscrew the screw (A). Remove the valve cover
(B). Pull the valve (C) up out of the main cover.

Removing the terminal board

Unscrew the screws (A). Use two screwdrivers
to lift up the terminal board (B) carefully.
Disconnect the stator leads from the underside
of the terminal board. Remove the O-ring (C).
Remove the cover (D) and O-ring (E).

Dismantling the stator

Remove the spade terminals and Systoflex
tubes. Place the stator housing on a suitable
support. Heat the outside of the stator housing
quickly and uniformly (using two LP-gas burners,
for example) until the stator slides out of the
housing under its own weight.

GRINDEX 15
 Workshop Manual Assembly

IMPORTANT
Before starting assembly, proceed as follows:
! Clean all machined surfaces carefully.
! Check that O-ring grooves are clean and undamaged.
! Replace all damaged or worn parts. Use only genuine spare parts.
! Always replace all O-rings, rubber gaskets and the cable entry grommet.
! Oil the sliding surfaces of O-rings and seals well.
! Grease screws and nuts before fitting them.

Fitting the stator

Place the stator on a suitable stand. Heat the
stator housing to a temperature of about 150°C.
(302°F). Lower the stator housing over the stator
so that the stator leads can be drawn through
the three openings in the top of the stator
housing. Allow the stator to cool and then draw
up the stator leads, uniformly distributed, through
the three openings in the stator housing. Fit
Systoflex tubes and spade terminals on the
stator leads.

CAUTION
Ensure that the stator leads do not come in contact with the hot stator housing.

GRINDEX 16
 Workshop Manual Assembly

Fitting the upper and lower ball

bearings and rotor unit

Lower ball bearing

Place the bearing holder (E) on tool 114450 so
that the hole for the ball bearing is facing
upwards. Insert the spacer washer (D) with the
depression facing downwards. Fill the ball
bearing (C) two-thirds full of grease. Press in
the ball bearing using the appropriate tool:
Minex: 114359
Others: 114311
Place the cover plate (B) on the ball bearing and
fit the circlip (A).

Upper ball bearing and rotor unit

Place the bearing holder on tool 114490. Place
the shaft of the rotor unit in the lower ball bearing
and the upper ball bearing on the top end of the
shaft. Press in the rotor unit and lower ball
bearing.

IMPORTANT
The sealing side of the upper bearing must face downwards. Place the tool (see below) on
the upper ball bearing and press down the rotor unit and upper ball bearing at the same
time. Pack the upper ball bearing two-thirds full of grease.

Drifts for the upper ball bearing:

Minex 114385
Minette 114384
Salvador “
Minor 114383
Major “
Master “
Senior “
Sandy “
Super “
The following or equivalent bearing greases are
recommended:
ESSO Unirex 3, BP Energrease LS3, Shell
Alvania Grease R3.

GRINDEX 17
 Workshop Manual Assembly

Fitting the motor unit

Place the bearing holder/rotor unit assembly on
a piece of wood measuring at least 220 x 220 x
100 mm (8 1/2 x 8 1/2 x 4 in) with a 30-mm
(1 1/4 in) diameter hole in the middle.
Fit onto the bearing holder the O-ring that seals
between the bearing holder and stator housing.
Fit into the stator housing the O-ring that seals
between the upper ball bearing and stator
housing. Fit the stator housing, with bearing
holder/rotor unit assembly. Tighten the screws.
Press the sealing washer firmly onto the upper
ball bearing.

Note on Minette and Salvador pumps Note on Minex pumps

Assemble the bearing holder and stator Fit O-ring (108). Place the stator housing
housing using studs and nuts. Tighten the upside down on the bench. Fit the bearing
studs and nuts. Press the statinary seal ring holder/rotor housing assembly into the
firmly onto the upper ball bearing. stator housing. Fit O-ring (120). Fit the
protection cover (107) for the upper ball
bearing after the upper diffuser has been
fitted.

Fitting the upper shaft seal unit

Place the motor unit on a
bench with the rotor shaft
facing upwards. Fit O-ring (A)
in the O-ring groove in the
seal ring (B). Use tool 114626
to press the seal ring into
position in the bearing holder.
Apply oil to the surface of the
seal ring. Oil the inside of the
rotating seal ring (C) and press it about 30 mm
(1 1/4 in) onto the shaft. Use a circlip pliers to fit
the circlip (D) onto the shaft. Use tool 114626 to
press down the circlip and rotating seal ring until
the circlip enters its groove.

IMPORTANT
Check that the surfaces of the seal rings are completely clean and that the shaft is free
from scratches.
GRINDEX 18
 Workshop Manual Assembly

Fitting the upper diffuser

– Dewatering pumps
Fit the spring support (B), spring (C) and thrust
plate (D). Fit the O-ring (A) into the bearing
holder. Fit the O-ring (E) into the O-ring groove
in the upper diffuser (F). Fit the upper diffuser.

IMPORTANT
Check that the pin in the upper diffuser (F)
enters the slot in the thrust plate (D). Tighten
the screws (G) and press in the protection
washers (H).

Note, on Minex pumps

Fit the studs (132) and tighten the nuts
(110). Fit the protective cover (107) for the
upper ball bearing.

Fitting the oil housing bottom

– Sludge pumps
Fit the O-ring (B) into the bearing holder. Fit the
spring support (A), spring (C) and thrust plate
(D). Fit the O-ring (E) into the O-ring groove in
the oil housing bottom (F).

IMPORTANT
Check that the guide pin in the oil housing
bottom (F) enters its slot in the thrust plate
(D).

Fit the oil housing bottom (F), fit the screws (G)
and tighten them securely.

GRINDEX 19
 Workshop Manual Assembly

Fitting the terminal board

For instructions on fitting the O-ring (E) and
protection cover (D) refer to Fitting the motor
unit.
Fit the O-ring (C) onto the terminal board (B).
Press the stator leads securely onto the
underside of the terminal board in accordance
with the wiring diagrams shown below. Use the
screw (A) to tighten the terminal board securely
onto the stator housing.

IMPORTANT
Ensure that the stator leads are connected in accordance with the wiring diagram. Incorrect
connection may result in damage to the motor and wrong direction of rotation.

4 456 7894 5 6

Y Y

2 5 1 14 13 1 2 3 13 14 1 2 3 13 14
220 V / 1 / 50 Hz 380 V / 3 / 50 Hz 9-Lead
500-550 V / 3 / 50 Hz 230 V / 3 / 60 Hz
346-440 V / 3 / 50 Hz

Connections of the stator leads 564

of the terminal board.
4 7
For other voltages and marking
see page 48:
Stator specifications. D Y
5 8

1 2 3 13 14 1 2 3 13 14
6 9
220 V / 3 / 50 Hz 9-Lead
500-550 V / 3 / 50 Hz 460 V / 3 / 60 Hz
346-440 V / 3 / 60 Hz

GRINDEX 20
 Workshop Manual Assembly

Fitting the main cover and valve

cover
Fit the O-ring (D) and the main cover onto the
stator housing. Fit the valve (C) so that the
rubber-clad side of the valve faces outwards.
Tighten the valve cover (B) securely by using
the screws (A).

Fitting the contactor and motor protector (3-phase) and capacitors

and start relay with motor protector (single-phase)
Fit the contactor and motor protector/capacitors and start relay. Connect the conductor set in
accordance with the wiring diagram.

IMPORTANT
Ensure that the conductor set leads are connected in accordance with the wiring diagram.
Incorrect connection can result in damage to the motor or wrong direction of rotation.

ØØØ
L1 L2 L3
Ø Ø Ø
A2
A2
T2 13
T1 T3 14 5
A1 1 3 5 13 L2 A2 14 18
L1 L3 I3
L1 L2 L3 A B C DE 1
17

T1 T2 T3
2 4 6 14 A2
M 20 5 1 14 13
A B C DE
22 20 18 16 14
21 19 17 15 13 Cs Cr
LN
Three phase 2 45 1 1413
SNT 330
Note!
If level regulator is used remove the jumper M
link and connect cable leads to the terminals Single phase
A2 on the contactor and A2 on the motor
protector. Note!
If level regulator is used remove the jumper
link and connect cable leads to the terminals
15 and 16.

GRINDEX 21
 Workshop Manual Assembly

Fitting the power cable

This must be done in the following order:
Thread the protection sleeve (G) onto the cable.
Slide the cable into the cover. Thread on the
washer (C), rubber seal (D) and the second
washer (C). Bolt on securely the cable entry
flange (E) using the screws (F). Tighten the cable
clamp (B) using the screws (A). Clamp the
receptacles (flat lug connectors) onto the cable
leads.

IMPORTANT
When fitting the power cable that has been used in the pump before, always cut off a piece of
it so that the rubber seal will be at a different place on the cable.

Fitting the cover

Place the gasket/O-ring between the cover and
the main cover. Connect the earth (ground) lead
between the cover and the main cover. Connect
the cable leads to the terminals of the start relay
(single-phase)/contactor (3-phase) in accor-
dance with the appropriate wiring diagram on
page 20. Screw in the screws securely.

IMPORTANT
On Minex, Minette and Salvador pumps, fit the rubber gasket so that the side with the two
sealing lips is facing up the cover.

GRINDEX 22
 Workshop Manual Assembly

Fitting the lower shaft seal

Lubricate the outside of the stationary seal ring.
(B) before pressing it in and turning it until a clear
click indicates that it is fixed in the thrust plate.
Grease the rubber ring (D) and place it in the
seal ring holder (E). Place the rotating seal ring.
(C) in the seal ring holder (E). Fit the O-ring (A)
in conjunction with fitting of the upper diffuser
(dewatering pumps) and oil housing bottom
(sludge pumps).
Lubricate the surface of the sealing sleeve. Slide
the seal ring holder onto the shaft.
Check that there is springiness in the lower shaft-
seal assembly.

IMPORTANT
Make sure that the stationary seal ring is
properly fixed in the thrust plate. The rotating
seal ring. (C) has a lip on one side. The side
not to be used as a sealing surface is
marked and should be turned towards the
rubber ring (D).

IMPORTANT
Check that the surfaces of the stationary
seal ring and rotating seal ring are
completely clean. During assembly, never
use anything that can damage the sealing
surfaces.

GRINDEX 23
 Workshop Manual Assembly

Fitting the impeller

Dewatering pumps
Fit a suitable number of adjusting washer (A)
onto the shaft so that a clearance of 0.1 mm
(0,004”) is obtained (use tool 114648) between
the impeller and the upper diffuser when the
impeller has been tightened. Slide on the
impeller carefully so that the key (B) fits into the
keyway in the impeller. Fit in the lock washer
(C), and use tool 114386 to retain the impeller
while tightening the screw (D). Lock the screw
by bending the lock washer. Check that the
impeller rotates easily when turned by hand.

Sludge pumps
Fit the guide plate (A). Fit a suitable number of
adjusting washer (B) onto the shaft so that the
impeller rotates clear of the guide plate (A) when
the impeller has been tightened. Slide the
impeller carefully onto the shaft so that the key
(C) fits into the keyway in the impeller. Fit the
washer (E), and use tool 114386 to retain the
impeller while tightening the screw (F).

IMPORTANT
The screw for sludge pumps is self-locking. It cannot be reused. Check that the impeller can
be turned easily by hand.

GRINDEX 24
 Workshop Manual Assembly

Filling up with oil

Lay the pump on a bench with the oil-filler hole Minex 0.33 litres (0.35 US quarts)
pointing upwards. Fill up with oil in accord-ance Minette 0.45 litres (0.48 US quarts)
with the table below. Never fill the oil housing
completely. Fit the O-ring onto the oil-filler plug, Minor, Major,
fit the plug and tighten it. Master 0.58 litres (0.61 US quarts)
Salvador 0.35 litres (0.37 US quarts)
Senior, Sandy,
Super 0.45 litres (0.48 US quarts)
Recommended oil:
White oil, viscosity ISO VG 15.

Fitting the lower diffuser, outer

casing, strainer bottom and dis-
charge connection
– Dewatering pumps
Fit the studs into the bearing holder. Fit the
rubber sleeves onto respective studs. Fit the
lower diffuser and the nuts.
Tighten the nuts in opposing pairs until the
impeller just runs clear of the lower diffuser. Use
tool 114648 to determine when a clearance of
0.1 mm (0,004”) is achieved between the
impeller and the lower diffuser and then lock the
nuts against one another. Check that the impeller
turns freely.
Grease the outside of the diffuser. Fit the O-ring
that seals between the main cover and the outer
casing. Fit the outer casing and strainer bottom.
Fit the discharge connection.

IMPORTANT
If the pump diffuser is equipped with a polyurethane diffuser, the clearance between it and the
impeller must be 0.30 mm (0,012”).

GRINDEX 25
 Workshop Manual Assembly

Fitting the pump casing, outer

casing, stand and discharge
connection – Sludge pumps
Fit the O-ring that seals between the main cover
and the outer casing. Fit the outer casing.
Press the cylindrical guide pins (71) into the wear
lining (73). Place the gasket (46) on the bearing
holder and the seals (45) on respective studs.
Fit the pump casing unit onto the bearing holder.
Fit a washer (48) and tighten the nut (49) to
secure the assembly.
Place the lower wear lining (78) in the lower
pump housing (79) and fit these to the upper
pump housing assembly (72) using a spring
washer (50) and nut (51). Fit the stand (80) and
discharge connection (75).

IMPORTANT
Check that the cylindrical guide pin (71) fits
into the hole in the guide plate.

Note, on Salvador pumps

Fit the O-ring (22) in the main cover. Fit the
outer casing (23). Fit the O-ring (66) in the
pump housing (70). Press the pin (45) into
the pump housing (70). Fit the pump
housing (70). Fit the stand (80) and
discharge connection (67). Check that the
cylindrical guide pin (45) fits into the hole in
the guide plate (61).

GRINDEX 26
 Workshop Manual Fault tracing

CAUTION
Fault tracing must be carried out with the power switched off, except in the case of checks that
cannot be performed when the equipment is unenergized. All electrical work shall be carried
out under the supervision of an authorized electrician.

PUMP DOES NOT START

Cause Remedy
1. Incorrect phase sequence Grindex pumps are equipped with Rotasense, which
(3-phase). permits the pump to start only if the correct phase
sequence is connected. Interchange two phases.

2. One or more phases are dead Replace the fuses/cable.

- blown fuses Check the power source.
- power failure Re-set circuit breaker.
- cable failure.
- tripped circuit breaker

3. Inadequate power source. Check that the power source is adequate for the power
required by the pump. Check that the fuse is adequate.

4. Impeller blocked. Clean.

5. Burnt stator. See “Checking the stator insulation and the resistance of
the stator windings”.

6. Open holding coil of the See “Checking contactors”.

contactor

PUMP STARTS BUT STOPS DURING OPERATION

Cause Remedy
1. A fuse has blown. Grindex pumps are equipped with a phase guard that permits
the pump to work only when all three phases are connected.
Replace the fuse. Note that the pump will restart
automatically whenever all the phases are connected.

2. Temperature guards have Grindex pumps are equipped with temperature guards in
broken the power supply to each winding. These open at a temperature of 130°C (266°F)
the contactor’s holding coil. and disconnect the power supply to the holding coil.
Remedy the cause of the high temperature.
- the pump has dug itself in Grindex pumps are equipped with a manual restart. Restart
mudd/sand. the pump by disconnecting the power supply and then re-
- excessive medium tempera- connecting it.
ture (>40°C) (>105°F).
- the density/-viscosity of the
medium is too high.
- the impeller is difficult to Clean the impeller. Check that the impeller is not adjusted
rotate by hand. to tight.
GRINDEX 27
 Workshop Manual Fault tracing

3. Voltage drop caused by: The voltage drop to pumps may not exceed 5% of the rated
- Long cables. volt-age. Remedy the cause of the voltage drop. Restart the
- Undersized cables which re- pump.
sult in a temperature rise. Maximum cable lengths are specified in the Technical File.
- Cables exposed to excessive
heat.

4. Insulation between phases If the stator is moist, dry it, then check the insulation. Then
and earth (ground) in the sta- check the resistance of the insulation and windings (see
tor is insufficient (see Check- Checking the stator insulation). If the stator fault cannot be
ing the stator insulation). remedied, replace the stator.

5. The line currents are not uni- Check the power source. Check the stator (see “Checking
form or excessive. the resistance of the stator windings”, and “Checking the
power cable”). See motor specifications page 5, 46 and 48.

PUMP STARTS BUT PUMPS LITTLE OR NO WATER

Cause Remedy
1. Excessively worn impeller and Adjust the pump to take up the wear (see “Assembling/
lower diffuser. dismantling the impeller and Dismantling the impeller and
lower diffuser”.

2. Excessive pressure losses as If possible reduce the length of the hose/pipe and reduce
a result of a long hose, pipe, the number of valves, or increase the size of the hose/pipe.
valves, etc.

3. Discharge hose is pinched or Arrange the hose so that it will have as few bends as possible.
kinked.

4. Excessive discharge head. Change to a pump with a greater discharge head or connect
several pumps in series.

5. Incorrect direction of rotation. The pump motor surveillance system ensures that the
impeller cannot rotate in the wrong direction. If the internal
wiring has been done incorrectly, the pump can run
backwards see “Contactor and motor protector”.

GRINDEX 28
 Workshop Manual Inspection

IMPORTANT
Regular inspection and maintenance of the pump will prolong its service life and ensure more
reliable operation. The oil in the pump and the discharge head of the pump should be checked
after 2000 hours of operation. A major service of the pump should be done after about one
year under normal operating conditions.

Tightness check
The following inspection is recommended to
check that the motor unit is tight. Make a cover
that fits onto the stator housing. Fit an air nipple
in the cover. Fit a gasket to the cover to ensure
its tight fit and fit the cover. Pressurize the motor
unit to a gauge pressure of 1 to 1.5 bar (14 to
22 psi) (use only dry air). Lower the motor unit
into water and check for any air bubbles leaking
from it.

Note, on Minex pumps

If the above test is to be performed, the
upper diffuser or holder for the bearing
holder must be fitted.

Checking the power cable

Check that the power cable sheath is undamaged. Damage may permit water to enter into the
cable and on into the junction box. Use an ohm meter to check whether any of cable’s conductors
are broken.
Use a 1 kV megger to check the insulation between the phase conductors and the protective earth
(ground) and between respective phase conductors.

Checking the stator insulation

Use a 1 kV megger to check that the resistance of the insulation between respective windings and
between them and the earth (ground) is at least 1 Mohm.

Checking the oil

If the oil is pale or whitish and of high viscosity, or if any oil/water separation is noted, this is a
sign that water has penetrated into the oil housing. If this is the case, replace the lower shaft
seal.

IMPORTANT
A certain amount of leakage can occur when the shaft seal is new. This need not mean that
the shaft seal is defective. Change the oil and check it after a few days. If the oil is still
miscoloured, replace the lower shaft seal.
Following carefully the oil volumes recommended under Filling up with oil.
GRINDEX 29
 Workshop Manual Inspection
Checking the discharge head
Fit pressure gauge tube 114422 to the discharge connection of the pump. Use a rubber hose.
Place the pump in water and start it. Read off the pressure gauge (114335). The maximum discharge
head of respective pumps is shown under Technical data.
If the discharge head is too low, adjust the lower diffuser and replace worn parts. For adjustment,
see “Fitting the lower diffuser”.

Checking the resistance of the stator windings

Use an ohmmeter to check the resistance of each stator winding. The difference in a 3-phase
stator between each winding may not exceed 5%.
The resistance values tabulated below are guiding values and apply at 20°C (68°F).
Stator specifications
winding W
Pump Voltage 1-4 2-5 3-6
Minex 110 V, single phase 1.70 0.90 -
220 V, single phase 6.70 3.10 -
220/380 V 4.10 4.10 4.10
500-550 V Y 7.80 7.80 7.80
Minette/Salvador 220V, single phase 3.20 1.70 -
220/380 V 2.83 2.83 2.83
500-550 V Y 6.31 6.31 6.31
Minor 220/380 V 1.64 1.64 1.64
500-550 V D 9.45 9.45 9.45
Major/Sandy/Super stator No. 50044xx 220/380 V 0.94 0.94 0.94
500-550 V D 5.34 5.34 5.34
Major/Sandy/Super stator No. 50306xx 220/380 V 0.80 0.80 0.80
500-550 V D 4.59 4.59 4.59
Master 220/380 V 0.51 0.51 0.51
380/660 V 1.67 1.67 1.67
500/550 V 2.89 2.89 2.89
Senior 220/380 V 1.25 1.25 1.25
500-550 V Y 2.20 2.20 2.20
(For other voltages see page 33).
GRINDEX 30
 Workshop Manual Inspection

Checking the contactor (3-phase)

Check the mechanical parts of the contactor. Check that the contactor contacts are not burnt.
Measure the resistance across the contactor contacts. The difference between contacts should
not exceed 5%.
Check that there is no break in the contactor coil (continuity test).

Checking the capacitors

Grindex single-phase pumps are equipped with two capacitors, one starting and one operat-ing
capacitor. The operating capacitor is larger in size and has an external casing of metal.
The starting capacitor has an outer casing of plastic and is of electrolyte type.
Test: Charge the capacitor using a 1 kV megger for a short period (2 - 5 seconds). Then short-
circuit the capacitor leads. The capacitor will discharge its stored energy and a spark will be
generated.
If no spark is generated, the capacitor has not stored the energy, which is a sign that it is defective.

CAUTION
Do not touch the capacitor’s leads. The voltage may be dangerous whenever the capacitor is
charged.

GRINDEX 31
 Workshop Manual Inspection

Checking the 3-phase motor protector SMART

Checking the function of the motor protector:

1. Connect a voltmeter between the input phase (L3) and pin (A2) on the motor protector.
2. Connect a switch between pins 13 and 14 on the motor protector.
3. Check that the voltage and frequency of the power supply is the same as that marked on the
motor protector. Then connect cables L1 (R), L2 (S) and L3 (T) from the motor protector to
the 3-phase power supply.
4. Now that power is connected to the cables L1, L2 and L3, the built-in relay should close and
the voltmeter indicates a reading. If this does not occur, interchange two phases.
5. Switch off the switch connected between pins 13 and 14 on the motor protector. The built-in
relay will open and no reading will be indicated by the voltmeter. Switch on the switch. The
voltmeter should indicate no reading. Disconnect the 3-phase power supply and then
reconnect it again. The voltmeter should indicate a reading (voltage in power lines).

GRINDEX 32
 Workshop Manual Inspection

Marking of stator leads

Three phase pumps SIngle phase pumps
1–4 (red – blue) 1–4 (red – blue) Aux. winding
2–5 (red – blue) 2–5 (red – blue) Main winding
3–6 (red – blue) Thermal contacts
7 – 8 – 9 (red)
13 – 14 (yellow)

Stator specifications
Minex Major - Sandy - Super stator No. 50044xx
PH U Hz Coils Resistance Ohm PH U Hz Coils Resistance Ohm
1 110 50 1-4, 2-5 1.7 0.9 3 200/346 50 1-4, 2-5, 3-6 0.76
3 200/346 50 1-4, 2-5, 3-6 3.20 3 400-440 50 1-4, 2-5, 3-6 3.35
3 400/440 50 1-4, 2-5, 3-6 5.05 3 220/380 60 1-4, 2-5, 3-6 0.65
1 115 60 1-4, 2-5 1.33 0.61 3 230/460 60 1-4, 2-5, 3-6 0.611
1 230 60 1-4, 2-5 5.15 2.25 7-8, 7-9, 8-9 1.222
3 220/380 60 1-4, 2-5, 3-6 2 3 575 60 1-4, 2-5, 3-6 5.35
3 230/460 60 1-4, 2-5, 3-6 2.25
7-8, 7-9, 8-9 4.50
3 575 60 1-4, 2-5, 3-6 7.05 Major - Sandy - Super stator No. 50306xx
PH U Hz Coils Resistance Ohm
Minette - Salvador 3 200/346 50 1-4, 2-5, 3-6 0.64
PH U Hz Coils Resistance Ohm 3 400-440 50 1-4, 2-5, 3-6 2.84
3 220/380 60 1-4, 2-5, 3-6 0.56
3 400/440 50 1-4, 2-5, 3-6 3.70
3 230/460 60 1-4, 2-5, 3-6 0.43
1 230 60 1-4, 2-5 2.5 1.15
7-8, 7-9, 8-9 0.86
3 220/380 60 1-4, 2-5, 3-6 1.98
3 575 60 1-4, 2-5, 3-6 3.57
3 230/460 60 1-4, 2-5, 3-6 1.35
7-8, 7-9, 8-9 2.7
3 575 60 1-4, 2-5, 3-6 4.11 Master
PH U Hz Coils Resistance Ohm
Minor 3 200/346 50 1-4, 2-5, 3-6 0.42
PH U Hz Coils Resistance Ohm 3 400-440 50 1-4, 2-5, 3-6 1.75
3 200/346 50 1-4, 2-5, 3-6 1.35 3 220/380 60 1-4, 2-5, 3-6 0.35
3 400-440 50 1-4, 2-5, 3-6 5.78 3 230/460 60 1-4, 2-5, 3-6 0.25
3 220/380 60 1-4, 2-5, 3-6 1.15 7-8, 7-9, 8-9 0.51
3 230/460 60 1-4, 2-5, 3-6 0.73 3 575 60 1-4, 2-5, 3-6 2.2
7-8, 7-9, 8-9 1.46
3 575 60 1-4, 2-5, 3-6 7.36

Senior
PH U Hz Coils Resistance Ohm
3 200/346 50 1-4, 2-5, 3-6 1.18
3 400/440 50 1-4, 2-5, 3-6 1.50
3 220/380 60 1-4, 2-5, 3-6 0.82
3 230/460 60 1-4, 2-5, 3-6 1.36
7-8, 7-9, 8-9 1.36
3 575 60 1-4, 2-5, 3-6 6.31

GRINDEX 33
Workshop Manual Tools

114646

114334

114645
114626

114422
(114335)
114450
114627
114648

114310 114649
114311 114490

114386
114359 114383 114384 114385

GRINDEX 34
Grindex AB Box 538 SE-136 25 Haninge Sweden
Tel:+46 8 606 66 00 Fax:+46 8 745 53 28
e-mail: grindex@grindex.com www.grindex.com