Wacker Neuson PS31500 User manual

Operator’s Manual

Pump

PS3 1500

PS3 2200

Type PS3 1500, PS3 2200

Document 5000187821

Date 0719

Revision 04

Language EN

5000187821

Copyright notice

All rights, including copying and distribution rights, are reserved.

This publication may be photocopied by the original purchaser of the

machine. Any other type of reproduction is prohibited without express

written permission from Wacker Neuson Production Americas LLC.

Any type of reproduction or distribution not authorized by Wacker

Neuson Production Americas LLC represents an infringement of valid

copyrights. Violators will be prosecuted.

Trademarks

All trademarks referenced in this manual are the property of their

respective owners.

Manufacturer

Wacker Neuson Production Americas LLC

N92W15000 Anthony Avenue

Menomonee Falls, WI 53051 U.S.A.

Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957

www.wackerneuson.com

Original instructions

This Operator’s Manual presents the original instructions. The original

language of this Operator’s Manual is American English.

wc_tx004643en.fm 3

CALIFORNIA Proposition 65 Warning

WARNING

The engine exhaust from this product contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive harm.

WARNING

Diesel engine exhaust and some of its constituents are known to the State of

California to cause cancer, birth defects, and other reproductive harm.

WARNING

Cancer and Reproductive Harm -

www.P65Warnings.ca.gov.

WARNING

Batteries, battery posts, terminals and related accessories contain lead and lead

compounds, and other chemicals known to the State of California to cause cancer

and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.

CALIFORNIA Proposition 65 Warning Proposition 65 Warning

4 wc_tx004643en.fm

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PS3 1500 / PS3 2200 Foreword

Foreword

SAVE THESE INSTRUCTIONS—This manual contains important instructions for

the machine models below. These instructions have been written expressly by

Wacker Neuson Production Americas LLC and must be followed during

installation, operation, and maintenance of the machines.

Machines discussed in this manual:

Machine

documentation

 From this point forward in this documentation, Wacker Neuson Production

Americas LLC will be referred to as Wacker Neuson.

 Keep a copy of the Operator’s Manual with the machine at all times.

 For spare parts information, please see your Wacker Neuson Dealer, or visit

the Wacker Neuson website at http://www.wackerneuson.com/.

 When ordering parts or requesting service information, be prepared to provide

the machine model number, item number, revision number, and serial number.

Expectations

for

information in

this manual

 This manual provides information and procedures to safely operate and

maintain the above Wacker Neuson model(s). For your own safety and to

reduce the risk of injury, carefully read, understand, and observe all instructions

described in this manual.

 Wacker Neuson expressly reserves the right to make technical modifications,

even without notice, which improve the performance or safety standards of its

machines.

 The information contained in this manual is based on machines manufactured

up until the time of publication. Wacker Neuson reserves the right to change

any portion of this information without notice.

 The illustrations, parts, and procedures in this manual refer to Wacker Neuson

factory-installed components. Your machine may vary depending on the

requirements of your specific region.

Manufacturer’s

approval

This manual contains references to approved parts, attachments, and

modifications. The following definitions apply:

 Approved parts or attachments are those either manufactured or provided by

Wacker Neuson.

 Approved modifications are those performed by an authorized Wacker

Neuson service center according to written instructions published by Wacker

Neuson.

 Unapproved parts, attachments, and modifications are those that do not

meet the approved criteria.

Unapproved parts, attachments, or modifications may have the following

consequences:

 Serious injury hazards to the operator and persons in the work area

 Permanent damage to the machine which will not be covered under warranty

Contact your Wacker Neuson dealer immediately if you have questions about

approved or unapproved parts, attachments, or modifications.

Part No. PS3 1500

0009117, 0009118

PS3 2200

0009119

Foreword PS3 1500 / PS3 2200

6 wc_tx002040gb.fm

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wc_bo5000187821_04TOC.fm 1

PS3 1500 / PS3 2200 Table of Contents

CALIFORNIA Proposition 65 Warning 3

Foreword 5

1 Safety Information 3

1.1 Signal Words Used in this Manual ................................................................ 3

1.2 Machine Description and Intended Use ........................................................ 3

1.3 Operating and Electrical Safety ..................................................................... 5

1.4 Service Safety ............................................................................................... 5

1.5 Labels ............................................................................................................ 7

2 Lifting and Transporting 8

3 Installation 9

3.1 Components .................................................................................................. 9

3.2 Preparing the Machine for First Use ............................................................ 10

3.3 Application Area .......................................................................................... 10

3.4 Maximum Allowable Water Pressure .......................................................... 11

3.5 Preparing for installation .............................................................................. 11

3.6 Checks to Make Before Installation ............................................................. 11

3.7 Changing the Operating Voltage ................................................................. 12

3.8 Precautions in Installation ........................................................................... 13

3.9 Electrical Wiring ........................................................................................... 14

3.10 Connecting the power supply ...................................................................... 15

3.11 Cable Assembly .......................................................................................... 15

4 Operation 16

4.1 Before Starting ............................................................................................ 16

4.2 Operating Water Level ................................................................................ 18

4.3 Motor Protection System ............................................................................. 19

4.4 Emergency Shutdown Procedure ................................................................ 19

5 Maintenance 20

5.1 Periodic Maintenance Schedule .................................................................. 20

5.2 Maintenance and Inspection ....................................................................... 20

5.3 Storage ........................................................................................................ 21

5.4 Inspecting and Replacing Lubricant ............................................................ 21

5.5 Disassembly and Reassembly .................................................................... 23

Table of Contents PS3 1500 / PS3 2200

2 wc_bo5000187821_04TOC.fm

5.6 Disassembly ................................................................................................ 23

5.7 Reassembly ................................................................................................. 25

5.8 Troubleshooting ........................................................................................... 25

6 Technical Data 27

7 Schematics 29

8 AEM Safety Manual 31

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PS3 1500 / PS3 2200 Safety Information

1 Safety Information

1.1 Signal Words Used in this Manual

This manual contains DANGER, WARNING, CAUTION, NOTICE,

and NOTE signal words which must be followed to reduce the

possibility of personal injury, damage to the equipment, or improper

service.

NOTICE: Used without the safety alert symbol, NOTICE indicates a

situation which, if not avoided, could result in property damage.

Note: A Note contains additional information important to a procedure.

1.2 Machine Description and Intended Use

This machine is a submersible water pump. The Wacker Neuson Submersible

Pump consists of an electric motor, an impeller, a strainer, and a metal casing

with ports for water suction and discharge. Power is supplied to the pump

through a corded plug or a hard-wired connection, depending on the installation.

The operator connects hoses to the pump and routes them so that water is

pumped from the work area and discharged into an appropriate location.

This is the safety alert symbol. It is used to alert you to potential personal hazards.

► Obey all safety messages that follow this symbol.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death

or serious injury.

► To avoid death or serious injury from this type of hazard, obey all safety mes-

sages that follow this signal word.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in

death or serious injury.

► To avoid possible death or serious injury from this type of hazard, obey all

safety messages that follow this signal word.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in

minor or moderate injury.

► To avoid possible minor or moderate injury from this type of hazard, obey all

safety messages that follow this signal word.

Safety Information PS3 1500 / PS3 2200

4 wc_si000036gb.fm

This machine is intended to be used for general de-watering applications. This

machine is intended for the pumping of clear water, or water containing solids up

to the size stated within the product’s specifications, and up to the flow, head,

and suction lift limits also stated within the product’s specifications.

This machine has been designed and built strictly for the intended use described

above. Using the machine for any other purpose could permanently damage the

machine or seriously injure the operator or other persons in the area. Machine

damage caused by misuse is not covered under warranty.

The following are some examples of misuse:

• Pumping flammable, explosive, or corrosive fluids

• Pumping hot or volatile fluids that result in pump cavitation

• Operating the pump outside of product specifications due to incorrect

diameter hoses, incorrect length hoses, other inlet or outlet restrictions,

or excessive suction lift or head

• Using the machine as a ladder, support, or work surface

• Using the machine to carry or transport passengers or equipment

• Operating the machine outside of factory specifications

• Operating the machine in a manner inconsistent with all warnings found

on the machine and in the Operator’s Manual.

This machine has been designed and built in accordance with the latest global

safety standards. It has been carefully engineered to eliminate hazards as far as

practicable and to increase operator safety through protective guards and

labeling. However, some risks may remain even after protective measures have

been taken. They are called residual risks. On this machine, they may include

exposure to:

• Electric shock from improper electrical connections or high voltage

• Personal injury from improper lifting techniques

• Projectile hazard from discharge

To protect yourself and others, make sure you thoroughly read and understand

the safety information presented in this manual before operating the machine.

Operator qualifications

Only trained personnel are permitted to start, operate, and shut down

the machine. They also must meet the following qualifications:

• Have received instruction on how to properly use the machine

• Are familiar with required safety devices

The machine must not be accessed or operated by:

•Children

• People impaired by alcohol or drugs

wc_si000036gb.fm 5

PS3 1500 / PS3 2200 Safety Information

Personal Protective Equipment (PPE)

Wear the following Personal Protective Equipment (PPE) while

operating this machine:

• Close-fitting work clothes that do not hinder movement

• Safety glasses with side shields

• Hearing protection

• Safety-toed footwear

Replacement parts

When replacement parts are required for this machine, use only

Wacker Neuson replacement parts or those parts equivalent to the

original in all types of specifications, such as physical dimensions,

type, strength, and material.

1.3 Operating and Electrical Safety

This pump has not been investigated for use in swimming pool areas.

An acceptable motor-control switch shall be provided at the time of

installation according to local codes and regulations.

1.4 Service Safety

Service training

Before servicing or maintaining the machine:

• Read and understand the instructions contained in all manuals

delivered with the machine.

• Familiarize yourself with the location and proper use of all

controls and safety devices.

WARNING

Electric shock hazard.

► To reduce risk of electric shock, connect only to a properly grounded, ground-

ing-type receptacle.

► To reduce risk of electric shock, follow instructions in this manual for proper

installation.

CAUTION

Electric shock hazard. This pump may automatically restart.

► Prior to working on the pump or control panel, all supply circuits must be discon-

nected.

► Do not remove cord and strain relief.

Safety Information PS3 1500 / PS3 2200

6 wc_si000036gb.fm

• Only trained personnel shall troubleshoot or repair problems

occurring with the machine.

• Contact Wacker Neuson for additional training if necessary.

When servicing or maintaining this machine:

• Do not allow improperly trained people to service or maintain the

machine. Personnel servicing or maintaining the machine must

be familiar with the associated potential risks and hazards.

Personal Protective Equipment (PPE)

Wear the following Personal Protective Equipment (PPE) while

servicing or maintaining this machine:

• Close-fitting work clothes that do not hinder movement

• Safety glasses with side shields

• Hearing protection

• Safety-toed footwear

In addition, before servicing or maintaining the machine:

• Tie back long hair.

• Remove all jewelry (including rings).

Replacing parts and labels

• Replace worn or damaged components.

• Replace all missing and hard-to-read labels.

• When replacing electrical components, use components that are

identical in rating and performance to the original components.

• When replacement parts are required for this machine, use only

Wacker Neuson replacement parts or those parts equivalent to

the original in all types of specifications, such as physical

dimensions, type, strength, and material.

wc_si000036gb.fm 7

PS3 1500 / PS3 2200 Safety Information

1.5 Labels

A nameplate listing the model number, item number,

revision number, and serial number is attached to each

unit. Please record the information found on this nameplate

so it will be available should the nameplate become lost or

damaged. When ordering parts or requesting service

information, you will always be asked to specify the model

number, item number, revision number, and serial number

of the unit.

CAUTION

Do not attempt to operate this product before reading the

Operator’s Manual and understanding its contents.

Mishandling of this product may result in explosion, fire, or

electrical shock.

 Do not pull on the power cord or use the power cord to lift

the pump.

 Always use a dedicated ground leakage circuit breaker.

 Be sure to install the ground wire securely.

 Be sure to disconnect the power supply before handling

or inspecting the pump.

Never insert your hand into the pump inlet holes while the

pump is connected to the power supply.

California Proposition 65 Warning

Cancer and Reproductive Harm -

www.P65Warnings.ca.gov.

Menomonee Falls, WI 53051 USA

Model

Item No. Rev.

Serial No.

VHz

kWkgMax. L/minMax. m

MADE IN

JAPAN

HPlbsMax. GPMMax.

ft

C

US

L

I

S

T

E

D

R

Phase

C22.2 No. 108-M89

2001992

Conforms to UL Std.778

Cert . to CAN/CSA

Std.

Amp.

Man. Y/ M

Y THERMALL PROTECTED

INDOORS OR OUTDOORS

CSA ENCLOSURE

3

Wacker Neuson Production Americas LLC

Cancer and Reproductive Harm

www.P65Warnings.ca.gov

Cáncer y daño reproductivo

www.P65Warnings.ca.gov

Cancer ou malformations

congénitales

www.P65Warnings.ca.gov

WARNING

AVERTISSEMENT

ADVERTENCIA

5100045462

Lifting and Transporting PS3 1500 / PS3 2200

8 wc_tx001959gb.fm

2 Lifting and Transporting

Do not under any circumstances install or move the pump by

suspending it from the cable assembly. The cable may be damaged,

causing electrical leakage, shock, or fire.

When installing the pump, pay close attention to its center of gravity

and weight. If it is not lowered into place correctly, it may fall and be

damaged or cause injury.

When transporting the pump by hand, be sure to employ manpower

commensurate with the weight of the pump. To avoid back injury

when lifting the pump, bend the knees to pick it up rather than

bending your back only.

Avoid dropping the pump or other strong impact. Lift the pump by

holding it firmly with the hands or by attaching a rope or chain to the

handle.

WARNING

CAUTION

wc_tx001974gb.fm 9

PS3 1500 / PS3 2200 Installation

3 Installation

3.1 Components

Ref. Description Ref. Description

1. Coupling 9. Dust Seal

2. Mechanical Seal 10. Wear Ring

3. Gasket 11. Oil Housing

4. Sleeve 12. Impeller

5. Cable Assembly 13. Volute

6. Lifting Handle 14. Strainer

7. Lubricant 15. Retainer Plate

8. Oil Plug

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

wc_gr000321

Installation PS3 1500 / PS3 2200

10 wc_tx001974gb.fm

3.2 Preparing the Machine for First Use

When the pump is delivered, first perform the following inspection checks:

■ While unpacking, inspect the product for damage during shipment, and make

sure all bolts and nuts are tightened properly.

■ Check the model number to make sure it is the product that was ordered. Be

certain it is the correct voltage and frequency.

Note: If there is any problem with the product as shipped, contact your nearest

dealer or Wacker Neuson representative at once.

3.3 Application Area

Note: Consult your local dealer or Wacker Neuson representative before using

with any liquids other than those indicated in this document.

ATENCIÓN

Personal injury hazard. Failure to observe this caution can lead to electrical shock,

current leakage, fire, water leakage, or other problems.

► Do not operate this product under any conditions other than those for which it is

specified.

ADVERTENCIA

Personal injury hazard.

► If the pump is used to drain a swimming pool, the pump must be connected to a

Ground Fault Interrupter (GFI).

► If the pump is used in fountains, the pump must be connected to a Ground Fault

Interrupter (GFI).

► The pump must not be used when people are in the water.

► Leakage of pump lubricants may cause pollution of water.

► Proper plug must be provided according to local codes and standards. Refer to

wiring diagram.

► Do not use this pump in liquids other than water, such as oil, salt water, or

organic solvents.

► Use with a power supply voltage within ±5% of the rated voltage.

► Do not use in water temperatures outside the range of 0–40°C (32–104°F)

which can lead to failure, current leakage or shock.

► Do not use in the vicinity of explosive or flammable materials.

► Use only in fully assembled state.

wc_tx001974gb.fm 11

PS3 1500 / PS3 2200 Installation

3.4 Maximum Allowable Water Pressure

AVISO: Do not use at greater than the water pressure shown, which can damage

the pump resulting in electrical leakage and electrical shock.

3.5 Preparing for installation

Before installing the pump at a work site, you will need to have the following tools

and instruments ready:

■ Insulation resistance tester (megohmmeter)

■AC voltmeter

■ AC ammeter (clamp-on type)

■ Bolt and nut tighteners

■ Power supply connection tools (screwdriver or box wrench)

Nota: Note: Please also read the instructions that come with each of the test

instruments.

3.6 Checks to Make Before Installation

With the megohmmeter, measure the insulation resistance between each of the

power wires and grounding wire to verify the insulation resistance of the motor.

Reference insulation resistance: 20M or greater

Nota: The reference insulation resistance (20M



or greater) is the value when the

pump is new or has been repaired. For the reference value after installation, see

Maintenance and Inspection.

DO NOT measure the insulation resistance with insulation resistance tester for the

following parts. It will cause damage (Model PSA 2 500).

Improper ways to measure insulation resistance

Model Maximum Allowable Water Pressure

PS 3 1500/2200 0.3 MPa (43 PSI)

1 Between the plug prongs.

2 Between the electrodes on the level relay unit.

3 Between the electrodes on the level relay unit and the plug prongs.

CAUTION

1

2

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3

Installation PS3 1500 / PS3 2200

12 wc_tx001974gb.fm

3.7 Changing the Operating Voltage

The operating voltage of the motor can be changed from 110V to 220V depending

on the available power source.

Requirements

■ Pump disconnected from the power source

■ Hand tools (screwdriver and wrench)

Procedure

Follow the procedure below to change the operating voltage of the motor.

1. Remove the four bolts (c), lockwashers (d), and flat washers (e) that fasten the

housing cover (j) to the motor bracket.

2. Carefully lift the housing cover.

AVISO: Avoid entangling the power cord lead wires with internal components such

as the centifugal switch (p) or the capacitor (o). Be careful not to damage the O-

ring (w) while lifting the housing cover.

3. Support the housing cover so that it allows access to the terminal box (q).

ADVERTENCIA

Electric shock hazard.

► Ensure that the pump is disconnected from the power source before changing

the operating voltage.

wc_gr008856

p

wc_tx001974gb.fm 13

PS3 1500 / PS3 2200 Installation

4. Remove the plastic cover (not shown) from the front face of the terminal box.

Using a screwdriver, detach and move the lead wires as needed to configure the

operating voltage.

5. Reinstall the plastic cover.

6. Make sure that the O-ring (w) and gasket (x) are properly seated.

AVISO: Replace the O-ring or gasket if either shows signs of damage or wear.

7. Lower the housing cover onto the motor bracket. Align the housing cover as

shown.

8. Fasten the housing cover to the motor bracket.

3.8 Precautions in Installation

3.8.1 The pump is supplied with a threaded discharge fitting.

Tighten hose coupling or discharge pipe securely and

with proper gaskets.

3.8.2 Install the pump in a location with sufficient water level,

where water collects readily.

Note: See Operation (“Operating Water Level”) for the

water level necessary for operation. The discharge end

of the hose should be located higher than the water

surface. If the end of the hose is submerged, water

may flow back to the pump when the pump is stopped;

and if the hose end is lower than the water surface,

water may overflow when the pump is turned off.

3.8.3 The hose should be run as straight as possible, since

excessive bending will hinder the water flow,

preventing sufficient lift, and can even cause the hose

to become clogged with earth. If the hose is crimped

near the pump, air can become trapped in the pump

and cause idle running.

If large quantities of earth are sucked up, damage

resulting from friction in the pump can lead to electrical

leakage and shock.

Desired

voltage

Terminal block Wire locations

110V Upper L2 and T2 together at position 2 (from left)

Lower T1 and T3 together at position 3 (from left)

220V Upper T2 at position 5 (from left)

Lower T1 at position 4 (from left)

T3 at position 5 (from left)

CAUTION

Installation PS3 1500 / PS3 2200

14 wc_tx001974gb.fm

NOTICE: When the pump is installed at a work site,

make sure the hose is connected in such a way as to

ensure proper drainage. Otherwise water may leak out

and cause damage to surrounding walls or flooring, or

to equipment.

3.8.4 Use the pump in the upright position. To prevent the

strainer from becoming submerged in mud, causing it

to suck in sand or debris, mount it on a block or other

firm base.

3.8.5 If used in a permanent installation, where the pump is

not readily accessible after installation, please contact

Wacker Neuson for a duplicate nameplate to be

installed at the wellhead or on the control box so that it

will be readily visible.

Do not operate the pump dry. Doing so will prevent the

pump from attaining its full potential and may also

damage the pump and lead to a short and electrical

shock.

3.9 Electrical Wiring

Always make sure the pump is equipped with the specified overload protectors and

fuses or breakers, so as to prevent electrical shock from a current leak or pump

malfunction.

Operate within the capacity of the power supply and wiring.

CAUTION

ADVERTENCIA

Personal injury hazard. Incorrect wiring can lead to current leakage, electrical

shock or fire.

► Electrical wiring should be connected by a qualified person in accordance with

all applicable regulations. Failure to observe this precaution not only risks

breaking the law but is extremely dangerous.

ADVERTENCIA

Electrical shock hazard. Failure to ground the pump properly can lead to electrical

shock from a current leak or pump malfunction.

► Do not attach the grounding wire to a gas pipe, water pipe, lightning arrester or

telephone grounding wire.

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