Wacker Neuson PSC31603EX User manual

Operator’s Manual

Pump

PSC3 1603EX

PSC4 2303EX

PSC4 3803EX

5000187881 03 1211

5000187881

EN

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.

Foreword

wc_tx001310gb.fm 3

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 covered in this manual

Machine

documentation

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

 Use the separate Parts Book supplied with the machine to order replacement

parts.

 Refer to the separate Repair Manual for detailed instructions on servicing and

repairing the machine.

 If you are missing any of these documents, please contact Wacker Neuson

Corporation to order a replacement or visit 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 main-

tain 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 Corporation 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 Corporation reserves the right

to change any portion of this information without notice.

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 Neu-

son service center according to written instructions published by Wacker Neu-

son.

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

meet the approved criteria.

Unapproved parts, attachments, or modifications may have the following

consequences:

Machine Item Number

PSC3 1603EX

PSC4 2303EX

PSC4 3803EX

0620471

0620472

0620473

Foreword

4 wc_tx001310gb.fm

 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.

Translation of the original Declaration of Conformity

EC Declaration of Conformity

Manufacturer

Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, 80809 München

Product

Directives and standards

We hereby declare that this product meets and complies with the relevant regulations and

requirements of the following directives and standards:

2006/42/EG, 2006/95/EG, 2004/108/EG, EN 809, EN 60335-2-41, EN 61000-6

Authorized person for technical documents

Axel Häret,

Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, 80809 München

Product

PSC3 1603Ex PSC4 2303Ex PSC4 3803Ex

Product category Submersible water pump

Product function Water pumping

Item number 0620471 0620472 0620473

Dr. Michael Fischer

Director of Technology and Innovation

München, 01.08.2011

PSC EX Table of Contents

wc_bo5000187881_03TOC.fm 7

Foreword 3

EC Declaration of Conformity 5

1 Safety Information 9

1.1 Signal Words Used in this Manual ....................................................... 9

1.2 Machine Description and Intended Use ............................................. 10

1.3 Operating and Electrical Safety .......................................................... 12

1.4 Informational Labels ........................................................................... 12

2 Operation 14

2.1 Names of Parts ................................................................................... 14

2.2 Prior to Operation ............................................................................... 16

2.3 Installation .......................................................................................... 16

2.4 Preparing for installation ..................................................................... 17

2.5 Installing the Pump ............................................................................. 20

2.6 Electrical Wiring .................................................................................. 22

2.7 Cable Assembly ................................................................................. 24

2.8 Motor Wiring ....................................................................................... 25

2.9 Operation ............................................................................................ 26

2.10 Operating Water Level ....................................................................... 28

2.11 Motor Protectors ................................................................................. 29

2.12 Emergency Shutdown Procedure ....................................................... 29

3 Maintenance 30

3.1 Periodic Maintenance Table ............................................................... 30

3.2 Maintenance and Inspection .............................................................. 31

3.3 Inspecting and Replacing Lubricant ................................................... 32

3.4 Disassembly/Reassembly .................................................................. 33

3.5 Disassembly ....................................................................................... 34

3.6 Reassembly ........................................................................................ 35

3.7 Troubleshooting .................................................................................. 36

Table of Contents PSC EX

8 wc_bo5000187881_03TOC.fm

4 Technical Data 38

4.1 Standard Specifications .......................................................................38

4.2 Operating Specifications .....................................................................39

5 AEM Safety Manual 41

PSC EX Safety Information

wc_si000372gb.fm 9

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 situa-

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

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

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

f 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.

f

To avoid death or serious injury from this type of hazard, obey all safety messages that

follow this signal word.

WARNING

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

death or serious injury.

f

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

sages that follow this signal word.

CAUTION!

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

minor or moderate injury.

f

To avoid possible minor or moderate injury from this type of hazard, obey all safety mes-

sages that follow this signal word.

Safety Information PSC EX

10 wc_si000372gb.fm

1.2 Machine Description and Intended Use

This machine is a submersible cutter pump. The Wacker Neuson

Submersible Cutter Pump consists of an electric motor, an impeller with a

carbide tip and cutter plate, a stand, and a metal casing with ports for

water or sewage suction and discharge. During operation, the impeller

cuts solid material until it is small enough to pass through the discharge

port. Power is supplied to the pump through a corded plug or a hard-wired

connection, depending on the installation. The operator connects pipes to

the pump and routes them so that water or sewage is pumped from the

work area and discharged into an appropriate location.

This machine is intended to be used for residential, commercial, and

industrial pumping of waste water with variable solids inclusion. This

machine is designed and intended to operate efficiently up to the flow,

head, and suction lift limits stated within the product 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 pipes, incorrect length pipes, 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

PSC EX Safety Information

wc_si000372gb.fm 11

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

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

Safety Information PSC EX

12 wc_si000372gb.fm

1.3 Operating and Electrical Safety

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

grounding-type receptacle.

Risk of electric shock—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.

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

proper installation.

CAUTION: This pump may automatically restart. Prior to working on

the pump or control panel, all supply circuits must be disconnected.

CAUTION: Risk of shock—do not remove cord and strain relief.

1.4 Informational Labels

Label Meaning

A nameplate listing the model number, item num-

ber, revision number, and serial number is

attached to each unit. Please record the informa-

tion found on this nameplate so it will be available

should the nameplate become lost or damaged.

When ordering parts or requesting service infor-

mation, 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.

WARNING

JAPAN

PSC EX Safety Information

wc_si000372gb.fm 13

Notes:

Operation PSC EX

14 wc_tx001311gb.fm

2 Operation

2.1 Names of Parts

See Graphics: wc_gr007086 and wc_gr007096

Ref Description Ref Description

1 Cable 15 Flange

2 Gland 16 Motor bracket

3 Stuffing box 17 Upper bearing

4 Pump casing 18 Lower bearing

5 Impeller 19 Miniature protector

6 Suction cover 20 Shaft

7 Stand 21 Rotor

8 Mechanical seal 22 Stator

9 Oil seal 23 Bearing housing

10 Oil lifter 24 Bearing cover

11 Oil plug 25 Motor frame

12 Lubricant 26 Eye bolt

13 Discharge bend —

14 Air release valve —

PSC EX Operation

wc_tx001311gb.fm 15

2

12

1

2

3

16

11

26

17

19

21

22

24

18

23

20

4

25

7

15

9

10

8

13

14

5

6

wc_gr007096

PSC4 2303EX

PSC4 3803EX

1

2

3

16

25

20

26

17

19

21

22

24

18

23

4

15

7

8

9

10

11

12

13

14

5

6

wc_gr007086

PSC3 1603EX

Operation PSC EX

16 wc_tx001311gb.fm

2.2 Prior to Operation

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

• Inspection

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

make sure all bolts and nuts are tightened properly.

• Specification check

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.

• Product specifications

Do not operate this product under any conditions other than those for

which it is specified. Failure to observe this precaution can lead to

electrical shock, current leakage, fire, water leakage or other

problems.

2.3 Installation

Preparing for Installation

Observe the following points when preparing to install the pump.

• Be aware that leakage of pump lubricants may cause pollution of

water.

• An appropriate plug or electrical connection must be provided

according to local codes and standards. Refer to the wiring

diagram.

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

Operating Safety

• Do not operate the pump if the maximum water pressure in the

area exceeds 0.3 Mpa–discharge pressure.

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

water, or organic solvents. Contact your Wacker Neuson dealer

with questions about specific fluids.

• Do not use in water temperatures outside the range of 0–40°C

(32–104°F) which can lead to failure, electrical leakage or shock.

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

• Do not operate the pump if any parts are loose or missing.

CAUTION

PSC EX Operation

wc_tx001311gb.fm 17

2.4 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)

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

instruments.

Measure resistance

Use a megohmmeter to measure the insulation resistance between

each core lead and the ground lead to verify the insulation resistance

of the motor.

• Reference insulation resistance: 20MΩ or greater

Note: The reference insulation resistance (20M

Ω

or greater) is the value

when the pump is new or has been repaired. For the reference value after

installation, see “Periodic Maintenance Table.”

Description Description

U Power Lead (Black) S1 Protector Circuit (Black)

V Power Lead (Black) S2 Protector Circuit (Black)

W Power Lead (Black) G Ground (Green/Yellow)

wc_gr007215

Operation PSC EX

18 wc_tx001311gb.fm

Checks to make before installation

With the megohmmeter, measure the insulation resistance between

each core lead and the ground lead.

Reference insulation resistance: 20MΩ or greater

Note: The reference insulation resistance (20M

Ω

or greater) is the

value when the pump is new or has been repaired. For the reference

value after installation, see “Periodic Maintenance Table.”

PSC EX Operation

wc_tx001311gb.fm 19

Notes

Operation PSC EX

20 wc_tx001311gb.fm

2.5 Installing the Pump

Overview

This pump requires careful installation to operate at peak efficiency.

Observe the following recommendations when installing the pump.

Placing the pump

A sample installation diagram is provided below. Contact your Wacker

Neuson dealer for help in installing the pump for your particular

application.

• Install the pump on a flat, smooth surface, such as a concrete

pad.

• Do not place the pump in areas that may be susceptible to

turbulence or may allow the pump to take in air—for example,

near the inlet of a water tank. Install a baffle if it is impossible to

keep the pump away from these areas.

• Install piping so that air pockets cannot form anywhere in the

system.

NOTICE: If the pump is being controlled automatically, discharged water

could flow backwards. This backflow may trigger the water surface control

immediately, forcing the pump to continuously cycle ON and OFF.

Permanent damage to the pump may result.

• Install a check valve if the pump tank is deep, or if the vertical

head or the lateral distance is long.

Description Description

a Cable g Manhole cover

b Baffle plate h Control panel

c Start position j Gate valve

d Stop position k Check valve

e Level switch l Pipe

f Chain m Pump

wc_gr007207

a

h

j

g

f

k

l

m

b

c

d

e

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