Wacker Neuson PSC42203 User manual

Operator’s Manual

Pump

PSC2 0753

PSC3 1503

PSC4 2203

PSC4 3703

0179832en 001 0210

0179832EN

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 Corporation.

Any type of reproduction or distribution not authorized by Wacker Neuson Corporation

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 Corporation

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_tx001305gb.fm 3

Foreword

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

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 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

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.

Machine Item Number

PSC2 0753

PSC3 1503

PSC4 2203

PSC4 3703

0620467

0620468

0620469

0620470

Foreword

4 wc_tx001305gb.fm

Table of Contents PSC

wc_bo0179832en_001TOC.fm 5

1. Foreword 3

2. Safety Information 7

2.1 Machine Description and Intended Use ............................................... 8

2.2 Operating and Electrical Safety .......................................................... 10

2.3 Informational Labels ........................................................................... 10

3. Operation 11

3.1 Names of Parts ................................................................................... 11

3.2 Prior to Operation ............................................................................... 12

3.3 Preparing for Installation .................................................................... 12

3.4 Installing the Pump ............................................................................. 15

3.5 Electrical Wiring .................................................................................. 18

3.6 Cable Assembly ................................................................................. 20

3.7 Electrical Circuit Diagram ................................................................... 21

3.8 Operation ............................................................................................ 22

3.9 Operating Water Level ...................................................................... 24

3.10 Motor Protector ................................................................................... 25

3.11 Emergency Shutdown Procedure ....................................................... 25

4. Maintenance 26

4.1 Periodic Maintenance Table ............................................................... 26

4.2 Maintenance and Inspection .............................................................. 27

4.3 Disassembly/Reassembly .................................................................. 29

4.4 Disassembly ....................................................................................... 30

4.5 Reassembly ........................................................................................ 31

4.6 Troubleshooting .................................................................................. 32

5. Technical Data 34

5.1 Standard Specifications ...................................................................... 34

5.2 Operating Specifications .................................................................... 35

5.3 Dimensions ........................................................................................ 36

PSC Table of Contents

6 wc_bo0179832en_001TOC.fm

PSC Safety Information

wc_si000370gb.fm 7

1 Safety Information

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.

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 mes-

sages 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

messages 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 messages that follow this signal word.

Safety Information PSC

8 wc_si000370gb.fm

1.1 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 Safety Information

wc_si000370gb.fm 9

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

10 wc_si000370gb.fm

1.2 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.

1.3 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 plate 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.

WARNING

JAPAN

PSC Operation

wc_tx001306gb.fm 11

2 Operation

2.1 Names of Parts

See Graphic: wc_gr007098

Ref Description Ref Description

1 Cable 8 Oil lifter

2 Pump casing 9 Oil plug

3 Impeller 10 Lubricant

4 Suction cover 11 Discharge bend

5 Stand 12 Air release valve

6 Mechanical seal 13 Flange

7 Oil seal 14 Eye bolt

1

2

3

11

4

13

7

8

9

10

14

13

12

5

6

wc_

g

r007098

Operation PSC

12 wc_tx001306gb.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 Preparing for 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 Operation

wc_tx001306gb.fm 13

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 (Brown) W Power Lead (Black)

V Power Lead (Blue or Gray) G Ground (Green/Yellow)

wc_gr007262

Operation PSC

14 wc_tx001306gb.fm

Checks to make before installation

• When a grounded plug is used:

Use the megohmmeter to measure the insulation resistance between

the cable assembly prongs and ground.

• When connection leads are used:

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 Operation

wc_tx001306gb.fm 15

2.4 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 Hook l Pipe

f Chain m Pump

wc_gr007263

a

e

h

j

g

f

k

l

m

b

c

d

Operation PSC

16 wc_tx001306gb.fm

• If the pump is being installed in a permanent location where it is

not readily accessible after installation, request a duplicate

nameplate from Wacker Neuson. The duplicate nameplate

should be installed at the wellhead or on the control box for ready

visibility.

Suspending the pump

The pump may be suspended by a chain. Use a shackle (a) to fasten

the chain to the pump eye bolt (b) as shown in the illustration.

Safety

considerations

• Do not lift or suspend the pump by the cable.

• The chain and lifting apparatus must be capable of supporting the

pump. See Technical Data for weight and dimensional

information.

• Make sure that the chain does not become twisted during

installation. A twisted chain may break, causing the pump to fall.

• Do not operate the pump if the cable is hanging loose. An

unrestrained cable can be sucked into the impeller.

CAUTION

Personal injury or equipment damage hazards. An improperly suspended pump

may fall unexpectedly, causing injury or equipment damage.

f Observe the following safety considerations when suspending the pump.

wc_gr007208

a

b

PSC Operation

wc_tx001306gb.fm 17

Notes:

Operation PSC

18 wc_tx001306gb.fm

2.5 Electrical Wiring

General information

• Electrical wiring should be performed by a qualified electrician in

accord with all applicable regulations. Failure to observe this

precaution not only risks breaking the law, but is extremely

hazardous.

• Make sure the pump is equipped with the specified overload

protectors, fuses, and/or breakers. These items are designed to

guard against electrical shock from a current leak or pump

malfunction.

• Operate within the capacity of the power supply and wiring.

Grounding the pump

• Do not use the pump without first grounding it properly.

• Do not attach the grounding wire to a gas pipe, water pipe,

lightning rod, or telephone grounding wire.

Connecting the power supply

• Before connecting leads to the terminal strip, make certain the

power supply is disconnected (i.e. through circuit breakers) to

avoid electrical shock, shorting, or unexpected starting of the

pump.

• Do not use the pump with the cable assembly connected loosely.

• Draw power from a dedicated power outlet rated at 15 A or

above. Sharing the outlet with other equipment may cause

overheating at the branch outlet and could result in fire.

• Use a dedicated power supply with a ground leakage circuit

breaker.

• Tighten the ends of the cable assembly securely against the

terminal board.

WARNING

An improperly wired pump can result in current leakage, personal injury, electrical

shock, fire, or permanent equipment damage.

f Observe the safety considerations below when performing electrical wiring.

PSC Operation

wc_tx001306gb.fm 19

Description Description

U Power Lead (Brown) W Power Lead (Black)

V

Power Lead (Blue or Gray)

G Ground (Green/Yellow)

wc_gr007264

Operation PSC

20 wc_tx001306gb.fm

2.6 Cable Assembly

Extending the cable

If it is necessary to extend the cable assembly, use a core size equal

to or larger than the original. This is necessary to avoid a performance

drop and cable overheating which may result in current leakage,

electrical shock, or fire.

Avoiding cable damage

• Do not suspend the pump by the cable.

• Make sure the cable does not become excessively bent or

twisted.

• Do not allow the cable to rub against a structure in a way that

might damage it.

• Repair or replace a cut or damaged cable immediately.

Submerging the cable

• Do not submerge a cable with cut insulation or other damage.

• If it is necessary to submerge the connection wires of the cable

assembly in water, first seal the wires completely in a molded

protective sleeve.

• Do not allow the cable assembly wires or power supply plug to

become wet.

WARNING

Current leakage, electrical shock, or fire hazards.

f Observe the safety considerations below when handling the cable assembly.

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