PS 2 500 PS 2 750 PSA 2 500 - Wacker Neusonproducts.wackerneuson.com/manuals/Operators/0154625en_003.pdf · PS 2 500 / PS 2 750 / PSA 2 500 Safety Information wc_si000040gb.fm 5 2

Pump

PS 2 500PS 2 750PSA 2 500

OPERATOR’S MANUAL

0154625en 003

0409

0 1 5 4 6 2 5 E N

PS 2 500/PS 2 750/PSA 2 500 Table of Contents

wc_bo0154625003enTOC.fm 3

1. Foreword 4

2. Safety Information 5

2.1 Operating and Electrical Safety ............................................................ 62.2 Information Labels ................................................................................ 6

3. Technical Data 7

3.1 Standard Specifications ........................................................................ 73.2 Operating Specifications (50 Hz) .......................................................... 83.3 Dimensions ........................................................................................... 9

4. Operation 10

4.1 Names of Parts ................................................................................... 104.2 Prior to operation ................................................................................ 114.3 Installation .......................................................................................... 114.4 Electrical Wiring .................................................................................. 154.5 Electrical Circuit Diagrams ................................................................. 174.6 Operation ............................................................................................ 20

5. Maintenance 25

5.1 Periodic Maintenance Table ............................................................... 255.2 Maintenance and Inspection .............................................................. 265.3 Disassembly/Reassembly .................................................................. 285.4 Disassembly ....................................................................................... 295.5 Reassembly ........................................................................................ 305.6 Troubleshooting .................................................................................. 31

Foreword

4

1. ForewordThis manual provides information and procedures to safely operateand maintain this Wacker model. For your own safety and protectionfrom injury, carefully read, understand and observe the safetyinstructions described in this manual.

Keep this manual or a copy of it with the machine. If you lose thismanual or need an additional copy, please contact WackerCorporation. This machine is built with user safety in mind; however,it can present hazards if improperly operated and serviced. Followoperating instructions carefully! If you have questions about operatingor servicing this equipment, please contact Wacker Corporation.

The information contained in this manual was based on machines inproduction at the time of publication. Wacker Corporation reserves theright to change any portion of this information without notice.

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

Copyright 2007 by Wacker Corporation.

No part of this publication may be reproduced in any form or by anymeans, electronic or mechanical, including photocopying, withoutexpress written permission from Wacker Corporation.

Any type of reproduction or distribution not authorized by WackerCorporation represents an infringement of valid copyrights and will beprosecuted. We expressly reserve the right to make technicalmodifications, even without due notice, which aim at improving ourmachines or their safety standards.

PS 2 500 / PS 2 750 / PSA 2 500 Safety Information
2. Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE andNOTE callouts which must be followed to reduce the possibility ofpersonal injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potentialpersonal injury hazards. Obey all safety messages that follow thissymbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, willresult in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, couldresult in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, couldresult in minor or moderate injury.

NOTICE: Used without the safety alert symbol, NOTICE indicates ahazardous situation which, if not avoided, could result in propertydamage.

Note: Contains additional information important to a procedure.

DANGER

WARNING

CAUTION

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Safety Information PS 2 500 / PS 2 750 / PSA 2 500
2.1 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, see instruction 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.

2.2 Information 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

MADE IN TAIWAN

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PS 2 500 / PS 2 750 / PSA 2 500 Technical Data
3. Technical Data
Machines discussed in this manual:

3.1 Standard Specifications

Part No. PS2 5000008793, 00087940008795, 00087960009176, 00091770009178, 0620124

PSA 2 5000008787, 00087900008791, 00087920009179, 00091800009181, 0620125

PS2 7500008797, 00087980008799, 00088000009182, 00091830009184, 0620126

Applicable Liquids, Consistency and Temperature

Rain Water, Fountain Water, Ground Water, Sand-Carrying Water0–40°C (32–104°F)

Pump Impeller Semi-Vortex Type: (PS 2 500, PSA 2 500)Open Type: (PS 2 750)

Shaft Seal Double Mechanical Seal

Bearing Shielded Ball Bearing

Motor Specification Dry Submersible Induction Motor (2-Pole)

Insulation Class E

Protection System Miniature Protector: (PS 2 500, PSA 2 500)Circle Thermal Protector: (PS 2 750)

Lubricant SAE 10W/20W Such as:–Turbine Oil ISO VG #32–Shell Victrolia Oil #27–British Pet Energol THB #32–Gulf Paramount #32–Tellus #T22 Shell Oil–Shell Turbo T32

Connection Hose Coupling (Barb, BSP, QD–2")

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Technical Data PS 2 500 / PS 2 750 / PSA 2 500
3.2 Operating Specifications (50 Hz)
* The weight (mass) given above is the operating weight of the pump itself, not including the cable assembly.

Part No. PS 2 500 PSA 2 500 PS 2 750

0008793000879400087950008796000917600091770620124

0009178

0008787000879000087910008792000917900091800620125

0009181

0008797000879800087990008800000918200091830620126

0009184

Pump

Electric Power V/Ph/Hz 230/1/50 110/1/50 230/1/50 110/1/50 230/1/50 110/1/50

Rated Current A 2.9 6.2 2.9 6.2 6.3 13.9

Starting Method

Capacitor-Run

Discharge mm (in.) 50 (2)

Output kW (Hp) 0.48 (2/3) 0.75 (1)

Max. Head m (ft.) 11 (36) 16 (52.2)

Max. Capacity L/min(GPM)

220 (58) 276 (73)

Max. Pressure kg/cm2

(psi)1.19 (17) 1.83 (26)

Soild Size Capacity

mm (in.) 6 (0.2)

Weight* Kg (lbs.) 9.5 (21) 10.0 (22) 16.0 (35)

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PS 2 500 / PS 2 750 / PSA 2 500 Technical Data
3.3 Dimensions
PS 2 750

185(7.3)

185(7.3)

414(16.3)

PSA 2 500PS 2 500

305(12)

305(12)

229(9)

200(11)

229(9)

200(11)

185(7.3)

185(7.3)

185(7.3)

222(8.8)

mm (in.)

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Operation PS 2 500 / PS 2 750 / PSA 2 500
4. Operation
4.1 Names of Parts

See Graphic: wc_gr001185

Ref. Description Ref. Description

1. Lifting Handle 8. Seal-mechanical

2. Coupling 9. Lubricant

3. Oil Lifter 10. Seal-dust

4. Oil Plug 11. Sleeve

5. Cover-suction 12. Housing-oil

6. Strainer 13. Wear Ring

7. Cable Assembly 14. Impeller

1

27

891011121314

3

4

5

6

wc_gr001185

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PS 2 500 / PS 2 750 / PSA 2 500 Operation
4.2 Prior to operation
When the pump is delivered, first perform the following checks:

• Inspection

While unpacking, inspect the product for damage during shipment, andmake sure all bolts and nuts are tightened properly.

• Specification check

Check the model number to make sure it is the product that wasordered. Be certain it is the correct voltage and frequency.Note: If there is any problem with the product as shipped, contact yournearest dealer or Wacker representative at once.

• Product specifications

Do not operate this product under any conditions other than those forwhich it is specified. Failure to observe this precaution can lead toelectrical shock, current leakage, fire, water leakage or otherproblems.

4.3 Installation

If the pump is used for outdoor fountains, garden ponds and similarplaces, or to drain a swimming pool, the pump must be supplied by anisolating transformer or connected to a Residual Current Device (RCD)with a residual operating current not exceeding 30 mA.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, saltwater, 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, electrical leakage or shock.DO NOT use in the vicinity of explosive or flammable materials.Use only in fully assembled state.Note: Consult your local dealer or Wacker representative before usingwith any liquids other than those indicated in this document.

CAUTION

WARNING

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Preparing for InstallationBefore installing the pump at a work site, you will need to have thefollowing 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 testinstruments.

Checks to Make Before InstallationWhen a grounded plug is used:Use the megohmmeter to measure the insulation resistance betweenthe cable assembly prongs and ground.When connection leads are used:With the megohmmeter, measure the insulation resistance betweeneach core lead and the ground lead.Reference insulation resistance: 20MW or greater Note: The reference insulation resistance (20MW or greater) is thevalue when the pump is new or has been repaired. For the referencevalue after installation, see Maintenance and Inspection.

DO NOT measure the insulation resistance with insulation resistancetester for the following parts. It will cause damage (Model PSA 2 500).

Improper ways to measure insulation resistance


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

wc_gr000258

3

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Precautions During InstallationDo not under any circumstances install or move the pump bysuspending 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 gravityand weight. If it is not lowered into place correctly, it may fall and bedamaged or cause injury.When transporting the pump by hand, be sure to employ manpowercommensurate with the weight of the pump. To avoid back injury whenlifting the pump, bend the knees to pick it up rather than bending yourback only.
4.3.1 This pump series is offered with a variety of discharge fittings. Followprocedures noted below to assure a proper discharge connection.

Threaded Discharge Fitting (BSP) –Tighten hose coupling or discharge pipe securely and with propergaskets.Quick Disconnect Coupling (QD) –Assure coupling is tightened securely to pump discharge fitting andcompanion coupling is securely fastened with proper gaskets.Barbed Discharge Fitting (Barb) –Place hose clamp over hose and push hose to the base of thedischarge fitting. Tighten the hose clamp to secure the hose in place.

4.3.2 Avoid dropping the pump or other strong impact. Lift the pump byholding it firmly with the hands or by attaching a rope or chain to thehandle.

Note: On cable assembly handling, see Electrical Wiring.

4.3.3 Install the pump in a location with sufficient water level, where watercollects readily.

Note: See “Operating Water Level” for the water level necessary foroperation. The discharge end of the hose should be located higherthan the water surface. If the end of the hose is submerged, water mayflow back to the pump when the pump is stopped; and if the hose endis lower than the water surface, water may overflow when the pump isturned off.

4.3.4 The hose should be run as straight as possible, since excessivebending will hinder the water flow, preventing sufficient lift, and caneven cause the hose to become clogged with earth. If the hose iscrimped near the pump, air can become trapped in the pump andcause idle running.

WARNING

CAUTION

wc_tx000121gb.fm 13


If large quantities of earth are sucked up, damage resulting fromfriction in the pump can lead to electrical leakage and shock.

4.3.5 Use the pump in the upright position. To prevent the pump frombecoming submerged in mud, mount it on a block or other firm base ifnecessary.

4.3.6 If used in a permanent installation, where the pump is not readilyaccessible after installation, please contact Wacker for a duplicatenameplate to be installed at the wellhead or on the control box so thatit will be readily visible.

DO NOT lift or hang the pump by the level relay unit (1). It will lead todamage and may cause leakage, electric shock, and fire (Model PSA2 500).


CAUTION

CAUTION

1

wc_gr000259

wc_tx000121gb.fm 14

4.4 Electrical Wiring
Performing electrical wiring Electrical wiring should be performed by a qualified person in accordwith all applicable regulations. Failure to observe this precaution notonly risks breaking the law but is extremely dangerous. Incorrect wiring can lead to current leakage, electrical shock or fire.ALWAYS make sure the pump is equipped with the specified overloadprotectors and fuses or breakers, so as to prevent electrical shock froma current leak or pump malfunction.Operate within the capacity of the power supply and wiring.

GroundingDO NOT use the pump without first grounding it properly. Failure toground it can lead to electrical shock from a current leak or pumpmalfunction. DO NOT attach the grounding wire to a gas pipe, water pipe, lightningarrestor or telephone grounding wire. Improper grounding can result inelectrical shock.

Connecting the power supplyBefore connecting leads to the terminal strip, make certain the powersupply is turned off (circuit breaker, etc.), to avoid electrical shock,shorting, or unexpected starting of the pump, leading to injury.Before inserting the power supply plug, make certain the power supplyis turned off (circuit breaker, etc.), to avoid electrical shock, shorting,or unexpected starting of the pump, leading to injury.Do not use the pump with the cable assembly or plug connectedloosely, which can result in electric shock, shorting, or fire.Draw power from a dedicated power outlet rated at 15 A or above.Sharing the outlet with other equipment may cause overheating at thebranch outlet and could result in fire.NOTICE: Be sure to use a dedicated power supply with a groundleakage circuit breaker.

Grounded Plug –Connect only to receptacle of proper voltage and current ratingmatching that of the plug provided with the cable assembly.

WARNING

WARNING

CAUTION

WARNING

CAUTION

wc_tx000121gb.fm 15

Without Plug –Tighten the ends of the cable assembly securely against the terminalboard. If installation of grounded plug is required, use only properlyrated and approved CEE plug and secure ends of the cable assemblysecurely to power and ground terminals in accordance with plugmanufacturer’s instructions.

Cable AssemblyIf it is necessary to extend the cable assembly, use a core size equalto or larger than the original. This is necessary not only for avoiding aperformance drop, but to prevent cable overheating which can result infire, electrical leakage or electrical shock.If a cable with cut insulation or other damage is submerged in thewater, there is a danger of damage to the pump, electrical leakage,electrical shock, or fire.Be careful not to let the cable assembly be cut or become twisted. Thismay result in damage to the pump, electrical leakage, electrical shock,or fire.If it is necessary to submerge the connection wires of the cableassembly in water, first seal the wires completely in a moldedprotective sleeve, to prevent electrical leakage, electrical shock, or fire.DO NOT allow the cable assembly wires or power supply plug tobecome wet.Make sure the cable does not become excessively bent or twisted, anddoes not rub against a structure in a way that might damage it.If used in a deep-well installation, the cable assembly should besecured every twenty feet.

Br

L

L1 L2

G/Y

wc_gr000309

G

CAUTION

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4.5 Electrical Circuit Diagrams
See Graphic: wc_gr001261, wc_gr001259, wc_gr001260

PS 2 500 POWER SOURCE SINGLE PHASE


1. Capacitor 4. Protector

2. Main Coil 5. Frame Grounding

3. Auxiliary Coil 6. Ground

Wire Colors

B Black V Violet Or Orange

G Green W White Pr Purple

L Blue Y Yellow Sh Shield

P Pink Br Brown LL Light Blue

R Red Cl Clear G/Y Green/Yellow

T Tan Gr Gray

Br R1

L WB

L

325

46

G/YG/Y

wc_gr001261

wc_tx000121gb.fm 17


PSA 2 500 POWER SOURCE SINGLE PHASE


1. Level Relay Unit 6. Main Coil

2. Transformer 7. Auxiliary Coil

3. Electrode 8. Miniature Protector

4. Capacitor 9. Frame Grounding

5. Triac 10. Ground

Wire Colors






T Tan Gr Gray

Br B

1

L WB

L

769

810

G/YG/Y

3

5

24

W

R

W

wc_gr001259

wc_tx000121gb.fm 18


PS 2 750 POWER SOURCE SINGLE PHASE

If connected to a circuit protected by a fuse, use a time-delay fuse withthis pump.


1. Circle Thermal Protector 5. Centrifugal Switch

2. Auxiliary Coil 6. Capacitor

3. Heater 7. Frame Grounding

4. Main Coil 8. Ground

Wire Colors






T Tan Gr Gray

Br R2

L W

R

57

4

8

G/Y L L

6

R

11

2

G/Y

3

3

wc_gr001260

CAUTION

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4.6 Operation
Before starting4.6.1 Make sure once again that the product is of the correct voltage and

frequency rating.

NOTICE: Using the product at other than rated voltage and frequencywill not only lower its performance but may damage the product.Note: Confirm the rated voltage and frequency on the modelnameplate.

4.6.2 Confirm the wiring, supply voltage, circuit breaker capacity, and motorinsulation resistance.

Reference insulation resistance = 20 MΩ or greater.Note: The reference insulation resistance (20 MΩ or greater) is thevalue when the pump is new or has been repaired. For the referencevalue after installation see Maintenance and Inspection.

4.6.3 The setting on the circuit breaker or other overload protector should bemade in accord with the rated current of the pump.

Note: See Standard Specifications for the rated current of the pump.

4.6.4 When powering the pump with a generator, be certain the generator issized to supply the required power for the pump and any otherequipment powered by the generator.

Non-Automatic Models (PS 2 500, PS 2 750)Test OperationNEVER operate the pump while it is suspended in the air. The recoilmay result in injury or other major accident.

NEVER start the pump when people are standing next to it. A currentleak can result in electrical shock.

Run the pump for a short time (3–10 minutes) and confirm thefollowing:

• Using an ammeter (clamp-on type), measure the operating current at the L1 and L2 phase wires on the terminal.

COUNTERMEASURE: If the operating current exceeds the ratedvalue, pump motor overload may be a cause. Make sure the pump hasbeen installed under proper conditions as described in Installation.

• Using an AC voltmeter (tester), measure voltage at the terminals. Supply voltage tolerance: within ±5% of rated voltage.

WARNING

WARNING

wc_tx000121gb.fm 20

COUNTERMEASURE: If the supply voltage is outside the tolerance,possible causes are the power supply capacity or an inadequateextension cable. Look again at Electrical Wiring and make sure theconditions are proper. In case of very excessive vibration, unusual noise or odor, turn off thepower immediately and consult with your nearest dealer or Wackerrepresentative. Continuing to operate the pump under abnormalconditions may result in electrical shock, fire, or current leakage.
OperationMake sure no extraneous objects such as pins, nails or other metalobjects are sucked into the pump. These can damage the pump orcause it to malfunction, and can result in electrical shock or electricalleakage.When the pump is not used for an extended period, be sure to turn offthe power (circuit breaker, etc.). Deterioration of the insulation maylead to electrical leakage, electrical shock, or fire.In case of a power outage, turn off the power to the pump to avoidhaving it start unexpectedly when the power is restored, presentingserious danger to people in the vicinity.

The pump may become hot during operation. Do not touch anoperating pump. Allow the pump to cool before handling.

Pay careful attention to the water level while the pump is operating. Dryoperation may cause the pump to malfunction.Note: See section Operating water level, for the water level necessaryfor operation.

If the protection system operates due to an overload or malfunction,causing the pump to stop, first investigate and remove the causebefore restarting.

Operating water level Do not operate the pump below the C.W.L. (Continuous running WaterLevel) indicated below. Failure to observe this condition may result indamage to the pump, current leakage or electrical shock.

CAUTION

WARNING

CAUTION

CAUTION

wc_tx000121gb.fm 21

Operating Water Level (PS 2 500, PS 2 750).

Operating water level (PSA 2 500 only)Starting the Pump:This pump starts when water reaches the electrodes on the level relayunit, conducting current between them.Note: The necessary water level to operate the pump is 115 mm(4-½") from the bottom of the pump. To force start the pump for trialoperation, short-circuit the electrodes (a) with a screwdriver (b) asillustrated. Please keep items that may clog the pump (such as wires,nails, cords, etc.) away from it.

Motor Protection System (Motor Protector)Circle Thermal protector (PS 2 750)Miniature Protector (PS 2 500, PSA 2 500)

Pump Model C.W.L.

PS 2 500 50mm (2”)

PS 2 750 100mm (4”)

C.W.L

PS 2 500, PS 2 750

115 mm (4-1/2")

a

b

wc_gr001225

PSA 2 500

wc_tx000121gb.fm 22

The pump has a built-in motor protection system. If an excessivecurrent is detected (PS 2 750) or the motor overheats, for reasonssuch as the following, the pump will automatically stop operatingregardless of the water level, to protect the motor:
• Change in supply voltage polarity

• Overload

• Open-phase operation or operation under constraint

Note: Always determine the cause of the problem and resolve it beforeresuming operation. Simply repeating cycles of stopping and restartingwill end up damaging the pump. Do not continue operation at very lowlift, low water level, or while the strainer stand is clogged with debris.Not only will performance suffer, but also such conditions may causenoise, heavy vibration, and malfunctioning.

Operating Cycle of Automatic Type (PSA 2 500) .

Stage Level Relay Unit Pump Water Level

1 When electrodes (b) of level relay units (a) submerge under water, the resulting elec-tric current causes the pump to operate. (Electrodes sensing the electricity)

Operation starts (drainage)

Falls

2 When the water level goes below the height of the electrodes, a timer is acti-vated. The pump keeps operating. (No electric current –>Timer activates.)

Operation remains (drainage)

Falls

3 The pump keeps operating for approxi-mately one minute. (The pump resumes the operation if the electrodes contact the water again within one minute.)

Operation remains (drainage)

Falls

4 The pump stops one minute later. (The pump may not stop operating for a longer period of time.)

Operation stops

Rises

5 When the water level rises again and the electrodes touch the water, the pump starts operating again. (Electrodes sens-ing the electricity)

Operation starts again (drainage)

Falls

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1

2

3

4

5

a

bab

wc_gr000312

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PS 2 500 / PS 2 750 / PSA 2 500 Maintenance
5. Maintenance
5.1 Periodic Maintenance Table

(1) If the insulation resistance has become noticeably lower than the previous inspection, an inspec-tion of the motor will be necessary.

(2) See Lubricant Inspection and Lubricant Change in this section.(3) Specialized know-how is required for inspecting and replacing the mechanical seal. Consult with

your nearest dealer or Wacker representative.(4) Consult with your nearest dealer or Wacker representative regarding overhauls.

Pump Weekly Monthly Every1000hrs.

Every2000hrs.

Measure insulation resistance.Reference insulation resistance =1MW or greater. (1)

Measure operating current.Compare with rated current.

Measure supply voltage.Compare with allowable range (within ±5% of rated voltage).

Pump inspection.A noticeable drop in performance may indicate wear in the impeller, etc., or else clogging of the strainer, etc. Remove the clogged debris and replace any worn parts.

Lubricant inspection.

Change lubricant.

Designated lubricant: SAE 10W/20W. (2)

Change mechanical seal. (3)

Overhaul.This should be carried out even if there are no prob-lems with the pump. The frequency depends on how continuously the pump is in use. (4)

wc_tx000114gb.fm 25

Maintenance PS 2 500 / PS 2 750 / PSA 2 500
5.2 Maintenance and Inspection
Regular maintenance and inspections are a necessity for continuedefficient functioning of the pump. If any abnormal conditions arenoticed, refer to Troubleshooting section and take corrective measuresimmediately. It is recommended that a spare pump be kept ready incase of any problems.Prior to inspectingBefore inspecting the pump, make certain the power supply (circuitbreaker, etc.) is turned off. Then, unplug the cable assembly from thereceptacle or detach it from the terminals. Failure to follow thisprecaution may result in a serious accident from electrical shock orunexpected starting of the pump motor.

5.2.1 Washing the pump

Remove accumulated matter from the surface of the pump and washit with clean water. Take special care to remove any debris from theimpeller.

5.2.2 Inspecting the pump exterior

Look for any peeling or chipped paint, and make sure the nuts andbolts are fastened tightly. Any cracks in the surface should be repairedby cleaning that area, drying it and then applying a touch-up coating.Note: Touch-up paint is not supplied. Note that some kinds of damageor looseness may require that the unit be disassembled for repairs.Please consult with your nearest dealer or Wacker representative.

StorageWhen the pump is out of use for an extended period, wash it and dry itthoroughly, then store it indoors.Note: Always run a test operation before putting the pump back intoservice.

If the pump is left in the water, it should be run a minimum of once aweek.

Lubricant Inspection and Lubricant Change• Inspecting Lubricant

Remove the Oil Plug and tilt the pump to drain a small amount oflubricant. If the lubricant is milky white or has water mixed in with it, themechanical seal may be faulty. In this case the pump will need to bedisassembled and repaired.

• Replacing Lubricant

Remove the Oil Plug and drain all the lubricant, then replace it with thespecified amount.

WARNING

wc_tx000114gb.fm 26

Note: Worn lubricant and other waste products should be disposed ofby a qualified agent, in accord with applicable laws. The oil plug gasketshould be replaced each time the lubricant is inspected or changed.

Replacement PartsThe table lists the parts that need to be replaced periodically. Replacethese using the recommended frequency as a guideline.


1. Oil Inlet 3. Oil Plug

2. Gasket 4. Allen Wrench

Pump Model Lubricant Capacity

PS 2 400 160 ml (5.4 fl. oz.)

PS 2 500, PSA 2 500 155 ml (5.2 fl. oz.)

PS 2 750 210 ml (7.1 fl. oz.)

Part Replacement Frequency

Seal - Mechanical When lubricant in oil compartment becomes milky.

Lubricant (SAE 10W/20W) Every 2,000 hours or 12 months, whichever comes first.

Gasket Each time pump is disassembled or inspected.

Seal-dust When ring is worn, and each time pump is disassem-bled or inspected.

Sleeve When it becomes worn.

wc_gr001204

12

3

4

wc_tx000114gb.fm 27

5.3 Disassembly/Reassembly
Before disassembling the pump, make certain the power supply (circuitbreaker, etc.) is turned off. Then, unplug the cable assembly from thereceptacle or detach it from the terminals. To avoid electrical shock,DO NOT work with wet hands.NEVER check the operation of any parts (impeller rotation, etc.) byturning on the power while the unit is partially assembled. Failure toobserve these precautions may result in a serious accident.DO NOT disassemble or repair any parts other than those designatedhere. If repairs are necessary in any other than the designated parts,consult with your nearest dealer or Wacker representative. Improperrepairs can result in electrical leakage, electrical shock, fire, or waterleaks.After reassembly, ALWAYS perform a test operation before resuminguse of the pump. Improper assembly will cause the pump tomalfunction, resulting in electric shock or water leaks.

The procedure for disassembly and reassembly is shown here to theextent necessary for impeller replacement. A specialized environmentand facilities are necessary for work on the mechanical seal and themotor parts. Contact your nearest dealer or Wacker representative inthe event such repairs are necessary.

WARNING

wc_tx000114gb.fm 28

5.4 Disassembly

5.4.1 Removing the strainer, suction cover, and volute:

Remove the bolts (1) under the strainer (2), then remove the strainer,suction cover (3), and volute (4).

5.4.2 Removing the Impeller:

With a box wrench or other tool, remove the acorn nut (6), lockwasher(7) and washer (8), then remove the impeller (9), sleeve (10) and dustseal (11) from the shaft.

5.4.3 Removing the wear ring:

Remove the wear ring (12) from the volute.A worn impeller may have sharp edges that can cause injury, andshould be handled with care.Note: The exploded view shown is for model PS 2 500. Other modelsmay differ slightly in shape and structure.

WARNING

11

10

12

9

87

61

2

3

4

wc_gr001206

wc_tx000114gb.fm 29

5.5 Reassembly
See Graphic: wc_gr001206, wc_gr001205

5.5.1 Mount the dust seal (11) onto the outside of the sleeve (10) as shownin the drawing. When doing so, do not apply oil or other lubrication tothe surface where the dust seal contacts the sleeve (a).

5.5.2 When replacing the wear ring (12), make sure the front and back areoriented correctly. The side with the protrusions around the edgeshould face the volute (4). Press the wear ring firmly onto the surface.

5.5.3 Replace the dust seal and sleeve as one piece.

5.5.4 Align the impeller keyway with the rotor shaft keyway and push theimpeller (9) onto the rotor shaft. Secure the impeller on the shaft withthe washer (8), lockwasher (7), and acorn nut (6). While keeping theimpeller and shaft from rotating, tighten the acorn nut.

5.5.5 Position volute (4) flush with oil housing. Assemble suction cover (3)and strainer (2) and secure the assembly with the three bolts (1).

11

10

a

wc_gr001205

wc_tx000114gb.fm 30

5.6 Troubleshooting
Before ordering repairs, carefully read through this manual, thenrepeat the inspection. If the problem remains, contact your nearestdealer or Wacker representative.ALWAYS turn off the power before inspecting the pump. Failure toobserve this precaution can result in serious accident.

Problem / Symptom Reason / Remedy

Pump will not start • Power is off. Restore power.

• Cable assembly is cut or not connected properly. Repair/replace the cable or fix the connection.

• Plug is not inserted. Connect the plug.

• Impeller is clogged. Inspect the pump and remove any debris.

• Start float does not operate. Remove any obstruction and check the float operation.

Pump stops soon after start-ing (Motor protector operates)

• Impeller is clogged. Remove debris.

• Low voltage. Provide the rated voltage, or make sure the cable assembly extension is the proper standard.

• Wrong power frequency. Check the nameplate, and replace the pump or the impeller.

• Extended operation with a clogged strainer. Remove debris from the strainer.

• Faulty motor (burning, water infiltration, etc.). Repair or replace the motor.

• Motor protection system was triggered. Identify and cor-rect cause before re-starting.

Poor lift or discharge capacity

• Worn out impeller or suction cover. Repair or replace the worn parts.

• Sharply bent or clogged hose. Straighten out any sharp bends. Enclose the pump with a screen to keep away debris.

• Strainer clogged or buried. Remove debris from the strainer, or place a block under the pump.

• Wrong power frequency. Check the nameplate, and replace the pump or the impeller.

Heavy vibration or noise • Damaged motor shaft. Contact dealer and replace motor.

Pump will not stop automati-cally

• Something is interfering with the float operation, or the float switch is faulty. Remove any obstacles, or replace the switch.

WARNING

wc_tx000114gb.fm 31


Notes

wc_tx000114gb.fm 32

2008-CE-PS2-500-750_Q.fm

William Lahner Dan DomanskiVice President of Engineering Manager, Product Engineering

WACKER NEUSON CORPORATIONDate / Datum / Fecha / Date

EC DECLARATION OF CONFORMITYCE-KONFORMITÄTSERKLÄRUNG

DECLARACIÓN DE CONFORMIDAD DE LA CE DÉCLARATION DE CONFORMITÉ C.E.

WACKER NEUSON CORPORATION, N92 W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA

hereby certifies that the construction equipment specified hereunder: bescheinigt, daß das Baugerät: certifica que la máquina de:construcción / atteste que le matériel :

1. Category / Art / Categoría / Catégorie Water Pump Units

WasserpumpenEquipos de Bomba de AguaGroupe Motopompe à Eau

2. Type - Typ - Tipo - Type PS2 500, PS2 750

3. Item number of equipment / Artikelnummer / Número de referencia de la máquina / Numéro de référence du matériel :

0008793, 0008794, 0008795, 0008796, 0008787, 0008790, 0008791, 0008792, 0009176, 0009178, 0009179, 0009180, 0009181, 0008797, 0008798, 0008799, 0008800, 0009182, 0009184, 0620124, 0620125, 0620126

and has been produced in accordance with the following standards:und in Übereinstimmung mit folgenden Richtlinien hergestellt worden ist:y ha sido fabricado en conformidad con las siguientes normas:et a été produit conforme aux dispositions des directives européennes ci-après :

EN 60 335-2-41:96EN 60 335-1:94 + A11:95EMC 89/336/EECEN 50081-1:1992

AUTHORIZED REPRESENTATIVE IN THE EUROPEAN UNIONBEVOLLMÄCHTIGTER VERTRETER FÜR DIE EUROPÄISCHE GEMEINSCHAFTREPRESENTANTE AUTORIZADO EN LA UNIÓN EUROPEAREPRÉSENTANT AGRÉÉ AUPRÈS DE L’UNION EUROPÉENNE

WACKER CONSTRUCTION EQUIPMENT AGPreußenstraße 4180809 München

28.07.08

Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21

Documents

PS 2 500 PS 2 750 PSA 2 500 - Wacker Neusonproducts.wackerneuson.com/manuals/Operators/0154625en_003.pdf · PS 2 500 / PS 2 750 / PSA 2 500 Safety Information wc_si000040gb.fm 5 2