WTP4800 Hydraulic Trash Pump
Contents
1. 5 Grease the woodruff key impeller bore and motor shaft with underwater grease 6 Replace the woodruff key and then slip the impeller onto the motor shaft 7 Secure the impeller to the motor shaft using the washer and nut 8 Prepare the trash pump for normal operation accord ing to the procedure in Chapter 6 TROUBLESHOOTING Refer to the troubleshooting chart on the following page E H Wachs Company Part No 08 MAN 04 Rev 0 0206 33 Chapter 7 Service and Repair WTP4800 Hydraulic Trash Pump User s Manual TROUBLESHOOTING If symptoms of poor performance develop the following chart can be used as a guide to correct the problem When diagnosing faults in operation of the tool always make sure the hydraulic power source is supplying the correct hydraulic flow and pressure as listed in the table Use a flowmeter know to be accurate check the flow with the hydraulic fluid temperature at least 80 F 27 C PROBLEM CAUSE SOLUTION Pump will not start Poor pump performance No hydraulic fluid flow or pressure Turn on power unit and check that 7 10 gpm 26 38 Ipm at 2000 psi 140 bar is available at the trash pump Defective couplers Impeller jammed with debris Check the couplers by connecting them together with the hydraulic power supply operating and with the control valve in the ON position The power supply should operate without loading from the cou pler2. E H Wachs Company 100 Shepard Street Wheeling IL 60090 www wachsco com WTP4800 Hydraulic Trash Pump User s Manual E H Wachs Company Part No 08 MAN 04 Rev 0 0506 May 2006 Revision History May 2006 Copyright 2006 E H Wachs Company All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Part No 08 MAN 04 Rev 0 0506 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 1 About This Manual Chapter 1 About This Manual PURPOSE OF THIS MANUAL This manual explains how to operate and maintain your WTP4800 Hydraulic Trash Pump It includes instructions for set up operation and routine maintenance It also con tains parts lists assembly diagrams and troubleshooting instructions to help you order replacement parts and per form user serviceable repairs Before operating your WTP4800 Hydraulic Trash Pump you should read through this manual and become familiar with all instructions At a minimum make sure you read and understand the following chapters e Chapter 1 About This Manual e Chapter 2 Safety e Chapter 3 Introduction e Chapter 5 Operating Instructions If you will be performing service or repairs make sure you read and understand these chapters e Chapter 1 About This Manual e Chapter 4 Assembly Disassembly and Storage e Chapter 6
3. Never point the hose at bystand 3 Observe the arrow on the couplers to ensure that the flow is in the proper direction The female coupler on the pump is the inlet pressure coupler PUMP OPERATION 1 Observe all safety precautions 2 Attach a discharge hose part no 08 400 04 to the trash pump outlet For best performance keep the hose as short as possible and lay it out to avoid sharp bends or kinks 3 Attach a rope or cable to the pump s handle Lower the pump into the liquid to be pumped Do not raise or lower the trash pump by its hoses or couplers 4 Turn on the hydraulic power source Watch for solids in the liquid being pumped If solids are excessive the discharge flow might decrease If this happens stop the pump and check for the cause of the problem Under some conditions the liquid being pumped might be slowed enough so it can no longer push particles in the liq ate it dry uid If this happens particles can accumulate in the pump ing chamber causing further restriction The impeller then acts as a grinding wheel which causes accelerated pump wear Reduced liquid flow can be caused by the following e The pump sinks into solids at the bottom of the hole e The end of the outlet hose is too high causing an exces sive lift height for the column of liquid being pushed by the pump This slows the flow of liquid to a level where it can no longer carry solids out the end of the hose
4. e The flow and pressure of hydraulic fluid to the pump is too low which reduces impeller speed A 20 decrease in hydraulic fluid flow can reduce pump performance by 50 When operating at reduced hydraulic flow and pressure the end of the outlet hose should not be more than 30 ft 9 m above the liquid 5 When pumping is complete set the hydraulic control valve to the OFF position Lift the pump from the work area using the attached rope or cable 6 The pump must maintain a minimum impeller speed 20 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 5 Operating Instructions in order to move solid particles through the pump While pumping liquids containing large solids moni tor the flow from the outlet of the fire hose If it begins to slow turn off the hydraulic power source and lift the trash pump from the work area Disconnect the hydraulic hoses and clean out the water hose and pumping chamber 7 To maintain optimum performance it is good practice to periodically inspect the impeller for wear or dam age This is especially important following the pump ing of liquids containing sharp abrasive solids COLD WEATHER OPERATION If the pump is to be used during cold weather preheat the hydraulic fluid at low power source speed When using the normally recommended fluids fluid should be at or above 50 F 10 C 400 ssu 82 centistokes before use Damage
5. 25 microns 30 gpm 114 Ipm 100 400 ssu 25 microns 30 gpm 114 Ipm 100 400 ssu 25 microns 30 gpm 114 Ipm 100 400 ssu 20 82 centistokes 25 microns 30 gpm 114 Ipm 100 400 ssu When choosing hydraulic fluid the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the require ments over a wide range of operating temperatures SSU Saybolt Seconds Universal NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements E H Wachs Company Part No 08 MAN 04 Rev 0 0206 15 Chapter 3 Introduction WTP4800 Hydraulic Trash Pump User s Manual PUMP SPECIFICATIONS Capacity Weight Height over handle Length Width Pressure Flow Range Maximum Flow Porting Connect Size and Type Discharge Diameter Inlet Diameter ACCESSORIES 800 gpm 3028 Ipm 59 Ibs 26 7 kg 16 5 in 42 cm 19 in 48 3 cm 15 in 38 1 cm 2000 psi 140 bar 7 10 gpm 26 38 lpm 10 gpm 38 lpm 10 SAE pressure 12 SAE return 1 2 in male pipe pressure 1 2 in male pipe return 4 in 100 mm camlock 4 in 100 mm e Lay flat discharge hose 4 in x 25 ft with camlock fit tings part no 08 400 04 16 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump U
6. Name Tag 18 STN 15875 1 Warning Tag Not Shown 19 STN 15664 8 Washer 20 STN 21978 3 Capscrew 21 STN 21977 1 Plate Volute Motor Mount 22 STN 21993 1 Wear Plate Top 23 STN 21979 1 Impeller 24 STN 06311 1 V Ring 25 STN 21988 1 Acorn Nut 26 STN 03827 1 Washer 27 STN 00600 1 Woodruff Key 28 STN 21989 6 Capscrew 29 STN 21981 1 Seal Anvil 30 STN 21976 1 Housing Lip Excluder 31 STN 01220 1 Grease Fitting 32 STN 31266 1 Seal Carrier 33 STN 21021 1 Seal 34 NO ITEM 35 STN 01872 1 O Ring 36 STN 26812 1 Retaining Ring 37 STN 20680 2 Bearing Race 38 STN 08020 1 Thrust Bearing 39 STN 21971 1 Motor Shaft 40 STN 21985 1 Key 41 STN 20691 1 Bearing Carrier 42 STN 22065 2 Dowel Pin E H Wachs Company Part No 08 MAN 04 Rev 0 0206 37 Chapter 8 Parts Lists and Drawings WTP4800 Hydraulic Trash Pump User s Manual Table 1 WT P4800 Parts List Item No Part No Qty Description 43 STN 21974 1 Drive Gear 44 STN 21983 1 Idler Gear 45 STN 21984 1 Idler Shaft 46 STN 15385 1 O Ring 47 STN 21972 1 Motor Cap Assembly 48 STN 21986 3 Capscrew 49 STN 10793 2 Capscrew 50 STN 06264 1 Adapter 51 STN 06891 1 O Ring Supplied with Item 50 52 STN 07882 1 Adapter 53 STN 01604 1 O Ring Supplied with Item 52 54 STN 21987 2 Capscrew STN 22546 1 Seal Kit 38 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User
7. Power Source 1 Using a calibrated flow meter and pressure gauge make sure the hydraulic power source develops a flow of 7 10gpm 26 38 Ipm at 2000 psi 140 bar 2 Make certain that the power source is equipped with a relief valve set to open at 2100 2250 psi 145 155 bar maximum 3 Make certain that the power source return pressure does not exceed 250 psi 17 bar 4 Make sure the pump inlet is clear of debris Remove any obstruction before operating Refer to the pump cleaning procedures in Chapter 6 Connect Hoses 1 Wipe all hose couplers with a clean lint free cloth before making connections 2 Connect the hoses from the hydraulic power source to the couplers on the pump or hoses It is a good prac tice to connect the return hose first and disconnect it last to minimize or avoid trapped pressure within the pump motor In This Chapter PRE OPERATION PROCEDURES PUMP OPERATION COLD WEATHER OPERATION If uncoupled hoses En are left in the sun pressure increase inside the hoses might make them difficult to connect Whenever possible connect the free ends of the hoses together E H Wachs Company Part No 08 MAN 04 Rev 0 0206 Chapter 5 Operating Instructions WTP4800 Hydraulic Trash Pump User s Manual NOTICE Do not connect pressure to the return port Motor shaft seal limit is 250 psi 17 bar ers Personal injury could result It will not damage the pump to oper WARNING
8. a situation that if not avoided may result in damage to the equipment Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 2 Safety SAFETY LABELS The safety tag illustrated below is attached to the pump when it is shipped from the factory Read and understand the instructions listed on this tag before you remove it We suggest you retain this tag and attach it to the tool when it is not in use GANGER VALLE 1O VE MOAMAR HOSE LABELED AND CENTS MED AS WONCONDUCTIVE EMEN USD mTORAULC TOOLS ON OF MEAR EU ECTRCA LAES War RESULT N EAT OA SEROUS m BEFORE WONG MOSE LABELED ano connate AS non CORBECTINE OF OF NEAR DEC TAK LEAKAGE IN ACOOROANCE WITH YOUN SAFETY DEPRI MENT SRC NONS 2 AWD LEAs OF it war Cash OL BECTON arto THE BOY OF ASE OTER SEVERE PERSONAL nam A 00 WOT EXCEED SPECWMD FLOW AND PRESSURE EXCESS FLOM OA PRESSURE MAN IMPORTANT IMPORTANT READ OPERATION MANUAL AND READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY PROCEDURES APPROVED BY MANUFACTURER AND DESCRIBED IN MANUFACTURER AND DESCRIBED IN THE OPERATION MANUAL THE OPERATION MANUAL TAG TO BE REMOVED ONLY BY TAG TO BE REMOVED ONLY BY TOOL OPERATOR TOOL OPERATOR SEE OTHER SIDE 5 peP SEE OTER Ot Figure 2 1 The front and back sides of the safety
9. of this manual by emailing customer service at sales wachsco com E H Wachs Company Part No 08 MAN 04 Rev 0 0206 Chapter 1 About This Manual WTP4800 Hydraulic Trash Pump User s Manual 4 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 2 Safety Chapter 2 Safety The E H Wachs Company takes great pride in designing and manufacturing safe high quality products We make user safety a top priority in the design of all our products Z WARNING Read this chapter carefully before operating your WTP4800 Hydraulic Trash Pump Serious injury or death could result from improper repair or service of this equipment Repair and or service to this equipment must only be done by an authorized and certified dealer OPERATOR SAFETY Follow these guidelines for safe operation of any mechani cal equipment associated with the data logger e READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin e INSPECT MACHINE AND ACCESSORIES Before starting the machine look for loose bolts or nuts leak ing lubricant rusted components and any other physical conditions that may affect operation Properly maintain ing the machine can greatly decrease the chances for injury In This Chapter OPERATOR SAFETY SAFETY LABELS SAFETY PRECAUTIONS MACHINE SAFETY Look for this sym IN bol throughout the manual
10. tag attached to the pump Tag is part no STN 15875 CAUTION 7 10 GPM 26 34 LPM DO NOT EXCEED 2000 PSI 140 BAR DO NOT EXCEED SPECIFIED FLOW OR PRESSURE USE CLOSED CENTER TOOL ON CLOSED CENTER SYSTEM CORRECTLY CONNECT HOSES TO TOOL IN AND OUT PORTS IMPROPER HANDLING USE OR OTHER MAINTENANCE OF TOOL COULD RESULT IN A LEAK BURST OR OTHER TOOL FAILURE CONTACT AT A LEAK OR BURST CAN CAUSE OIL INJECTION INTO THE BODY FAILURE TO OBSERVE THESE PRECAUTIONS CAN RESULT IN SERIOUS PERSONAL INJURY Figure 2 2 The GPM tag attached to the pump gives flow specifications Tag is part no STN 03787 E H Wachs Company Part No 08 MAN 04 Rev 0 0206 7 Chapter 2 Safety WTP4800 Hydraulic Trash Pump User s Manual WARNING Failure to follow the IN instructions for safe operation could result in operator injury SAFETY PRECAUTIONS Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hose These safety precautions are given for your safety Review them carefully before operating the tool and before per forming general maintenance or repairs Supervising personnel should develop additional precau tions relating to the specific work area and local safety regu lations If so place the added precautions in the space provided in this manual The model WTP4800 Hydraulic Trash Pump wi
11. volute weldment using the six 1 4 20 wing nuts E H Wachs Company Part No 08 MAN 04 Rev 0 0206 25 Chapter 6 Routine Maintenance WTP4800 Hydraulic Trash Pump User s Manual 26 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 7 Service and Repair Chapter 7 Service and Repair For the procedures in this chapter refer to the parts drawing on the next page The reference numbers on the drawing are keyed to the parts list in Chapter 8 PUMP DISASSEMBLY The following procedures should be performed only if e Itis determined after a complete inspection that the trash pump power module motor is malfunctioning e Hydraulic fluid is leaking between the motor cap assem bly and the bearing carrier assembly e Hydraulic fluid is leaking from the motor shaft e The shafts and gears need to be replaced Clean the exterior of the trash pump and put it on a clean work surface Before disassembling the pump obtain the Seal Kit part number STN 22546 to replace all seals exposed during dis assembly Remove Impeller 1 Open the trash pump Refer to the pump cleaning pro cedures provided in Chapter 6 2 Place the motor in a soft vise with the impeller facing up In This Chapter PUMP DISASSEMBLY CLEANING AND INSPECTION PUMP REASSEMBLY TROUBLESHOOTING Note the orienta By tion of the seals before removing them Make su
12. It indicates a personal injury hazard E H Wachs Company Part No 08 MAN 04 Rev 0 0206 Chapter 2 Safety WTP4800 Hydraulic Trash Pump User s Manual e ALWAYS READ PLACARDS AND LABELS Make sure all placards labels and stickers are clearly legible and in good condition You can purchase replacement labels from E H Wachs Company e KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts Always turn machine off before doing any adjustments or service e SECURE LOOSE CLOTHING AND JEWELRY Secure or remove loose fitting clothing and jewelry and securely bind long hair to prevent them from getting caught in moving parts of the machine e KEEP WORK AREA CLEAR Keep all clutter and nonessential materials out of the work area Only people directly involved with the work being performed should have access to the area Safety Symbols A This icon is displayed with any safety alert that indicates a personal injury hazard Z WARNING This safety alert indicates a potentially hazardous situation that if not avoided could result in death or serious injury Z CAUTION This safety alert with the personal injury hazard symbol indicates a potentially hazardous situation that if not avoided could result in minor or moderate injury NOTICE This alert indicates a situation that if not avoided will result in damage to the equipment IMPORTANT This alert indicates
13. PROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CON TACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDI ATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE OVL SIHL AAOWSY LON OC 6 AFTER EACH USE STORE IN A CLEAN DRY AREA Figure 3 3 Tag attached to Certified Non Conduc tive hose front and back CAUTION If the information on a tag is illegible because of wear or damage replace the tag immediately A new tag may be obtained from your the E H Wachs Company E H Wachs Company Part No 08 MAN 04 Rev 0 0206 13 Chapter 3 Introduction WTP4800 Hydraulic Trash Pump User s Manual DANGER M DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE TS NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY 2 FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WO
14. RK ON OR AROUND ELEC TRIC LINES B DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CON TACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY DO NOT REMOVE THIS TAG A HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC DANGER CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDI ATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE AFTER EACH USE STORE IN A CLEAN DRY AREA SVL SIHL AAOWAY LON OG Figure 3 4 Tag attached to Conductive hose front and back Hose Pressure Rating The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system 14 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 3 Introduction HTMA Requirements TOOL CATEGORY HYDRAULIC SYSTEM REQUIREMENTS FLOW RATE TOOL OPERATING PRESSURE at the power supply outlet SYSTEM RELIEF VALVE SETTING at the power supply outlet MAXIMUM BACK PRESSURE at tool end
15. Routine Maintenance e Chapter 7 Service and Repair You will also want to refer to Chapter 8 Parts Lists and Drawings In This Chapter PURPOSE OF THIS MANUAL HOW TO USE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES E H Wachs Company Part No 08 MAN 04 Rev 0 0206 Chapter 1 About This Manual WTP4800 Hydraulic Trash Pump User s Manual Throughout this manual refer to this column for warnings cautions and notices with supplementary information How TO USE THE MANUAL This manual is organized to help you quickly find the infor mation you need Each chapter describes a specific topic on using or maintaining your WTP4800 Hydraulic Trash Pump Each page is designed with two columns This large column on the inside of the page contains instructions and illustra tions Use these instructions to operate and maintain your WTP4800 Hydraulic Trash Pump The narrower column on the outside contains additional information such as warnings special notes and definitions Refer to it for safety notes and other information SYMBOLS AND WARNINGS The following symbols are used throughout this manual to indicate special notes and warnings They appear in the out side column of the page next to the section they refer to Make sure you understand what each symbol means and follow all instructions for cautions and warnings This is the safety alert symbol It is used to alert you to potential personal injury
16. UIREMENTS Hydraulic Hose Requirements Hose Types The following hose types are approved for use with the WDP3500 1 Certified non conductive 2 Wire braided conductive 3 Fabric braided not certified or labeled non conductive 12 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 3 Introduction Hose 1 listed above is the only hose authorized for use near electrical conductors Hoses 2 and 3 listed above are conductive and must never be used near electrical conductors Hose Safety Tags The following DANGER tags are attached to all hoses sup plied by the E H Wachs company for use with the WTP4800 pump DO NOT REMOVE THESE TAGS DANGER FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH OR SERIOUS INJURY FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS DO NOT REMOVE THIS TAG DANGER B DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IM
17. al carrier with seal anvil over the motor shaft Push the seal retainer up against the bearing carrier assembly Secure the seal carrier housing to the bearing carrier assembly using two 3 8 16 x 1 1 4 in 32 mm socket head capscrews Tighten the capscrews to a torque value of 18 Ib ft 24 3 Nm Secure the top wear plate to the volute motor mount plate using the six 1 4 20 x 1 2 in 13 mm flat head capscrews Lubricate and install the excluder lip seal over the motor shaft with the lip pressed against the anvil pocket Replace the impeller Refer to the IMPELLER REPLACEMENT procedures provided earlier in this section 30 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 7 Service and Repair Disassemble Motor 1 Remove the two 1 2 13 x 2 3 4 in 70 mm and the three 1 2 13 x 2 1 4 in 57 mm capscrews securing the motor cap assembly to the bearing carrier assem bly 2 Carefully lift the motor cap assembly away from the bearing carrier assembly 3 Remove the o ring from inside the motor cap assem bly CLEANING AND INSPECTING MOTOR CHAMBER AND PARTS Inspect and clean all parts as follows Cleaning Guidelines Clean all parts with a degreasing solvent Blow dry all parts with compressed air and wipe clean Use only lint free cloths Gears The gears should have straight tips without nicks square tooth ends and smooth even polish on the
18. ed Remove the excluder v ring and seal anvil from the bottom of the housing lip excluder Remove the two 3 8 16 x 1 1 4 in 32 mm socket head capscrews securing the housing lip excluder to the bearing carrier assembly Hold the motor shaft in to prevent bearing damage while removing the housing lip excluder and enclosed The woodruff key By might fall out of the motor shaft key way Make sure it is not lost E H Wachs Company Part No 08 MAN 04 Rev 0 0206 29 Chapter 7 Service and Repair WTP4800 Hydraulic Trash Pump User s Manual 10 11 12 13 14 15 16 17 18 19 parts from the bearing carrier housing and the motor shaft Remove the retainer ring seal and o ring from the seal carrier If the seal anvil has been damaged it can be pressed out from the inside and then replaced Inspect the motor shaft surface where the bronze seal carrier was installed If the motor shaft is damaged it must be replaced Refer to the Motor Disassembly section later in this chapter Using clean underwater grease and new seals from the Seal Kit part number STN 22546 lubricate the seal carrier seal and o ring then install into the seal car rier The greased seal will squeeze into the seal carrier and MUST NOT BE TWISTED or it will not seal Grease the motor shaft then place the seal carrier with the O D o ring side going on first over the motor shaft Place the se
19. ed in the pressure side of the system Do not lift the trash pump by pulling on the hydraulic hoses Use a suitable line fastened to the trash pump handle 10 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 3 Introduction Chapter 3 Introduction to the WTP4800 Hydraulic Trash Pump Read this chapter carefully to become familiar with the components and features of your WTP3500 hydraulic trash pump USAGE AND APPLICATIONS The WTP4800 is a high power trash pump with a flow rate of up to 800 gallons per minute 3028 l min and capacity for up to 4 inch 102 mm solids The pump is submersible with no priming required and can run dry without damage Figure 3 1 illustrates the components of the WTP4800 hydraulic trash pump In This Chapter USAGE AND APPLICATIONS REQUIREMENTS PUMP SPECIFICATIONS ACCESSORIES E H Wachs Company Part No 08 MAN 04 Rev 0 0206 Chapter 3 Introduction WTP4800 Hydraulic Trash Pump User s Manual Hydraulic return Hydraulic inlet pressure Pump outlet D en Lift handle Pump inlet Figure 3 1 WTP4800 hydraulic trash pump compo nents Figure 3 2 illustrates the name tag fastened to the pump housing E H Wachs Company wei 100 Shepard Street Wheeling IL 60090 U S A ah 26 38 LPM 7 10 CPM WTP4800 140 BAR 2000 PSI Figure 3 2 WTP4800 name tag part no 08 004 00 REQ
20. eplace if necessary Hydraulic fluid in discharge flow Motor shaft seal failure Replace the motor shaft seal Ensure power unit is delivering 7 10 gpm 26 38 lpm 34 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 8 Parts Lists and Drawings Chapter 8 Parts Lists and Drawings Refer to the drawing and the parts list on the following pages for ordering spare and replacement parts E H Wachs Company Part No 08 MAN 04 Rev 0 0206 35 s Manu WTP4800 Hydraulic Trash Pump User Chapter 8 Parts Lists and Drawings E H Wachs Company Part No 08 MAN 04 Rev 0 0206 WTP4800 Hydraulic Trash Pump User s Manual Chapter 8 Parts Lists and Drawings Table 1 WTP4800 Parts List Item No Part No Qty Description 1 STN 31505 1 Motor Assembly incl 20 24 29 48 2 STN 21960 1 Volute Weldment 3 STN 21961 6 Wing Nut 4 STN 65783 6 Capscrew 5 STN 01324 12 Lockwasher 6 STN 08937 6 Capscrew TP08013 only STN 15476 6 Capscrew TP0801302 only 7 STN 15476 3 Capscrew 8 STN 00788 3 Hex Nut 9 STN 21963 3 Brace 10 STN 21964 1 Wear Plate 11 STN 21965 1 Base 12 STN 21966 A R Shim 13 STN 21967 1 Male Camlock 14 STN 21968 1 Handle 15 NO ITEM 16 STN 03787 1 Sticker GPM 17 08 004 00 1 Sticker
21. h pump If the trash pump is not cleared heavy solids will not be removed from the trash pump eventually damaging or destroying the impeller In This Chapter PUMP CLEANING AND INSPECTION E H Wachs Company Part No 08 MAN 04 Rev 0 0206 23 Chapter 6 Routine Maintenance WTP4800 Hydraulic Trash Pump User s Manual Cleaning the Hose and Pumping Chamber 1 Remove the water hose from the trash pump If it is clogged lift near the outlet end of the hose and then shake it to loosen any debris Continue shaking while working toward the inlet end until the entire water hose is free of all debris 2 Look into the pump outlet and inlet bottom and remove any debris If you are unable to clear the debris you must open the trash pump Opening the Pump 1 Disconnect the hydraulic hoses from the pump 2 Remove the six 1 4 20 wing nuts securing the handle and volute motor mount plate to the volute weldment Lift the volute motor mount plate from the volute weldment and place it on a clean flat work surface 3 Remove the shim s from the top of the volute weld ment 4 Clean out the pumping chamber 5 Remove any debris from the water outlet and inlet Inspecting the Impeller 1 Check the impeller blades for cracks chips and signs of excessive wear Also see if it has been rubbing against the bottom wear plate If the impeller is exces sively worn it must be replaced Refer to the disas sembly ins
22. hazards Obey all safety messages that follow this symbol to avoid possible injury or death NOTE Ay This symbol indicates a user notice Notices provide additional information to supplement the instructions or tips for easier operation Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 1 About This Manual MANUAL UPDATES AND REVISION TRACKING Occasionally we will update manuals with improved opera tion or maintenance procedures or with corrections if nec essary Revised chapters will be available for customers If you receive revised chapters for your manual remove the old chapters from your binder and replace them with the new chapters When a manual is revised we will update the revision his tory on the title page and at the bottom of the pages in the revised chapters It is important to put the current title page with the revision history in your manual This will help you make sure you have all current information You may have factory service or upgrades performed on your equipment If this service changes any technical data or operation and maintenance procedures we will include revised sections of the manual when we return the equip ment to you Remove the old chapters from your manual and replace them with the revised chapters Current versions of E H Wachs Company manuals are also available in PDF for mat You can request an electronic copy
23. ing can get entangled with the tool and cause serious injury e Supply hoses must have a minimum working pressure rating of 2500 psi 175 bar e Be sure all hose connections are tight e The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling the tool Wipe all couplers clean before connecting Failure to do so may result in damage to the quick couplers and cause overheating Use only lint free cloths e Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher oil temperatures can cause operator discomfort and may cause damage to the tool e Do not operate a damaged improperly adjusted or incompletely assembled tool e To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained personnel e Do not exceed the rated limits of the tool or use the tool for applications beyond its design capacity e Always keep critical tool markings such as labels and warning stickers legible e Always replace parts with replacement parts recom mended by the E H Wachs Company e Check fastener tightness often and before each use daily e Do not put your hands or any other body part under the volute while the trash pump is running e Do not point water discharge toward bystanders MACHINE SAFETY Observe the following guidelines for reliable machine oper ation and care e Make sure all coup
24. ired to com plete it In This Chapter REPLACEMENT PARTS REPAIR INFORMATION WARRANTY INFORMATION RETURN GOODS ADDRESS E H Wachs Company Part No 08 MAN 04 Rev 0 0206 41 Chapter 10 Ordering Information WTP4800 Hydraulic Trash Pump User s Manual WARRANTY INFORMATION Enclosed with the manual is a warranty card Please fill out the registration card and return to E H Wachs Company Retain the owner s registration record and warranty card for your information RETURN GOODS ADDRESS Return equipment for repair to the following address E H Wachs Company 100 Shepard Street Wheeling Illinois 60090 USA 42 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company
25. lers are wiped clean before connec tion e The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling hydraulic tools Failure to do so may result in damage to the quick couples and cause overheating of the hydraulic system e Always store the tool in a clean dry space safe from damage or pilferage NOTICE Failure to follow the instruc tions for machine safety could result in damage to the equipment E H Wachs Company Part No 08 MAN 04 Rev 0 0206 Chapter 2 Safety WTP4800 Hydraulic Trash Pump User s Manual Make sure the circuit PRESSURE hose with male quick disconnect is connected to the IN port The cir cuit RETURN hose with female quick disconnect is connected to the opposite port Do not reverse circuit flow This can cause damage to internal seals Always replace hoses couplings and other parts with replacement parts recommended by the E H Wachs Company Supply hoses must have a minimum working pressure rating of 2500 psi 172 bar Do not exceed the rated flow see Specifications in Chapter 3 for correct flow rate and model number Rapid failure of the internal seals may result Always keep critical tool markings such as warning stickers and tags legible Do not use the pump for applications for which it is not intended Pump repair should be performed by experienced per sonnel only Make certain that the recommended relief valves are install
26. ll provide safe and dependable service if operated in accordance with the instructions given in this manual Read and understand this manual and any stickers and tags attached to the pump and hoses before operation Failure to do so could result in personal injury or equipment damage e Operator must start in a work area without bystanders The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions e Establish a training program for all operators to ensure safe operations e Do not operate the tool unless thoroughly trained or under the supervision of an instructor e Always wear safety equipment such as goggles head protection and safety shoes at all times when operating the tool e Do not inspect or clean the tool while the hydraulic power source is connected Accidental engagement of the tool can cause serious injury e Do not operate this tool without first reading the Operat ing Instructions e Do not install or remove this tool while the hydraulic power source is connected Accidental engagement of the tool can cause serious injury e Never operate the tool near energized transmission lines Know the location of buried or covered services before starting work Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 2 Safety Do not wear loose fitting clothing when operating the tool Loose fitting cloth
27. of the return hose Measured at a max fluid viscosity of at min operating temperature TEMPERATURE Sufficient heat rejection capacity to limit max fluid temperature to at max expected ambient temperature Min cooling capacity lat a temperature difference of between ambient and fluid temps NOTE TYPE 4 6 gpm 15 23 Ipm 2000 psi 138 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu TYPE Il 7 9 gpm 26 34 Ipm 2000 psi 138 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu TYPE Ill 11 13 gpm 42 49 Ipm 2000 psi 138 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu TYPE RR 9 10 5 gpm 34 40 Ipm 2000 psi 138 bar 2200 2300 psi 152 159 bar 250 psi 17 bar 400 ssu 82 centistokes 82 centistokes 82 centistokes 82 centistokes 3 hp 2 24 kW 40 F 22 C 5 hp 3 73 kW 40 F 22 C 140 F 60 C 7 hp 4 47 kW 40 F 22 C 140 F 60 C 6 hp 5 22 kW 40 F 22 C Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause operator discomfort at the tool FILTER Min full flow filtration Sized for flow of at least For cold temp startup and max dirt holding capacity HYDRAULIC FLUID Petroleum based premium grade anti wear non conductive VISCOSITY at min and max operating temps NOTE
28. r I 2 If the motor shaft was replaced install the two bearing races and thrust bearing onto the motor shaft Using clean underwater grease grease the motor shaft and then insert it through the lower end of the bearing carrier assembly Replace the motor shaft seal parts according to the procedure earlier in this chapter Using clean underwater grease grease the keyway and motor shaft Replace the key and then place the drive gear over the key Install the idler shaft and idler gear assembly onto the flat motor surface of the bearing carrier Lubricate and install the o ring into the motor cap assembly groove Slide the motor cap assembly over the gears and shafts until completely down flat DO NOT TIP CAP OR FORCE IT OVER GEARS Secure the motor cap assembly to the bearing carrier assembly using the two greased 1 2 13 x 2 3 4 in 70 mm and the three greased 1 2 13 x 2 1 4 in 57 mm capscrews Tighten each capscrew to a torque value of 60 lb ft 81 4 Nm Assemble Pump L 2 Clean all parts with a degreasing solvent Make sure all seals that were exposed have been replaced with new parts Apply clean underwater grease to all parts during assembly Secure the top wear plate to the volute motor mount plate using the six 1 4 20 x 1 2 in 13 mm flat head capscrews 32 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 7 Service and Repair
29. re to install new seals the same way they were removed E H Wachs Company Part No 08 MAN 04 Rev 0 0206 27 s Manu WTP4800 Hydraulic Trash Pump User nd Repair Chapter 7 Service a E H Wachs Company Part No 08 MAN 04 Rev 0 0206 WTP4800 Hydraulic Trash Pump User s Manual Chapter 7 Service and Repair Remove the nut and washer securing the impeller to the motor shaft Carefully pull the impeller off of the motor shaft Check the impeller blades for cracks chips and signs of excessive wear which can affect pump perfor mance Replace the impeller if damaged seriously worn or out of balance Replace Impeller L Grease the woodruff key impeller bore and motor shaft with underwater grease Replace the woodruff key Slip the impeller onto the motor shaft Secure the impeller to the motor shaft using the washer and nut Replace Motor Shaft Seal L 2 Remove the impeller according to the procedure ear lier in this section Remove the six 1 4 20 x 1 2 in 13 mm flat head cap screws securing the top wear plate to the volute motor mount plate Remove the three 3 8 x 1 3 4 in 44 5 mm flat hex head capscrews securing the volute motor mount plate to the power module Check the top wear plate for cracks deep scratches and signs of excessive wear Scratches deeper than 1 16 in 2 mm might affect pump performance If the wear plate is damaged it must be replac
30. s Clean the pumping chamber Check and adjust the impeller clearance Impeller rubbing against wear plates Defective power module Hydraulic flow reversed Repair or replace the power module Check that the hoses are correctly con nected to the pump motor ports The female coupler should be connected to the IN port The return fluid must never flow through a reversing valve Improper hydraulic fluid flow Trash pump submersed in sediment Trash pump inlet restricted Check that 7 10 gpm 26 38 Ipm at 2000 psi 140 bar is available at the trash pump A 20 decrease in flow can result ina 50 decrease in pump performance 8 gpm 30 Ipm is the best circuit flow Lift the pump from the bottom of the hole or chamber Use a flat support under the pump if necessary Remove restriction and thoroughly clean Discharge hose kinked or restricted Straighten the hoes If the hose must bend at the top of the hole use a piece of split rigid conduit with large diameter of the expanded hose This keeps the hose from kinking Use a 90 4 inch pipe elbow on the trash pump outlet if necessary Discharge hose too small Water lift too high Impeller worn or damaged Use a 4 inch diameter fire hose Lower the outlet end of the discharge hose Check impeller for damage and excessive wear Replace if necessary Wear plates worn or damaged Check wear plates for damage and exces sive wear R
31. s Manual Chapter 9 Accessories Chapter 9 Accessories Table 1 lists accessories available for the WTP4800 hydrau lic trash pump Lay flat discharge hose 4 in x 25 ft with cam lock fittings Table 1 Accessories for WTP4800 Hydraulic Trash Pump 08 400 04 no photo available E H Wachs Company Part No 08 MAN 04 Rev 0 0206 39 Chapter 9 Accessories WTP4800 Hydraulic Trash Pump User s Manual 40 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 10 Ordering Information Chapter 10 Ordering Information To place an order request service or get more detailed information on any E H Wachs Company products call us at one of the following numbers US 800 323 8185 International 847 537 8800 ORDERING REPLACEMENT PARTS When ordering parts refer to the parts lists in Chapter 8 Please provide the part description and part number for all parts you are ordering REPAIR INFORMATION Please call us for an authorization number before returning any equipment for repair or factory service We will advise you of shipping and handling When you send the equip ment please include the following information e Your name company name e Your address e Your phone number e A brief description of the problem or the work to be done Before we perform any repair we will estimate the work and inform you of the cost and the time requ
32. ser s Manual Chapter 4 Assembly and Disassembly Chapter 4 Assembly Disassembly and Storage The WTP4800 hydraulic sump pump is shipped fully assembled from the factory It is ready to operate as soon as you remove it from its shipping storage case CARE OF HYDRAULIC HOSES CONNECTORS Before storing the pump either short term or long term securely fasten protective caps over the hydraulic connec tors on the pump Also install caps on the hoses or connect the male and female ends of the hose together to seal the connectors and keep dirt and contaminants out of the hoses ENVIRONMENTAL REQUIREMENTS The pump should not be used to pump volatile liquids or water containing volatiles If you use the pump in a corrosive environment be sure to clean it thoroughly If possible pump clean water through to rinse the interior components and spray the outside of the pump LONG TERM STORAGE Always store the pump in a clean dry place safe from dam age In This Chapter CARE OF HYDRAULIC HOSES CONNECTORS ENVIRONMENTAL REQUIREMENTS LONG TERM STORAGE E H Wachs Company Part No 08 MAN 04 Rev 0 0206 Chapter 4 Assembly and Disassembly WTP4800 Hydraulic Trash Pump User s Manual 18 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 5 Operating Instructions Chapter 5 Operating Instructions PRE OPERATION PROCEDURES Check
33. teeth and end sur faces Check for cracks at the groove in the drive gear bore Motor Cap Assembly The surface near the gears should show two overlapping polished circles without a step The bottom of the o ring groove should be smooth as should the rest of the flat sur face Motor Shaft The diameter should be smooth on each side of the keyway Signs of polishing are normal Grooves roughness or a reduced diameter are indications of fluid contamination Replace the seals if the motor shaft requires replacement If the motor shaft must be removed refer to the Replace the Motor Shaft Seal section to remove the needle bearing In addition the key must also be removed from the motor shaft keyway before removing the motor shaft Check the hydraulic system for excess contamination in the fluid and for filter condition Operating conditions might The key might fall By out of the motor shaft keyway Make sure it is not lost Also the gears and idler shaft might remain in the motor cap assembly Do not drop or damage them The motor shaft En and needle bearing are separated by removing the retaining ring When separating make sure you do not scratch any seal areas E H Wachs Company Part No 08 MAN 04 Rev 0 0206 31 Chapter 7 Service and Repair WTP4800 Hydraulic Trash Pump User s Manual require changing from a 25 micron filter to an oversized 10 micron filter PUMP REASSEMBLY Assemble Moto
34. to the hydraulic system or pump motor seals can result from use with fluid that is too viscous or thick NOTICE Pumping liquids with a solids content of greater than 30 percent will cause acceler ated impeller wear E H Wachs Company Part No 08 MAN 04 Rev 0 0206 21 Chapter 5 Operating Instructions WTP4800 Hydraulic Trash Pump User s Manual 22 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 6 Routine Maintenance Chapter 6 Routine Maintenance Good maintenance practice keeps the trash pump on the job and increases its service life Use the procedures in this chapter to clean and inspect the pump and refer to Chapter 7 for any required repair procedures The most important maintenance practice is to keep the hydraulic fluid clean at all times Contaminated hydraulic fluid causes rapid wear and or failure of internal parts Fol low the procedures contained in the Hydraulic System Requirements in Chapter 3 to ensure peak performance from the trash pump PUMP CLEANING AND INSPECTION Debris such as weeds sand and other solids may become trapped in the pumping chamber This can reduce pump per formance It is important that the pumping chamber be kept clean at all times Clean out the debris and then determine whether or not the fire hose is clogged or the power source is not providing adequate flow pressure to properly drive the tras
35. tructions in Chapter 7 Note There should be a close fit between the impeller and the bottom wear plate However there should not be any drag 2 If there is excessive drag add a shim between the volute weldment and the volute motor mount plate 3 If the clearance between the volute weldment and the bottom wear plate exceeds 1 16 of an inch remove a shim to achieve a closer fit 24 Part No 08 MAN 04 Rev 0 0206 E H Wachs Company WTP4800 Hydraulic Trash Pump User s Manual Chapter 6 Routine Maintenance 4 If hydraulic fluid appears above the impeller the motor shaft seal has failed Refer to the motor shaft seal disassembly instructions in Chapter 7 Inspecting the Bottom Wear Plate L Check the bottom wear plate for cracks deep scratches and signs of excessive wear Scratches deeper than 1 16 inch 2 mm might affect pump per formance If the wear plate is not damaged add or remove shim s as required to achieve a proper fit If the wear plate is damaged it must be replaced Preparing the Pump for Operation If no other service is required prepare the pump for normal operation 1 Remove the grease fitting cap and inject two pumps of underwater grease into the lip excluder housing 2 Replace the grease fitting cap 3 Replace the shim s onto the top of the volute weld ment 4 Place the volute motor mount plate onto the volute weldment 5 Secure the volute motor mount plate to the
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