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WDP3500 Hydraulic Sump Pump

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1. E H Wachs Company 100 Shepard Street Wheeling IL 60090 www wachsco com WDP3500 Hydraulic Sump Pump User s Manual E H Wachs Company Part No 08 MAN 03 Rev 0 0106 January 2006 Revision History January 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 WDP3500 Hydraulic Sump Pump User s Manual Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Table of Contents Chapter 1 About This Manual ooooccooooocnnn nn nenn 1 Purpose of This Manu al 5 iii a na iD wi nme ce 1 How to Use The Manual 1 227 a rs a ae 2 Symbols and Warnings soc ote A pated Gatton eke ated See ot a ares 2 Manual Updates and Revision Tracking 0 cece rennen nenn nn nn 3 Chapter 2 Sally reitera A Ra a 5 Operator Safety so 222020 src dara AA 5 Protective Equipment Requirements 6 Safety Labels iaa e ad 7 Safety Precautlons 2022 E A EA E A 7 Machine Safety 335 24 222320 raso rr GAR 9 Chapter 3 Introduction to the WDP3500 Hydraulic Sump Pump 11 Usage and Applications sic a is a o a weed rR Re Re 11 Regliirements a AE da e E a ea 13 Hydraulic Hose Requirements oooocooccoooooo nenn 13 OSC TY BCS ur te la hte a o Diesel 13 Hose Satety Tags u un nes a Saw ate er a In a ah 13 Hose Pressure Rating iess rawa fe tue eier ee 15 HTMA R
2. mance WARNING Never point the hose at bystand ers Personal injury could result the pump is the inlet pressure coupler PUMP OPERATION 1 Observe all safety precautions 2 Connect a hose fitted with a 3 inch 76 2 mm female camlock coupler to the pump outlet fitting Make sure the fitting is securely tightened For best performance keep the hose as short as possible and lay it out to avoid sharp bends or kinks 3 Lower the pump into the liquid to be pumped Locate the outlet end of the discharge hose to disperse the liq uid as required Remove any kinks from the hose to assure maximum water flow 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 uid If this happens particles can accumulate in the hose and backup the pumping chamber causing further restric tion The impeller then acts as a grinding wheel which causes accelerated pump wear Reduced liquid flow can be caused by the following 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 ca
3. 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 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 03 Rev 0 0106 Chapter 2 Safety WDP3500 Hydraulic Sump Pump User s Manual e Do not use the pump for applications for which it is not intended e Pump repair should be performed by experienced per sonnel only e Make certain that the recommended relief valves are installed in the pressure side of the system 10 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 3 Introduction Chapter 3 Introduction to the WDP3500 Hydraulic Sump Pump Read this chapter carefully to become familiar with the components and features of your WDP3500 hydraulic sump pump USAGE AND APPLICATIONS The WDP3500 is a high power dewatering pump
4. MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 8 Parts Lists and Drawings Table 1 WDP3500 Parts List Item No Part No Qty Description 1 STN 52669 1 Volute 2 STN 52720 1 Camlock Coupling 3 in 3 STN 13815 1 HSHCS 5 16 18 x 3 4 4 STN 56763 1 Washer 5 STN 52671 1 Impeller 6 STN 52716 1 V Ring 7 STN 31032 Shim 020 8 STN 31033 i Shim 010 9 STN 00166 1 Retainer Ring 10 STN 52719 1 Seal Carrier 11 STN 01262 1 O ring 1 3 4 x 1 7 8 x 1 16 031 12 STN 58651 1 Cup Seal 13 STN 56658 1 Seal Retainer 14 STN 56697 1 Seal Race 15 STN 01211 1 O ring 5 8 x 3 4 x 1 16 016 16 STN 00148 2 Bearing 17 STN 52696 1 Drive Shaft 18 STN 00635 1 Key 19 STN 06881 1 Needle Roller 20 STN 00170 1 Retainer Ring 21 STN 00669 1 Quad Ring 1 2 x 5 8 x 1 16 014 22 STN 19884 1 Seal Gland 23 STN 00171 1 O Ring 11 16 x 13 16 x 1 16 017 24 STN 52693 1 Front Bearing Housing 25 STN 52718 2 HHCS M12 1 75x 30 mm 26 STN 00178 1 O ring 2 1 8 x 2 1 4 x 1 16 034 27 STN 06316 2 Bushing 28 STN 06853 1 Drive Gear 29 STN 06855 1 Idler Gear 30 STN 06854 1 Idler Shaft 31 STN 06857 1 Gear Housing 32 08 003 00 1 Name Tags and Safety Sticker 33 STN 00612 8 HSHCS 1 4 20 x 2 1 4 34 STN 00936 2 Adapter 35 09 025 00 1 Female Flush Face Coupler Body 3 8 NPT 36 09 026 00 1 Male Flush Face Coupler Nose 3 8 NPT 14 401 00 1 Co
5. the bearings and pressing drive shaft through bearings until the bear ings rest against the shoulder Installation by the outer race will cause bearing damage Pack grease into needle roller groove on drive shaft and insert drive shaft into the seal gland Using a bear ing pusher or a sleeve socket with a diameter slightly smaller than the bearing bore press the bearing assembly into place using the outer race Installation by the inner race will result in bearing damage Lubricate and install o ring 15 and seal race 14 onto drive shaft Lubricate and install seal retainer 13 and o ring 11 into bearing bore Heavily lubricate with underwater grease and install cup seal 12 and seal carrier 10 into bearing bore and secure with retaining ring 9 Installation of seal carrier and cup seal before seal race has been installed will result in damage to cup seal Lubricate with underwater grease and install v ring 6 onto seal race Install idler shaft 30 and idler gear 29 Use grease to hold needle roller 19 in place before installing drive gear 28 Motor Cap 1 2 Lubricate and install o ring 26 into motor cap 31 Lubricate hex socket head capscrews 33 with an antiseize compound and install motor cap to front bearing housing Tighten capscrews to 8 10 1b ft Note the orientation of the motor cap as the bolt holes will only line up one way E H Wachs Company Part No 08 MAN 03 Rev 0 01
6. with a flow rate of up to 500 gallons per minute 1850 l min Its small size allows you to use it in a box as small as 10 inches square and 11 inches deep The pump is submersible with no priming required and can run dry without damage Figure 3 1 illustrates the components of the WDP3500 hydraulic sump pump In This Chapter USAGE AND APPLICATIONS REQUIREMENTS PUMP SPECIFICATIONS ACCESSORIES E H Wachs Company Part No 08 MAN 03 Rev 0 0106 Chapter 3 Introduction WDP3500 Hydraulic Sump Pump User s Manual Hydraulic inlet pressure a Hydraulic return sO Pump outlet Lift hook Pump inlet Figure 3 1 WDP3500 hydraulic sump pump compo nents Figure 3 2 illustrates the product decal fastened to the pump housing E H Wachs Company me 100 Shepard Street Wheeling IL 60090 U S A 7 12 GPM 7 26 45 LPM s s moo DO NOT EXCEEO 138 BAR 2000 Psi Model No 45 Ipm 7 12 gpm E cl CENTER TOOL ON CLOSED C WDP3500 138 bor 2000 psi IM USE OPEN CENTER TOOL ON OPEN CENTES TER SOREN 30L pm of 138bar 40Lpm at 138bar PORTS B IMPROPER HANDLING USE OR MANTENANCE OF EHTMA CATEGORY EMTMA CATEGORY T A FALURE II CONTACT AT A LEAK OR BURST CAN CAUSE OL a in HTMA TYPE II HTMA TYPE Ill OBSERVE THESE PRECAUTIONS CAN RESULT IN SERIOUS PERSONAL INJURY Figure 3 2 WDP3500 combined decal part no 08 003 00 Part No 08 MAN 03 Rev 0 0106 E
7. 06 29 Chapter 7 Service and Repair WDP3500 Hydraulic Sump Pump User s Manual IMPORTANT Do not force parts together You could damage the pump s components Impeller 1 2 Install shim stack 7 amp 8 onto drive shaft Install key 18 and impeller 5 to drive shaft and using loctite secure with washer 4 and hex socket head capscrew 3 Tighten capscrew to 15 1b ft Using a depth mic measure the distance from the bot tom of the motor flange to the bottom of the stepped diameter as shown below Adjust shim stack accord ingly to achieve a 2 285 2 270 offset 2 285 2 2 0 Figure 7 1 There should be an offset of between 2 270 and 2 285 inch from the bottom of the motor flange to the bottom of the stepped diameter Volute L Assemble motor and impeller to volute 1 and secure with hex head cap screws 25 Use an allen wrench to ensure that the impeller with freewheel after assembly TROUBLESHOOTING Refer to the troubleshooting chart on the following page 30 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 7 Service and Repair If symptoms of poor performance develop the following chart can be used as a guide to correct the problem When diagnosing faults in operation 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
8. 16 from the front bearing housing 6 Spin the ball bearings on the drive shaft The bearing should turn smoothly To replace the bearing support the outer race and press down on the drive shaft from the threaded end Do not reuse the ball bearing once it has been removed from the drive shaft Remove Drive Shaft Seal Remove the retaining ring 20 quad ring 21 seal gland 22 and o ring 23 from the drive shaft bore using a pick CLEANING AND INSPECTION Cleaning Clean all parts with a degreasing solution Blow dry with compressed air or use lint free cloths Gear Chamber Motor Cap The chamber bores and bottoms around the shaft bushings should be polished and not rough or grooved If the bushing bores are yellow bronze replace them and investigate the cause of wear STN 65132 Motor assembly used on sump pumps with serial numbers 600 and above This motor can only be purchased as an assem bly individual parts are not available E H Wachs Company Part No 08 MAN 03 Rev 0 0106 27 Chapter 7 Service and Repair WDP3500 Hydraulic Sump Pump User s Manual The flat surfaces around the chamber and bolt holes should be flat and free of nicks or burrs that could cause misalign ment or leaks Bushings The inside of the bushings should be gray with some bronze showing through If significant yellow bronze shows replace the bushings Inspect the motor shaft and idler shaft for correspondin
9. 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 required to com plete it In This Chapter REPLACEMENT PARTS REPAIR INFORMATION WARRANTY INFORMATION RETURN GOODS ADDRESS E H Wachs Company Part No 08 MAN 03 Rev 0 0106 39 Chapter 10 Ordering Information WDP3500 Hydraulic Sump 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 DDRESS Return equipment for repair to the following address E H Wachs Company 100 Shepard Street Wheeling Illinois 60090 USA 40 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company
10. COSITY at min and max operating temps NOTE 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 03 Rev 0 0106 15 Chapter 3 Introduction WDP3500 Hydraulic Sump Pump User s Manual PUMP SPECIFICATIONS Capacity Weight Length Width Pressure Flow Range Maximum Flow Porting Connect Size and Type Discharge Diameter Sound Pressure ACCESSORIES 500 gpm 1890 Ipm 21 Ibs 9 5 kg 10 5 in 26 7 cm 10 in 25 4 cm 1000 2000 psi 70 140 bar 7 12 gpm 26 45 Ipm 12 gpm 45 lpm 8 SAE O Ring 3 8 in Flush Face Quick Disconnect Couplers 3 in 7 6 cm lt 85 dBA O 1m e Lay flat discharge hose 3 in x 25 ft with camlock fit tings part no 08 400 03 16 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 4 Assembly and Disassembly Chapter 4 Assembly Disassembly and Storage The WDP3500 hydraulic sump pump is shipped fully assembled from the factory It is ready to operate as soon as you remove it f
11. EPAIR 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 an SUL OTER SIDE Figure 2 1 The front and back sides of the safety tag attached to the pump Tag is part no STN 15875 SAFETY PRECAUTIONS Tool operators and maintenance personnel must always WARNING comply with the safety precautions given in this manual and AN Failure to follow the on the stickers and tags attached to the tool and hose instructions for safe operation These safety precautions are given for your safety Review could result in operator injury them carefully before operating the tool and before per forming general maintenance or repairs E H Wachs Company Part No 08 MAN 03 Rev 0 0106 7 Chapter 2 Safety WDP3500 Hydraulic Sump Pump User s Manual 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 WDP3500 Hydraulic Sump Pump will 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 i
12. H Wachs Company 12 WDP3500 Hydraulic Sump Pump User s Manual Chapter 3 Introduction REQUIREMENTS 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 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 CAUTION plied by the E H Wachs company for use with the If the information on a tag is WDP3500 pump DO NOT REMOVE THESE TAGS illegible because of wear or damage replace the tag immediately Anew tag may DANGER be obtained from your the E H Wachs Company 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 DEPAR
13. OT 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 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 DO NOT REMOVE THIS TAG 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 OVL SIHL AAOWSAY LON Od Figure 3 4 Tag attached to Conductive hose front and back 14 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 3 Introduction 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 HTMA Requirements TOOL CATEGORY HYDRAULIC SYSTEM EN REQUIREMENTS TYPE TYPE Il TYPE Ill TYPE RR FLOW RATE 4 6 gpm 7 9 gpm 11 13 gpm 9 10 5 gpm 15 23 Ipm 26 34 Ipm 42 49 Ipm 34 40 Ipm TTOOL OPERATING PRESSURE 2000 psi 2000 psi 2000 psi 2000 psi at the pow
14. TMENT INSTRUCTIONS DO NOT REMOVE THIS TAG E H Wachs Company Part No 08 MAN 03 Rev 0 0106 13 Chapter 3 Introduction WDP3500 Hydraulic Sump Pump User s Manual DANGER 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 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 AAOWAY LON OG 6 AFTER EACH USE STORE IN A CLEAN DRY AREA Figure 3 3 Tag attached to Certified Non Conduc tive hose front and back 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 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 DO N
15. any required repair procedures PUMP CLEANING PROCEDURE Debris such as weeds sand and other solids may become trapped in the water hose and pumping chamber This can reduce pump performance It is important that the pumping chamber be kept clean at all times The chamber can be cleaned using the following procedure 1 Remove motor and impeller by removing the two M12 x 1 75 Hex Head capscrews 2 Remove all debris from the pump screen 3 Thoroughly clean the volute and impeller Do not remove the impeller unless necessary for repair or replacement or to remove trapped debris 4 Assemble the motor and impeller to the volute Clean the capscrews and lubricate the threads with underwa ter grease before installation 5 Remove all debris from the hose Otherwise solids will backfill the pump In This Chapter PUMP CLEANING PROCEDURE E H Wachs Company Part No 08 MAN 03 Rev 0 0106 23 Chapter 6 Routine Maintenance WDP3500 Hydraulic Sump Pump User s Manual 24 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump 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 in the procedures refer to the drawing PUMP DISASSEMBLY Clean the exterior of the pump and put it on a clean work surface Remove Volute 1 Remove the volute 1 b
16. be accurate Check the flow with the hydraulic fluid tempera ture at least 80 F 27 C PROBLEM CAUSE SOLUTION Pump will not start No hydraulic fluid flow or pressure Turn on power unit and check that 7 12 gpm 26 45 Ipm at 1000 2000 psi 70 140 bar is available at the pump Defective couplers Check the couplers Replace if necessary Impeller jammed with debris Impeller rubbing against wear plates Defective hydraulic motor Clean the pumping chamber as described in the Maintenance section in this manual Check and adjust the impeller clearance as described in the Service Instructions section in this manual Repair or replace motor Poor pump performance Poor pump performance with excessive wear Hydraulic flow reversed Improper hydraulic fluid flow Pump submersed in sediment Trash pump inlet restricted 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 Check that 7 12 gpm 26 45 Ipm at 1000 2000 psi 70 140 bar is available at the trash pump A 20 decrease in flow can result in a 50 decrease in pump perfor mance Lift the pump from the bottom of the hole or chamber Use a flat support under the pump if necessary Remove suction screen and thoroughly clean Reassemble Discharge hose kinked or restricted Discharge hose t
17. equirements ss mn a ae ha 15 Pump Specifications qisni nieret ri 16 Accessories i urn un Ha aa ana AAA AR AAA Lat an Ge ba 16 Chapter 4 Assembly Disassembly and Storage oooooooomo o 17 Care of Hydraulic Hoses Connectors 000 cece eee eee 17 Environmental Requirements 002 c eee ee eee eee eee nn 17 Long Term Storage 2 2 a ete ess far pane geen wate x cacao ae See eng 17 Chapter 5 Operating Instructions 000 c cece eee ee eee 19 Pre Operation Procedures 200 c eee eee eee eee nennen nennen 19 Check Power Source prerani Ses ee de Sea pede sik I EEA A hea ey 19 COMMECETIOS ES onr Foes iy Stance le ete ie Seta e pis 19 PUMP Operatlon aione a es Wek bere test hea Ae crac eee area Sek prs 20 Cold Weather Operation ooocooocccocon eee eee 21 Chapter 6 Routine Maintenance 000c cece eee eee eee 23 Pump Cleaning Procedure 200 c eee eee eee eee nennen eee eee 23 Chapter 7 Service and Repair cooooocccnnco eee 25 Pump Disassembly ora AA a eae 25 Remove Voluleri seele ee dr Del Rh 25 Remove Impeller taste de e a ee RO ded BE es o ee as 25 Remove Moor Cap a rat engeren 25 E H Wachs Company Part No 08 MAN 03 Rev 0 0106 WDP3500 Hydraulic Sump Pump User s Manual Remove Drive Shaft eS tee Batre a e aa e A A A A ea 27 Remove Drive Shaft Seal 222 22 A Boe Lee ee 27 Cleaning and Inspection 0 cece eee eee eee eee eee eee 27 Cleanin
18. er supply outlet 138 bar 138 bar 138 bar 138 bar SYSTEM RELIEF VALVE SETTING 2100 2250 psi 2100 2250 psi 2100 2250 psi 2200 2300 psi at the power supply outlet 145 155 bar 145 155 bar 145 155 bar 152 159 bar MAXIMUM BACK PRESSURE 250 psi 250 psi 250 psi 250 psi at tool end of the return hose 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of 400 ssu 400 ssu 400 ssu 400 ssu at min operating temperature 82 centistokes 82 centistokes 82 centistokes 82 centistokes TEMPERATURE 140 F 140 F 140 F 140 F Sufficient heat rejection capacity 60 C 60 C 60 C 60 C to limit max fluid temperature to at max expected ambient temperature Min cooling capacity 3 hp 5 hp 7 hp 6 hp lat a temperature difference of 2 24 kW 3 73 kW 4 47 kW 5 22 kW between ambient and fluid temps 40 F 40 F 40 F 40 F 22 C 22 C 22 C 22 C NOTE 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 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm Sized for flow of at least 114 Ipm 114 Ipm 114 Ipm 114 Ipm For cold temp startup and max dirt holding capacity HYDRAULIC FLUID 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu Petroleum based 20 82 centistokes premium grade anti wear non conductive VIS
19. 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 of this manual by emailing customer service at sales wachsco com E H Wachs Company Part No 08 MAN 03 Rev 0 0106 Chapter 1 About This Manual WDP3500 Hydraulic Sump Pump User s Manual 4 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump 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 A WARNING Read this chapter carefully before operating your WDP3500 Hydraulic Sump 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 READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before y
20. g ee NE 27 Gear Chamber Motor Cap ze re er 27 BUSHINGS ac astas is aa A ad Sawada ead 28 OTIS vn Na AAA es Gente AG dd 28 Front Bearing Housing nr ee EN 28 MAS ae 2p la PRES ee rta 28 PUmp ReaSsSOMbIV gt 02 050003 RARA AA AAA 28 e AAA II ee ae 28 Duve Shatt a A NER Eee caos 29 M tor Cap ar A E ENS ae 29 TUS at a a e da ae Lae e AER dd Ad ee DO ha 30 A rn Indes Beit eer aan Re engl ea Meat Be eA A re niet okay 30 Troublesho8lng zu see area 30 Chapter 8 Parts Lists and Drawings 2000ee eee eee eee eee 33 Chapter 9 Accessories cuidate a daa ee Pew owes 37 Chapter 10 Ordering Information 0 0c eee eee eee eee 39 Ordering Replacement Parts ocooocconcocn eee eee eee eee 39 Repair Information 2 0922 evieuGeceg RARA aan nee eee ene ees 39 Warranty Information u a 40 Return Goods Address toreo se aye tenes ae De a 40 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump 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 WDP3500 Hydraulic Sump 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 WDP3500 Hydraulic Sump Pump you should read thro
21. g wear and replace as required Gears The drive and idler gears should have straight tips without nicks square tooth ends and a smooth even polish on the teeth and end faces Replace the gear if cracks are present Front Bearing Housing The surface near the gears should show two interconnecting polished circles without a step Shafts The shaft diameter at the bearing and seal locations must be smooth Grooves roughness or a reduced diameter indicate fluid contamination or damaged bushings Grit particles may have been imbedded in the bushings grinding into the hardened shaft If abnormal shaft wear as noted above occurs more than normal polishing replace both the shaft and associated bushings Also check the hydraulic system for excess contamination in the fluid and for filter condition Operating conditions may require changing from a 25 micron filter to an over sized 10 micron filter PUMP REASSEMBLY Drive Shaft Seal 1 Heavily lubricate and install a new o ring 23 and quad ring 21 into seal gland 22 Ensure the quad ring is not twisted during assembly 28 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 7 Service and Repair 2 Install seal gland and attached parts into front bearing housing and secure with retaining ring 20 Drive Shaft 1 Install bearings 16 onto lubricated drive shaft 17 by supporting the inner races of
22. ick couplers and cause overheating Use only lint free cloths Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 2 Safety 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 Do not operate a damaged improperly adjusted or incompletely assembled tool To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained personnel Do not exceed the rated limits of the tool or use the tool for applications beyond its design capacity Always keep critical tool markings such as labels and warning stickers legible Always replace parts with replacement parts recom mended by the E H Wachs Company Check fastener tightness often and before each use daily MACHINE SAFETY Observe the following guidelines for reliable machine oper ation and care Make sure all couplers are wiped clean before connec tion 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 Always store the tool in a clean dry space safe from damage or pilferage Make sure the circuit PRESSURE hose with male quick disconnect is connected to the
23. 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 a situation that if not avoided may result in damage to the equipment Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 2 Safety SAFETY LABELS The safety tag illustrated in Figure 2 1 is attached to the pump when it is shipped from the factory Read and under stand 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 DANGER 1 ALLE DO VSE TERM HOSE LABELED AND CENTS FED AS WON CONDUCTIVE WEN USNO HYDRAULIC TOOLS ON OF MAR ELECTINCAL LINES WAY RESULT N DEAT OF SEROUS RY BEFORE JONG MOSE LABELED And CLATFAS AS NOW CORDECTINE OF OF NEAR ELECTRA MES BE SURE DE OLE 5 MAMTAMED A NONCOMOUC TIVE THE HOSE D OE REGAAMY TESTED FOR ELECTRIC CURRENT 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 R
24. lief valve set to open at 2100 psi 145 bar maxi mum 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 return hose first and disconnect it last to minimize or avoid trapped pressure within the pump motor 3 Observe the arrow on the couplers to ensure that the flow is in the proper direction The female coupler on In This Chapter PRE OPERATION PROCEDURES PUMP OPERATION COLD WEATHER OPERATION IMPORTANT Improper pressure or relief on the power source could dam age the pump If uncoupled hoses En are leftin 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 03 Rev 0 0106 Chapter 5 Operating Instructions WDP3500 Hydraulic Sump Pump User s Manual The WDP3500 is not designed for A use with a suction pipe inlet The diameter ofthe suction screen at the bottom ofthe pump provides maxi mum pump efficiency Reduc ing the size of this inlet will greatly reduce pump perfor
25. n no longer carry solids out the end of the hose 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 20 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 5 Operating Instructions 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 to the hydraulic system or pump motor seals can result from use with fluid that is too viscous or thick E H Wachs Company Part No 08 MAN 03 Rev 0 0106 21 Chapter 5 Operating Instructions WDP3500 Hydraulic Sump Pump User s Manual 22 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 6 Routine Maintenance Chapter 6 Routine Maintenance The WDP3500 pump is reliable and requires little mainte nance Use the procedure in this chapter to clean the pump and refer to Chapter 7 for
26. njury 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 e Do not wear loose fitting clothing when operating the tool Loose fitting clothing 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 qu
27. oo small Straighten the hose 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 3 inch diameter fire hose Water lift too high Impeller worn or damaged Lower the outlet end of the discharge hose Increase hydraulic flow 12 gpm 45 Ipm max Check impeller for damage and excessive wear Replace if necessary Pump not matched to application Hose used on suction side of pump Too many solids in the water Water speed out of the hose may be too slow thereofre hose and pump load up with solids Obtain higher capacity pump Remove Use no plumbing on suction side of pump Reduce solids content Increase pump speed E H Wachs Company Part No 08 MAN 03 Rev 0 0106 31 Chapter 7 Service and Repair WDP3500 Hydraulic Sump Pump User s Manual 32 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump 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 03 Rev 0 0106 33 Chapter 8 Parts Lists and Drawings WDP3500 Hydraulic Sump Pump User s Manual 36 Ne 32 y j S E 4 7 eo O 34 Part No 08
28. ou begin 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 It indicates a personal injury hazard E H Wachs Company Part No 08 MAN 03 Rev 0 0106 Chapter 2 Safety WDP3500 Hydraulic Sump 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
29. rom 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 03 Rev 0 0106 Chapter 4 Assembly and Disassembly WDP3500 Hydraulic Sump Pump User s Manual 18 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 5 Operating Instructions Chapter 5 Operating Instructions PRE OPERATION PROCEDURES Check Power Source 1 Using a calibrated flow meter and pressure gauge make sure the hydraulic power source develops a flow of 7 12 gpm 26 45 Ipm at 1000 2000 psi 70 140 bar 2 Make certain that the power source is equipped with a re
30. to it for safety notes and other information SYMBOLS AND WARNINGS The following symbols are used throughout this manual to indicate special alerts and notes They appear in the outside 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 hazards Obey all safety messages that follow this symbol to avoid possible injury or death NOTE This symbol indicates a user notice Notices provide additional information to supplement the instructions or tips for easier operation Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump 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
31. ugh 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 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 03 Rev 0 0106 Chapter 1 About This Manual WDP3500 Hydraulic Sump 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 WDP3500 Hydraulic Sump 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 WDP3500 Hydraulic Sump Pump The narrower column on the outside contains additional information such as warnings special notes and definitions Refer
32. upler Set Notes A Items 9 24 26 31 and 33 are used on pumps with serial numbers 599 and below B All pumps with a serial number 600 and above are shipped with motor assembly STN 65132 installed A separate seal kit STN 65133 is available for this motor C For pumps with serial numbers 599 and below you may purchase individual parts in the table or purchase a complete STN 65132 motor assembly E H Wachs Company Part No 08 MAN 03 Rev 0 0106 35 Chapter 8 Parts Lists and Drawings WDP3500 Hydraulic Sump Pump User s Manual 36 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 9 Accessories Chapter 9 Accessories Table 1 lists accessories available for the WDP3500 hydrau lic sump pump Lay flat discharge hose 3 in x 25 ft with cam lock fittings Table 1 Accessories for WDP3500 Hydraulic Sump Pump 08 400 03 no photo available E H Wachs Company Part No 08 MAN 03 Rev 0 0106 37 Chapter 9 Accessories WDP3500 Hydraulic Sump Pump User s Manual 38 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump 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
33. y first removing the hex head cap screws 25 and pulling the motor and impeller off the volute Remove Impeller 1 Remove hex socket head capscrew 3 and washer 4 before lifting impeller 5 off motor assembly 2 Remove key 18 and shim stack 7 amp 8 from impel ler Remove Motor Cap 1 Remove the hex socket head cap screws 33 that secure the motor cap 31 to the front bearing housing 24 and remove the motor cap Do not in any way excessively force the motor cap off the front bearing housing In This Chapter PUMP DISASSEMBLY CLEANING AND INSPECTION PUMP REASSEMBLY TROUBLESHOOTING E H Wachs Company Part No 08 MAN 03 Rev 0 0106 25 Chapter 7 Service and Repair WDP3500 Hydraulic Sump Pump User s Manual 26 Part No 08 MAN 03 Rev 0 0106 E H Wachs Company WDP3500 Hydraulic Sump Pump User s Manual Chapter 7 Service and Repair 2 Remove the o ring 26 from the motor cap Remove Drive Shaft 1 Remove idler gear 29 idler shaft 30 drive gear 28 and needle roller 19 from front bearing hous ing 2 Remove the v ring 6 from the seal race 14 before pulling the seal race off the drive shaft 3 Remove retaining ring 9 4 Using a pick remove the seal carrier 10 cup seal 12 o ring 11 seal retainer 13 and o ring 15 from the bearing cavity 5 Press the drive shaft 17 and bearings

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