Wacker 0620435 Instructions / Assembly
Contents
1. 1 1 wc gr001699 Description Description Lifting handle Oil plug Mechanical seal Dust seal Lubricant Sleeve Oil housing Impeller Coupling Stirrer nut Volute Strainer Gasket 15 lifter Cable assembly wc tx000111gb fm 9 Operation 2 2 2 3 we_tx000111gb fm PST2 PSTF2 400 Prior to Operation CAUTION When the pump is delivered first perform the following checks e Inspection While unpacking inspect the product for damage during shipment and make sure all bolts and nuts are tightened properly e Specification check Check the model number to make sure it is the product that was ordered Be certain it is the correct voltage and frequency Note f there is any problem with the product as shipped contact your nearest dealer or Wacker Neuson representative at once e Product specifications Do not operate this product under any conditions other than those for which it is specified Failure to observe this precaution can lead to electrical shock current leakage fire water leakage or other problems Installation WARNING If the pump is used to drain a swimming pool the pump must be connected to a Ground Fault Interrupter GFI If the pump is used in fountains the pump must be connected to a Ground Fault Interrupter GFI The pump must not be used when people are in the water Leakage of pump lubricants may cause pollution of water Prope2. Association of Equipment Manufacturers REFERENCES ln M EE A o iaa a CC The following is a partial list of referenced material SAE Society of Automotive Engineers Inc on safe operating practices 400 Commonwealth Drive Warrendale PA 15096 U S Department of Labor publishes safety and dete health regulations and standards under the YU a list Operator Precautions SAE J153 authority of the Occupational Safety and Health Act for the general construction and mining industries AEM Association of Equipment Manufacturers U S Department of Labor 111 East Wisconsin Avenue Washington DC 20210 Milwaukee WI 53202 NFPA National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 5 FOREWORD 4 FOLLOW A SAFETY PROGRAM 5 PERFORM MAINTENANCE SAFELY 7 PREPARE FOR SAFE OPERATION 9 WORK SAFELY Pumps In General 10 WORK SAFELY Engine Driven 13 WORK SAFELY Electric Motor Driven Pumps 15 WORK SAFELY Submersibles 17 TEST YOUR KNOWLEDGE 19 FINAL
3. NEVER use a pump motor in an explosive atmosphere if it is not exclusively designed for the application Always ground electrical units Make certain to connect pump motor to the right phase and voltage Do not run pump if voltage is not within limits Make sure motor rotation is in accordance with impeller rotation which should be indicated somewhere on the pump check the manufacturer s manual Make all electrical installations in accordance with National Electric Code State and Local electrical codes Never use gas piping as an electrical ground Make sure the related electrical circuits are dead and locked out before performing any maintenance 4 Follow motor manufacturer s recommended maintenance and operation instructions If circuit breaker or fuse is tripped examine the system for the problem before restarting pump NEVER use the power cord to aid lifting the pump NEVER operate a pump with a plug in type power cord without a ground fault circuit interrupter NEVER use cords with frayed cut or brittle insulation Check the cord on the pump for nicks in the insulation and for sound connections to the ground fault interrupter plug and motor NEVER let extension cords or the plug connections lay in water Locate the pump so that the cord cannot fall into any water or be submerged by rising water unless the pump is designed for such use NEVER handle energized power cords with wet hands MOTO
4. gt WARNING gt CAUTION Draw power from a dedicated power outlet rated at 15 A or above Sharing the outlet with other equipment may cause overheating at the branch outlet and could result in fire e three prong grounded plug shall be connected as shown in the drawing NOTICE Be sure to use a dedicated power supply with a ground leakage circuit breaker Note The shape of the plug may differ from that shown in the illustration we_tx000111gb fm 1 5 Operation A CAUTION wc_tx000111gb fm PST2 PSTF2 400 See Graphic wc_gr000242 we_gr000242 Cable Assembly If it is necessary to extend the cable assembly use a core size equal to or larger than the original This is necessary not only to avoid a performance drop but to prevent cable overheating which can result in fire electrical leakage or electrical shock If a cable with cut insulation or other damage is submerged in the water 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 This may result in damage to the pump electrical leakage electrical shock or fire If it is necessary to submerge the connection wires of the cable assembly in water first seal the wires completely in a molded protective sleeve to prevent electrical leakage electrical shock or fire Do not allow the cable assembly wires or power supply plug to become wet Ma
5. KNOW WHAT IT IS Consult your supervisor for specific instructions and personal safety equipment required For instance you may need Hard Hat Reflector Vests e Safety Shoes Hearing Protection Eye Protection Face Protection Respirators Back Supports e Heavy Gloves Other job related specific items Do not wear loose clothing or any accessory flopping cuffs untied shoe laces dangling neckties and scarves rings wrist watches or other jewelry that can catch on protruding or moving parts or controls Long hair should be securely bound to prevent entanglement with moving parts FIG 3 FIG 3 FIG 4 FOLLOW A SAFETY PROGRAM Remember that YOU are the key to safety Good safety practices not only protect you but also protect the people around you Study this manual and the manufacturer s manual s for your specific pump Make them a working part of your safety program Keep in mind that this safety manual is written for only this type of equipment Practice all other usual and customary safe working precautions and above all FIG 1 REMEMBER SAFETY IS UP TO YOU YOU CAN PREVENT SERIOUS INJURY OR DEATH FIG 1 BE ALERT Know where to get assistance Know how to use a first aid kit and fire extinguisher or fire suppression System FIG 4 BE AWARE Take advantage of training programs offered Safety programs should require that one person at each job
6. initiating person prior to the return to start up see page 12 Fig 11 BEFORE doing any major work disconnect the ignition and battery if so equipped Always replace safety devices removed during service or repair before returning pump to operation Battery Servicing Always wear safety glasses and gloves when servicing or working with batteries Before servicing battery turn off electrical systems then disconnect ground terminal clamp Before installing a battery turn off electrical equipment then connect the battery ground clamp last Maintain electrolyte at the recommended level Check level frequently Add distilled water to batteries only when starting up never when shutting down Use a flashlight to check level NEVER use a flame Do not short across battery terminals the spark could ignite the battery gases Battery acids will burn skin eat holes in clothing and can cause blindness if splashed in eyes If you spill acid on yourself flush skin immediately with lots of water Apply baking soda to help neutralize the acid f acid gets into the eyes flush immediately with large amounts of water and seek proper medical treatment immediately 13 16 WORK SAFELY Electric Motor Driven Pumps SAFE WORKING PROCEDURES Allow only qualified personnel to INSTALL WIRE AND OPERATE electric motor driven pumps Whenever electricity is present there is the possibility of electrocution
7. operation may cause the pump to malfunction Note See section Operating water level for the water level necessary for operation Sharp bends in the hose especially near its base may cause air pockets to form resulting in idle operation Lessen the degree of bending while continuing to operate the pump 20 PST2 PSTF2 400 Operation Operating water level Do not operate the pump below the C W L Continuous running Water Level indicated below Failure to observe this condition may result in CAUTION Gamage to the pump current leakage or electrical shock See Graphic wc gr001222 L Bi e AW NPT 45 degree hose coupling is standard for the US market Pump Model Continuous running Water Level PST2 400 w strainer 90mm 3 5 PST2 400 w residue plate 10mm 0 4 PSTF2 400 120mm 4 75 wc tx000111gb fm Motor Protection System Motor Protector The pump has a built in motor protection system Miniature Protector If the motor overheats for reasons such as the following the pump will automatically stop operating regardless of the water level to protect the motor e Change in supply voltage polarity e Overload e operation or operation under constraint Note Always determine the cause of the problem and resolve it before resuming operation Simply repeating cycles of stopping and restarting will result in damage to the pump Do not continue operation at very low
8. 8 3 6 9 3 6 10 3 6 11 3 6 12 wc 1 000112 orig gb fm Note f upon inspection and testing a pump component requires replacement use only original manufacturer s replacement parts Turn pump on its side Pre assemble the dust seal u and sleeve v Slide the two pieces u amp v onto the rotor shaft DO NOT apply oil to the surface where the dust seal u contacts the sleeve v Align keyway of impeller w with keyway of rotor not shown and push impeller w onto rotor shaft Secure with washer x lockwasher y and stirrer nut z While holding the impeller from rotating tighten stirrer nut z Position volute aa on suction strainer ac aligning with the three bolts ab protruding from the suction strainer ac Replace gasket ah on top of volute aa Lift and hold remaining pump assembly in an upright position align three mounting flanges and lower into place Assemble and secure three nuts af Tighten three nuts af Pre test pump to verify proper operation Performance test pump Test results should be Maximum head gt 10 06m 33ft Maximum volume gt 170 3 Itr min 45gpm 30 PST2 PSTF2 400 Maintenance 3 7 Troubleshooting Before ordering repairs carefully read through this manual then repeat the inspection If the problem remains contact your nearest dealer or Wacker Neuson representative Always turn off the power before inspecting the pump Failure to observe this prec
9. Extension Cords Use the following chart to select the correct size extension cord to prevent excessive amperage draw or voltage drop which would cause the motor to overheat Cables that are too long or coiled can cause a voltage drop Be aware that strong sunlight can cause a voltage drop Wire Gauge and Cord Length in feet Amperes 100 16 14 WORK SAFELY Submersibles SAFE WORKING PROCEDURES ALLOW only qualified personnel to INSTALL WIRE and OPERATE submersible pumps Whenever electricity is present there is the possibility of electrocution NEVER use a pump motor in an explosive atmosphere if it is not exclusively designed for that application ALWAYS ground the pump Make certain to connect the pump to the right phase and voltage DO NOT run the pump if voltage is not within limits Make all electrical installations in accordance with National Electric Code State and Local electrical codes Mount electrical control box in a vertical position protected from the elements NEVER attempt to use the power cord or hydraulic hoses as a lifting or lowering device for submersibles Attach a lifting cable to the manufacturer s recommended attachment point on the pump for lowering and lifting the pump FIG 12 WORK SAFELY Submersibles FIG 12 NEVER position the pump directly on a soft loose bottom To attain maximum capacity and prevent excessive wear positi
10. MALFUNCTIONING If your daily check uncovers any items that need attention repair replacement or adjustment report them promptly The most minor malfunction could be the result of more serious trouble or can cause it if pump is operated When in doubt attach vj an OSHA Lockout Tagout device tag to the control panel to disconnected electrical power supply at breaker on electrically driven pumps and disconnect the battery and or spark plug wire on engine driven FIG 8 WORK SAFELY Pumps In General SAFE WORKING PROCEDURES USE COMMON SENSE Most accidents can be avoided by using common sense and concentrating on the job to be done ONLY EXPERIENCED AND QUALIFIED personnel should install and operate pump equipment KNOW THE PROPER starting procedure for your equipment Follow the manufacturer s operation manual to the letter DO NOT operate a pump without all guards and shields in place If OSHA required guards are damaged or misplaced contact the manufacturer for a replacement When lifting pump use only lifting equipment in good repair and with adequate capacity Follow manufacturer s lifting recommendation Check all lubricant levels before pump installation in accordance with manufacturer s maintenance programs pumps Keep hands and feet clear of moving parts DO NOT stick fingers into a pump when in operation Check suction strainer and hose regularly for proper subme
11. Troubleshooting E ng Sn n de 31 4 Technical Data 32 4 1 Standard Specifications ORDRE ODIO ROSE 32 4 2 Operating Specifications 33 4 3 ME TP 34 wc bo0154618en O05TOC fm 5 Table of Contents PST2 PSTF2 400 PST2 PSTF2 400 Safety Information 1 Safety Information wc si000034gb fm A A DANGER WARNING CAUTION This manual contains DANGER WARNING CAUTION NOTICE and NOTE callouts which must be followed to reduce the possibility of personal injury damage to the equipment or improper service 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 DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Used without the safety alert symbol NOTICE indicates a situation which if not avoided could result in property damage Note Contains additional information important to a procedure Safety Information PST2 PSTF2 400 1 1 Operating and Electrical Safety To reduce risk of electric shock connect only to a properly grounded grounding type receptacle Risk of electr
12. Wacker Neuson Corporation represents an infringement of valid copyrights and will be prosecuted We expressly reserve the right to make technical modifications even without due notice which aim at improving our machines or their safety standards Foreword wc tx001173gb fm PST2 PSTF2 400 Table of Contents Foreword 3 1 Safety Information 7 1 1 Operating and Electrical Safety 8 1 2 Informational 8 2 Operation 9 2 1 E 9 2 2 Prior to Operation 10 2 3 Installation nian 10 2 4 Installing the Float if equipped 13 2 5 Electical EHE 15 2 6 Electrical Circuit 17 2 7 19 2 8 Automatic Operation PSTF2 400 only 22 2 9 Resid e arcium 23 3 Maintenance 24 3 1 Periodic Maintenance Table 24 3 2 Maintenance and Inspection 25 3 3 Disassembly Reassembly 27 3 4 Brei 28 3 5 Impeller Inspection aoi ete ede dea deo dave oco eo ntt cd 29 3 6 Impeller Fl dssernbly secet obolis rd enean ee te teeth uberes 30 3 7
13. lift low water level or while the strainer is clogged with debris Not only will performance suffer but also such conditions may cause noise heavy vibration and malfunctioning 21 Operation PST2 PSTF2 400 2 8 Automatic Operation PSTF2 400 only See Graphic wc_gr005666 The PSTF2 400 pump is equipped with a float switch to detect the water level The float switch a enables the pump to perform an automatic drainage operation when connected to a continuous power supply wc_gr005666 Connect the power and perform a trial operation as follows 2 8 1 Move the float switch down to its lowest position 2 8 2 Raise the float switch This will start the pump 2 8 3 Lower the float switch to its original position This will stop the pump 2 8 4 Repeat this cycle two or three more times to verify the operation Note The trial operation must be completed within one minute If the pump operates abnormally i e exhibits an unusually large amount of vibration noise or odor disconnect the power supply CAUTION mmediately and contact your Wacker Neuson dealer Do not operate the pump in this condition otherwise there is a risk of current leakage electrical shock or fire wc tx000111gb fm 22 PST2 PSTF2 400 Operation 2 9 Residue Plate See graphic wc_gr001144 The residue plate kit contains the residue plate washers and bolts Reuse nuts from pump assembly 2 9 1 Remove the strainer 3 by loosening the three nuts 1 a
14. 9 5 0 4 The weight mass given above is the operating weight of the pump itself not including the cable assembly wc td000034gb fm 3 3 Technical Data 43 Dimensions 185 i 330 13 0 oo WW LAIN PST2 400 Start range Stop range Minimum Maximum wc td000034gb fm 34 PSTF2 400 PST2 PSTF2 400 wc gr006191 PORTABLE PUMPS WWW aem org SAFETY MANUAL FOR OPERATING AND MAINTENANCE PERSONNEL SAFETY ALERT SYMBOL A Why is SAFETY important to YOU The Safety Alert Symbol identifies important safety 3 BIG REASONS messages on machines safety signs in manuals elsewhere When you see this symbol be alert x Accidents COST DISABLE to the possibility of personal injury or death Follow Accidents the instructions in the safety message Accidents CAN BE AVOIDED NOTICE OF COPYRIGHT PROTECTION AEM Safety Manuals are protected as a copyrighted work with creation of derivative works based on an AEM Safety Manual ownership duly registered with the Copyright Office without the prior written approval of AEM is expressly Washington D C Any reproduction translation decompiling or prohibited Copyright infringement can result in civil and criminal other use of AEM Safety Manual or portion thereof or the sanctions damages and other penalties being imposed Copyright 2004
15. AYS use proper hoisting equipment for lifting heavy loads ALWAYS use a back brace when lifting by hand FIG 7 10 LEARN SAFE NEVER operate a pump which is new to you without first being instructed in it s proper operation READ the operator s manual If one has not been provided GET ONE AND STUDY IT BEFORE OPERATING THE PUMP Know the meaning of all identification symbols on your controls and gauges FIG 8 Know the location of the emergency shut down control if the machine is so equipped Before attempting to operate the pump know the capabilities and limitations of the pump Familiarize yourself with controls and instruments their locations and functions Keep hands levers and knobs clean of oil or grease to prevent slipping Carefully read and follow the instructions on all safety signs and decals on the pump Keep safety signs in good condition Replace missing or damaged safety signs PREPARE FOR SAFE OPERATION CHECK IT OUT Know what safety devices your machine is equipped with and see that each item is securely in place and in operating condition FIG 9 For example Drawbar Coupling Chains yy and Pins Alarms and Warning Lamps Reflectors Guards and Shields Drain Covers Plugs and Caps Shut Down Devices Leveling Jacks Pressure Relief Devices Lifting Devices FIG 9 NEVER START OR OPERATE A PUMP KNOWN OR SUSPECTED TO BE DEFECTIVE OR
16. OPERATOR S MANUAL 0 1 5 4 6 1 8 E N 0154618en 0209 Pump PST2 400 PSTF2 400 Foreword wc tx001173gb fm Foreword Machines covered in this manual PST2 400 0009112 PSTF2 400 0620435 This manual provides information and procedures to safely operate and maintain this Wacker Neuson model For your own safety and protection from injury carefully read understand and observe the safety instructions described in this manual Keep this manual or a copy of it with the machine If you lose this manual or need an additional copy please contact Wacker Neuson Corporation This machine is built with user safety in mind however it can present hazards if improperly operated and serviced Follow operating instructions carefully If you have questions about operating or servicing this equipment please contact Wacker Neuson Corporation The information contained in this manual was based on machines in production at the time of publication Wacker Neuson Corporation reserves the right to change any portion of this information without notice All rights especially copying and distribution rights are reserved Copyright 2009 by Wacker Neuson Corporation No part of this publication may be reproduced in any form or by any means electronic or mechanical including photocopying without express written permission from Wacker Neuson Corporation Any type of reproduction or distribution not authorized by
17. R OVERLOAD do not exceed the manufacturer s recommendation for maximum lift or discharge head See manufacturer s published curve for proper sizing of motors A misapplied motor can overheat 15 WORK SAFELY Electric Motor Driven Pumps Pump Maintenance and Repair MAKE SURE the pump is disconnected from the power source or the appropriate circuits are dead and OSHA Lockout Tagout is applied before doing any maintenance or repair work on the pump Maintenance work can be hazardous if not done in a careful manner All personnel should realize the hazards and strictly follow safe practices NEVER perform any work on the equipment unless authorized to do so FIG 11 Before performing any maintenance or repair work consult the manufacturer s instruction manual for recommended procedures Pumps with float switches or other automatic devices can start without warning if not properly locked out BEFORE ANY maintenance work is to be done a LOCKOUT TAGOUT standard device and procedure should be implemented Prior to removal of LOCKOUT TAGOUT the equipment must be fully operational and all personnel accounted for Except in cases of emergency the removal of the LOCKOUT TAGOUT should be done ONLY by the initiating person prior to the return to start up ALWAYS replace safety devices removed during the service or repair before returning pump to operation NEVER use the power cord to aid in lifting the pump Sizing
18. WORD TO THE USER 20 FOREWORD This safety manual is intended to point out some of the basic situations which may be encountered during the normal operation and maintenance of your equipment and to suggest possible ways of dealing with these conditions Additional precautions may be necessary depending on application pump type configuration and attachments used conditions at the work site or in the maintenance area The manufacturer has no direct control over pump application operation inspection lubrication or maintenance Therefore it is your responsibility to use good safe practices in these areas The information provided in this manual supplements the specific information about your pump that is contained in the manufacturer s manual s Other information which may affect the safe operation of your pump may be contained on safety signs decals markings insurance requirements employer s safety programs safety codes local state provincial and federal laws rules and regulations contracts agreements and warranties It is your responsibility to read and understand this safety manual and the manufacturer s manual s before operating your pump This safety manual takes you step by step through your working day If you do not understand any of this information or if errors or contradictions seem to exist consult with your supervisor before operating you
19. ative in the event such repairs are necessary 27 Maintenance PST2 PSTF2 400 34 Disassembly See Graphic wc_gr000411 3 4 1 3 4 2 3 4 3 CAUTION 3 4 4 wc 1 000112 orig gb fm Note For assembly or disassembly place the pump on its side Note is not necessary to drain the oil for disassembly and inspect ion of the impeller w or volute aa However drain oil if further disassembly and testing is required Remove three nuts af and the suction strainer ac Remove volute aa and volute gasket ah While keeping the impeller w from rotating remove stirrer nut z lockwasher y and washer x Impeller vanes may be very sharp due to excessive wear Handle with care Remove impeller w Note f the parts are worn or damaged make sure to replace them with new ones wc gr000411 28 PST2 PSTF2 400 Maintenance 3 5 Impeller Inspection See Graphic wc_gr000411 3 5 1 Visually inspect impeller w for corrosion wear or damage Worn impellers compromise peak performance 3 5 2 Visually inspect impeller key and rotor shaft keyway for signs of uneven wear 3 5 3 Visually inspect volute aa casting for cracks wear and damage Look for signs of wear on volute cutwaters and surfaces facing impeller wc gr000411 wc tx000112 orig gb fm 2 9 Maintenance PST2 PSTF2 400 3 6 Impeller Reassembly See Graphic wc_gr000411 3 6 1 3 6 2 3 6 3 3 6 4 3 6 5 3 6 6 3 6 7 3 6
20. aution can result in serious accident WARNING Problem Symptom Reason Remedy Pump will not start e Power is off Restore power e Cable assembly is cut or not connected properly Repair replace the cable or fix the connection e Impeller is clogged Inspect the pump and remove any debris Pump stops soon after e Impeller is clogged Remove debris starting Low voltage Provide the rated voltage or make sure the cable Motor protector operates assembly extension is the proper standard e Wrong power frequency Check the nameplate and replace the pump or the impeller e Extended operation with a clogged strainer Remove debris from the strainer Pump does not stop automatically e Float if equipped is obstructed not moving freely or malfunc tioning Remove obstructions Repair or replace float switch if necessary e Water level of float if equipped set lower than pump s mini mum operating water level Set float higher than pump s mini mum operating water level e Malfunction in level relay unit Repair or replace level relay unit e Electrode shorted by debris Use sandpaper to remove debris from electrode Electrical interference in vicinity of pump Check for tangled wires around electrode Check for nearby electrical devices that could generate electromagnetic interference relocate pump if necessary Poor lift or discharge e Faulty motor Repair or replace the motor capacity Excessi
21. e hoses carefully Heated water can be in hoses and static head produces pressure FIG 10 If safety related defects or malfunctions are detected SHUT DOWN the equipment Correct the problem or notify your supervisor DO NOT OPERATE EQUIPMENT WITH DEFECTS OR MALFUNCTIONS UNTIL CORRECTED If an unsafe condition cannot be remedied immediately notify your supervisor and tagout lockout the pump on the start switch and or appropriate prominent location FIG 11 FIG 11 11 14 WORK SAFELY Engine Driven Pumps SAFE WORKING PROCEDURES Do not jump start engine battery When operating internal combustion engines in an enclosed area always make provisions to pipe exhaust fumes to the outside EXHAUST FUMES CAN KILL Do not operate engine driven pump equipment in a confined or enclosed space without adequate ventilation Exhaust gases are odorless and deadly poison DO NOT TOUCH The exhaust system components get very hot and stay hot for some time after shutting the engine off Follow engine manufacturer s instructions explicitly on hand cranking Do not shut down high head pumps quickly A Throttle back slowly B Open by pass line C Should have a check valve D Slowly close gate valve on discharge if so equipped Check for fuel oil and hydraulic fluid leaks worn and damaged hoses lines or power cables Refueling When refueling the following precautions must be followed Add fu
22. el of proper type and grade only when the pump is not running and engine is cool Fuel in well ventilated area Turn off all electrical switches Keep lighted smoking materials flames or spark producing devices at a safe distance while refueling Keep fuel nozzle in contact with tank being filled or provide a ground to prevent static sparks from igniting fuel Do not spill fuel on hot surfaces Clean up spillage immediately Do not start engine until fuel cap is secured to the fuel tank Always make sure that fuel is being put in the fuel tank motor oil in the proper location and hydraulic oil into hydraulic oil reservoirs WORK SAFELY Engine Driven Pumps Maintenance and Repair All installations operations and maintenance should be in accordance with pump and engine manufacturer s recommended operation and maintenance program These manuals should be kept available with the equipment Maintenance work can be hazardous if not done in a careful manner All personnel should realize the hazards and strictly follow safe practices NEVER perform any work on the equipment unless authorized to do so BEFORE ANY maintenance work is to be done LOCKOUT TAGOUT standard device and procedure should be implemented Prior to removal of LOCKOUT TAGOUT the equipment must be fully operational and all personnel accounted for Except in cases of emergency the removal of the LOCKOUT TAGOUT should be done ONLY by the
23. er possible use a nonflammable solvent to clean parts Do not use gasoline or other fluids that give off harmful vapors If flammable fluids such as gasoline or diesel fuel must be used extinguish open flames or sparks and DO NOT smoke Store dangerous fluids in a suitable place in approved containers which are clearly marked NEVER smoke in areas where flammable fluids are used or stored FIG 7 Use proper nonflammable cleaning solvents Follow solvent manufacturer s instructions for use Always remove all flammable material in the vicinity of welding and or burning operations ALWAYS keep the floor in the work area clean and dry Oily greasy floors can easily lead to falls Wet spots especially near electrical equipment can be hazardous FIG 7 Know where fire extinguishers are kept how they operate and for what type of fire they are intended Check readiness of any fire detectors and fire suppression systems PERFORM MAINTENANCE SAFELY EXHAUST FUMES Engine exhaust fumes can cause sickness or death If it is necessary to run an engine in an enclosed area remove the exhaust fumes from the area with an exhaust pipe extension If you do not have an exhaust pipe extension be positive the area is adequately ventilated FIG 6 FIG 6 HEAVY PARTS Handle tools and heavy parts sensibly with regard for yourself and other persons Lower items don t throw or drop them ALW
24. g Performing electrical wiring Electrical wiring should be performed by a qualified person in accord with all applicable regulations Failure to observe this precaution not WARNING Oly 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 overload protectors and fuses or breakers so as to prevent electrical shock from a current leak or pump malfunction Operate within the capacity of the power supply and wiring Grounding Do not use the pump without first grounding it properly Failure to ground it can lead to electrical shock from a current leak or pump malfunction gt WARNING Do not attach the grounding wire to a gas pipe water pipe lightning arrester or telephone grounding wire Improper grounding can result in caution electrical shock gt Connecting the power supply Before connecting wires to the terminal make certain the power supply 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 supply is 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 connected loosely which can result in electric shock shorting or fire
25. gb fm A CAUTION AN WARNING AN CAUTION PST2 PSTF2 400 COUNTERMEASURE If the supply voltage is outside the tolerance possible causes are the power supply capacity or an inadequate extension cable Look again at the wiring diagram and make sure the conditions are proper In case of very excessive vibration unusual noise or odor turn off the power immediately and consult your nearest dealer or Wacker representative Continuing to operate the pump under abnormal conditions may result in electrical shock fire or current leakage Operation The pump may become very hot during operation Be careful not to contact the pump accidentally to avoid being burned Make sure no extraneous objects such as pins nails or other metal objects are sucked into the pump These can damage the pump or cause it to malfunction and can result in electrical shock or electrical leakage When the pump is not used for an extended period be sure to turn off the power circuit breaker etc Deterioration of the insulation may lead to electrical leakage electrical shock or fire In case of a power outage turn off the power to the pump to avoid having it start unexpectedly when the power is restored presenting serious danger to people in the vicinity The pump may become hot during operation Do not touch an operating pump Allow the pump to cool before handling Pay careful attention to the water level while the pump is operating Dry
26. ic shock this pump has not been investigated for use in swimming pool areas An acceptable motor control switch shall be provided at the time of installation according to local codes and regulations To reduce risk of electric shock follow instructions in this manual for proper installation CAUTION This pump may automatically restart Prior to working on the pump or control panel all supply circuits must be disconnected CAUTION Risk of shock do not remove cord and strain relief WARNING 1 2 Informational Labels Label Meaning A nameplate listing the model number item num ber revision number and serial number is attached to each unit Please record the informa SeriaINo __ Man M tion found on this plate so it will be available INDOORS OR OUTDOORS p CSA ENCLOSURE 3 Wacker Neuson Corporation Model ItemNo Rev Hz Phase AMP mio toUt S0778 should the nameplate become lost or damaged LI JL When ordering parts or requesting service infor MaxL min kg kW mation you will always be asked to specify the model number item number revision number and serial number of the unit Max ft MaxGPM 166 HP US 2001993 MADE IN TAIWAN wc si000034gb fm 8 PST2 PSTF2 400 Operation 2 Operation 21 Names of Parts See Graphic wc_gr001699
27. is disassembled or inspected Dust seal When ring is worn and each time pump is disassem bled or inspected Sleeve When it becomes worn wc tx000112 orig gb fm 26 PST2 PSTF2 400 Maintenance 3 3 Disassembly and Reassembly Before disassembling the pump make certain the power supply circuit breaker etc is turned off Then unplug the cable assembly from the WARNING receptacle or detach it from the terminals To avoid electrical shock we_tx000112_orig_gb fm DO NOT work with wet hands NEVER check the operation of any parts impeller rotation etc by turning on the power while the unit is partially assembled Failure to observe these precautions may result in a serious accident DO NOT disassemble or repair any parts other than those designated here If repairs are necessary in any other than the designated parts consult your nearest dealer or Wacker Neuson representative Improper repairs can result in electrical leakage electrical shock fire or water leaks After reassembly ALWAYS perform a test operation before resuming use of the pump Improper assembly will cause the pump to malfunction resulting in electric shock or water leaks The procedure for disassembly and reassembly is shown here to the extent necessary for impeller replacement A specialized environment and facilities are necessary for work on the mechanical seal and the motor parts Contact your nearest dealer or Wacker Neuson represent
28. ke sure the cable does not become excessively bent or twisted and does not rub against a structure in a way that might damage it If used in a deep well installation the cable assembly should be secured every twenty feet 16 PST2 PSTF2 400 Operation 2 6 Electrical Circuit Diagrams See Graphic wc_gr006190 PST2 400 eR R ul B W gt s 29 38 NEE 6 41 pru I 1 Gy a Gv 6a wc_gr006190 If connected to a circuit protected by a fuse use a time delay fuse with this pump CAUTION Description Description Capacitor Frame grounding Main coil Ground Auxiliary coil Float switch normally open contact Miniature protector we_tx000111gb fm 1 7 Operation PST2 PSTF2 400 Wire Colors Violet Orange White Purple Yellow Shield Brown Light Blue Clear Green Yellow Gray wc tx000111gb fm 1 8 PST2 PSTF2 400 Operation 2 7 wc tx000111gb fm Operation 2 7 1 2 7 2 2 7 3 2 7 4 WARNING gt WARNING Before starting 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 frequency will not only lower its performance but may damage the product Note Confirm the rated voltage and frequency on the model nameplate Confirm the wiring supply vo
29. ltage circuit breaker capacity and motor insulation resistance Reference insulation resistance 20 MW or greater Note The reference insulation resistance 20 MW or greater is the value when the pump is new or has been repaired For the reference value after installation see Periodic Maintenance Table The setting on the circuit breaker or other overload protector should be made in accord with the rated current of the pump Note See Operating Specifications for the rated current of the pump When powering the pump with a generator be certain the generator is sized to supply the required power for the pump and any other equipment powered by the generator Test Operation Do not operate the pump while it is suspended in the air The recoil may result in injury or other major accident Do not start the pump when people are standing next to it A current leak can result in electrical shock Run the pump for a short time 3 10 minutes and confirm the following e Using an ammeter clamp on type measure the operating current at the L1 and L2 phase wires on the terminal COUNTERMEASURE lf the operating current exceeds the rated value pump motor overload may be a cause Make sure the pump has been installed under proper conditions as described in nstallation e Using an AC voltmeter tester measure voltage at the terminals Supply voltage tolerance within 5 of rated voltage 19 Operation we_tx000111
30. n representative Storage When the pump is out of use for an extended period wash it and dry it thoroughly then store it indoors Note Always run a test operation before putting the pump back into service If the pump is left in the water it should be run a minimum of once a week Inspecting Lubricant Remove the oil plug and tilt the pump to drain a small amount of lubricant If the lubricant is milky white or has water mixed in with it the mechanical seal may be faulty In this case the pump will need to be disassembled and repaired Replacing Lubricant Remove the oil plug and drain all the lubricant then replace it with the specified amount Note Worn lubricant and other waste products should be disposed of by a qualified agent in accord with applicable laws The oil plug gasket should be replaced each time the lubricant is inspected or changed 25 Maintenance PST2 PSTF2 400 See Graphic wc gr000245 wc 9 000245 Ret Description 1 Oil inlet 3 Oil plug 2 Gasket 4 Allen wrench Pump Model Lubricant Capacity PST2 400 160 ml 5 4 fl oz PSTF2 400 Replacement Parts The table lists the parts that need to be replaced periodically Replace these using the recommended frequency as a guideline Part Replacement Frequency Mechanical seal 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
31. nd removing the three bolts 2 Keep nuts for reuse 2 9 2 Position washers 4 and attach the residue plate 5 with new bolts 6 included with kit Note Be certain to use washers to prevent motor shaft stirrer nut from protruding through residue plate wc gr001144 wc tx000111gb fm 2 3 Maintenance PST2 PSTF2 400 3 Maintenance 3 Periodic Maintenance Table Monthly 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 1 f 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 Neuson representa
32. necessary for operation Note The discharge end of the hose should be located higher than the water surface If the end of the hose is submerged water may flow back to the pump when the pump is stopped and if the hose end is lower than the water surface water may overflow when the pump is turned off If large quantities of earth are sucked up damage resulting from friction in the pump can lead to current leakage and shock Use the pump in the upright position To prevent the strainer from becoming submerged in mud causing it to suck in sand or debris mount it on a block or other firm base If used in a permanent installation where the pump is not readily accessible after installation please contact Wacker Neuson for a duplicate nameplate to be installed at the wellhead or on the control box so that it will be readily visible 12 PST2 PSTF2 400 Operation 2 4 Installing the Float if equipped See graphic wc gr005664 wc gr005664 2 41 Set the length of the float lead wire to the dimension indicated below Failure to set the correct lead wire length will lead to improper operation of the pump Pump model Length L PSTF2 400 150 mm 5 9 in NOTICE Install the float so that it moves freely up and down If the float binds or catches it will cause the pump to operate improperly wc tx000111gb fm 1 3 Operation PST2 PSTF2 400 Notes wc tx000111gb fm 1 4 PST2 PSTF2 400 Operation 2 5 Electrical Wirin
33. on the pump so it will not burrow itself into sand or clay Stand the pump on plank a bed of coarse gravel within a perforated container on a suitable floatation device or retain it hanging freely by a lifting cable FIG 13 FIG 13 18 Pump Maintenance and Repair MAKE SURE the pump is disconnected from the power source or the appropriate circuits are dead and OSHA Lockout Tagout is applied before doing any maintenance or repair work on the unit Maintenance work can be hazardous if not done in a careful manner All personnel should realize the hazards and strictly follow safe practices NEVER perform any work on the equipment unless authorized to do so Before performing any maintenance or repair work consult the manufacturer s instruction manual for recommended procedures BEFORE ANY maintenance work is to be done a LOCKOUT TAGOUT standard device and procedure should be implemented Prior to removal of LOCKOUT TAGOUT the equipment must be fully operational and all personnel accounted for Except in cases of emergency the removal of the LOCKOUT TAGOUT should be done ONLY by the initiating person prior to the return to start up Check oil level ONLY when pump is cool USE ONLY recommended oil per manufacturer s recommendation INSPECT ELECTRICAL WIRING for worn or damaged insulation INSTALL new wiring if wires are damaged After repairs are made clean the equipment before putting the pump back in
34. r 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 salt water 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 current 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 Neuson representative before using with any liquids other than those indicated in this document 10 PST2 PSTF2 400 Operation wc tx000111gb fm WARNING CAUTION 2 3 1 Preparing for installation Before installing the pump at a work site you will need to have the following tools and instruments ready e Insulation resistance tester megohmmeter e AC voltmeter ammeter clamp on type e Bolt and nut tighteners e Power supply connection tools screwdriver or box wrench Note Please also read the instructions that come with each of the test instruments Checks to Make Before Installation When a three prong grounded plug is used Use the megohmmeter to measure the motor insulation resistance between the grounding prong and each one of the two power prongs When connection wires are used With the megohmmeter measure the insulation resistance between the ground wire Green and each one of the t
35. r pump IMPORTANT If you do not have the manufacturer s manual s for your particular pump get a replacement manual from your employer equipment dealer or manufacturer of your pump Keep this safety manual and the manufacturer s manual s with your pump Unauthorized modifications of pumps create hazards Pumps must not be modified or altered unless prior approval is obtained from the manufacturer DO NOT PUMP VOLATILE FLAMMABLE OR CAUSTIC CORROSIVE LIQUIDS REFER TO THE OWNER S MANUAL OR CONSULT WITH THE MANUFACTURER FOR THE PROPER PUMP MATERIALS IF YOU ARE TO PUMP HAZARDOUS CAUSTIC CORROSIVE LIQUIDS Section N KNOW THE RULES Every employer is concerned about safety Safe operation and proper maintenance of your pump can prevent accidents KNOW the rules LIVE by them FIG 1 When starting work at a new site check with the designated safety coordinator for specific safety instructions DON T LEARN SAFETY THE HARD WAY Know the meaning of all hand signals signal flags signs and markings Know the traffic rules used at the work site Know who the signal man is watch and obey his signals Know where the fire extinguishers and first aid kits are kept and how to use them Know where to get proper aid and assistance when needed Use common sense to avoid accidents If an accident does occur be prepared to react to it quickly and effectively NEVER PANIC FOLLOW A SAFETY PROGRAM
36. rgence and to be sure it is free of obstructions NEVER operate a self priming pump unless the volute is filled with liquid The pump will not prime when dry PUMP only liquids for which the pump has been designed to handle DO NOT pump flammable corrosive or caustic materials unless the pump and piping are explicitly designed for that purpose NOTE the direction of rotation operation of a pump in the wrong direction can cause the impeller to unscrew and damage the volute case A pump should not be operated against a closed valve or other no flow conditions Refer to the pump manufacturer s recommended practice for start up operation and shut down procedures DO NOT close down or restrict a discharge hose Be careful of discharge hose whipping under pressure 12 MAKE CERTAIN that whatever is to be connected to he pump is not subjected to pressures greater than those given in the manufacturer s instructions MAKE CERTAIN all connections are securely made and hoses under pressure are secured with appropriate safety devices to prevent whipping BE AWARE OF LIGHTNING Stay clear of the pumping equipment during electrical storms It can attract lightning FIG 10 OVERHEATING PRECAUTIONS Overheated pumps can cause severe damage to the equipment and can cause severe physical burns and injury Operating a pump with the suction and or discharge valve closed is a principal cause of overheating Approach cautiously an
37. site be assigned the overall responsibility and authority for safety Know who the person is and COMMUNICATE with them Know what the jobsite rules are and FOLLOW THE RULES Be safety conscious responsible and reliable Think about safety BEFORE something happens BE CAREFUL Human error is caused by many factors carelessness fatigue overload preoccupation incompatibility between operator and the equipment drugs and alcohol to name a few Damage to the equipment can be fixed in a short period of time but injury or death has a lasting effect For your safety and safety of others encourage your fellow workers to act within safety rules CLOTHING AND PERSONAL PROTECTIVE ITEMS ALWAYS wear appropriate safety glasses goggles or face shield when working FIG 2 Proper eye protection can keep flying particles from grinding drilling or hammering operations or fluids such as fuel solvents lubricants and brake fluids from damaging your eyes Normal glasses do NOT provide adequate protection ALWAYS wear a hard hat and safety shoes FIG 2 ALWAYS wear hearing protectors when exposed to high noise levels for extended periods ALWAYS wear a respirator when painting or exposed to dusty conditions ALWAYS keep your pockets free of loose objects which can fall out and drop into machinery FIG 5 Heavy gloves should be worn for many operations FIG 5 PERFORM MAINTENANCE SAFELY FIRE PREVENTION Whenev
38. t www aem org Toll free 1 866 AEM 0442 e mail aem aem org ills WWW aem org Eu Association of Equipment Manufacturers MENI FORM PP 130 2 Wacker Construction Equipment AG PreuBenstraBe 41 D 80809 M nchen Tel 49 0 89 3 5402 0 Fax 49 0 89 3 54 02 3 90 Wacker Neuson Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker 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
39. tive 4 Consult with your nearest dealer or Wacker Neuson representative regarding overhauls wc 000112 orig gb fm 24 PST2 PSTF2 400 Maintenance 3 2 Maintenance and Inspection WARNING 3 2 1 3 2 2 wc tx000112 orig gb fm Regular maintenance and inspections are a necessity for continued efficient functioning of the pump If any abnormal conditions are noticed refer to the Troubleshooting section and take corrective measures immediately It is recommended that a spare pump be kept ready in case of any problems Prior to inspecting Before inspecting the pump make certain the power supply circuit breaker etc is turned off Then unplug the cable assembly from the receptacle or detach it from the terminals Failure to follow this precaution may result in a serious accident from electrical shock or unexpected starting of the pump motor Washing the pump Remove accumulated matter from the surface of the pump and wash it with clean water Take special care to remove any debris from the impeller Inspecting the pump exterior Look for any peeling or chipped paint and make sure the nuts and bolts are fastened tightly Any cracks in the surface should be repaired by cleaning that area drying it and then applying a touch up coating Note Touch up paint is not supplied Note that some kinds of damage or looseness may require that the unit be disassembled for repairs Please consult your nearest dealer or Wacker Neuso
40. to position 20 Do you understand this AEM SAFETY MANUAL AND ITEMS SUCH AS Your safety program Your pump manufacturer s manual s Proper clothing and personal safety equipment Your pump s controls warning signs and devices and safety equipment How to properly inspect mount and start your pump How to check your pump for proper operation Your work area and any special hazards that may exist FINAL WORD TO THE USER Remember that YOU are the key to safety Good safety practices not only protect you but protect the people around you You have read this safety manual and the manufacturer s manual s for your specific pump Make them a working part of your safety program Keep in mind that this safety manual is written for only this type of equipment Practice all other usual and customary safe working precautions and above all REMEMBER SAFETY IS UP TO YOU YOU CAN PREVENT SERIOUS INJURY OR DEATH TEST YOUR KNOWLEDGE Proper operating procedures Proper shutdown procedures Proper maintenance procedures Proper loading and unloading procedures for transporting Under what conditions you should not operate your pump If you do not understand any of these items consult with your supervisor BEFORE operating your equipment 19 This manual is another in a series on the safe operation of machinery published by AEM For additional publications visit our web site a
41. ve sand is discharged Place the pump on a block or other base to prevent the sand from being sucked into it e Worn out impeller Replace Sharply bent or clogged hose Straighten out any sharp bends Enclose the pump with a screen to keep away debris e Strainer clogged or buried Remove debris from the strainer or place a block under the pump Heavy vibration or noise Damaged motor shaft Contact dealer and replace motor wc tx000112 orig gb fm 3 1 Technical Data PST2 PSTF2 400 4 Technical Data 41 Standard Specifications Applicable Liquids Rain Water Ground Water Sand Carrying Water Consistency and Temperature 0 40 C 32 104 F Pump Impeller Semi Vortex Type Shaft Seal Double Mechanical Seal Bearing Shielded Ball Bearing Specification Dry Submersible Induction Motor 2 Pole Insulation Class E Protection System Miniature Protector 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 Coupling NPT 2 wc td000034gb fm 32 PST2 PSTF2 400 Technical Data 42 Operating Specifications Electric Power V Ph Hz 110 1 60 Rated Current 5 4 Starting Method Capacitor Run Bore 50 2 Output 0 40 0 50 Maximum Head 12 39 Maximum Capacity 200 53 Maximum Pressure 16 8 Solid Size Capacity in
42. wo power wires Reference insulation resistance 20MW or greater Note 7he reference insulation resistance 20MW or greater is the value when the pump is new or has been repaired For the reference value after installation see the Periodic Maintenance table Precautions in Installation When installing the pump pay close attention to its center of gravity and weight If it is not lowered into place correctly it may fall and be damaged or cause injury When transporting the machine by hand be sure to employ manpower commensurate with the weight of the machine To avoid back injury when lifting the machine bend the knees to pick it up rather than bending your back only Do not under any circumstances install or move the pump by suspending it from the cable assembly The cable may be damaged causing current leakage shock or fire Avoid dropping the pump or other strong impact Lift the pump by holding it firmly with the hands or by attaching a rope or chain to the lifting handle Note On cable assembly handling see Electrical Wiring Avoid dry operation which will not only lower performance but can cause the pump to malfunction leading to electrical leakage and CAUTION Shock 11 Operation we_tx000111gb fm 2 3 2 CAUTION 2 3 3 2 3 4 PST2 PSTF2 400 Install the pump in a location with sufficient water level where water collects readily Note See Operation Operating Water Level for the water level
43. y pump that has been in operation DO NOT remove hoses from a pump until the system is properly cooled to ambient temperature WORK SAFELY Pumps In General BEFORE STARTING Check the pump thoroughly at delivery for any shipping damage Locate ihe pump in an accessible location as close to the liquid as possible Secure the pump after it is placed in its intended operating position so it does not tip roll slide or fall IMMEDIATELY ON STARTING THE PUMP Observe gauges instruments and warning lights to ensure that they are functioning and their readings are within the norma operating range Be sure the immediate work area is safe for operation Operate controls make certain all operate properly and feel right Accustom yourself to the feel of the equipment Listen for any unusual noises smell for any unusual odors look for any signs of trouble Be sure to open all manual valves slowly to prevent WATER HAMMER Check all warning and safety devices and indicators WORK SAFELY Pumps In General DO NOT remove the cover plate or drain plugs from any overheated pump Allow the pump to cool Check pump temperature before opening fill port or drain plug If overheating of the pump casing occurs STOP the pump immediately Allow the equipment to cool completely Slowly and cautiously vent the pump Refer to the manufacturer s instruction manual before restarting the unit Remov
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