Wacker Neuson 0620412 User manual

Operator’s Manual
Pump
PSG2 500
Type PSG2 500
Document 5000187941
Date 1115
Revision 03
Language EN
5000187941

Copyright notice © Copyright 2015 by Wacker Neuson Production Americas LLC
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the
machine. Any other type of reproduction is prohibited without express
written permission from Wacker Neuson Production Americas LLC.
Any type of reproduction or distribution not authorized by Wacker
Neuson Production Americas LLC represents an infringement of valid
copyrights. Violators will be prosecuted.
Trademarks All trademarks referenced in this manual are the property of their
respective owners.
Manufacturer Wacker Neuson Production Americas LLC
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: [phone] · Fax: [phone] · Tel: [phone]
www.wackerneuson.com
Original instructions This Operator’s Manual presents the original instructions. The original
language of this Operator’s Manual is American English.

PSG2 500 Foreword
wc_tx002041gb.fm 3
Foreword
SAVE THESE INSTRUCTIONS—This manual contains important instructions for
the machine models below. These instructions have been written expressly by
Wacker Neuson Production Americas LLC and must be followed during installation,
operation, and maintenance of the machines.
Machines
covered in
this manual
Machine
documentation
From this point forward in this documentation, Wacker Neuson Production
Americas LLC will be referred to as Wacker Neuson.
Keep a copy of the Operator’s Manual with the machine at all times.
Use the separate Parts Book supplied with the machine to order replacement
parts.
Refer to the separate Repair Manual for detailed instructions on servicing and
repairing the machine.
If you are missing any of these documents, please contact Wacker Neuson to
order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
Expectations
for
information in
this manual
This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and observe all instructions
described in this manual.
Wacker Neuson expressly reserves the right to make technical modifications,
even without notice, which improve the performance or safety standards of its
machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson reserves the right to change
any portion of this information without notice.
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and
modifications. The following definitions apply:
Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
Approved modifications are those performed by an authorized Wacker
Neuson service center according to written instructions published by Wacker
Neuson.
Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following
consequences:
Serious injury hazards to the operator and persons in the work area
Machine Item Number
PSG2 500 0620412

Foreword PSG2 500
4wc_tx002041gb.fm
Permanent damage to the machine which will not be covered under warranty
Contact your Wacker Neuson dealer immediately if you have questions about
approved or unapproved parts, attachments, or modifications.

wc_bo5000187941_03TOC.fm 5
Table of ContentsPSG2 500
Foreword 3
1 Safety Information 7
1.1 Signal Words Used in this Manual ....................................................... 7
1.2 Machine Description and Intended Use ............................................... 8
1.3 Operating and Electrical Safety ............................................................ 9
1.4 Service Safety .................................................................................... 10
1.5 Labels ................................................................................................. 11
2 Lifting and Transporting 12
3 Installation 13
3.1 Components ....................................................................................... 13
3.2 Preparing the Machine for First Use ................................................... 14
3.3 Application Area ................................................................................. 14
3.4 Preparing for Installation .................................................................... 15
3.5 Checks to Make Before Installation .................................................... 16
3.6 Electrical Wiring .................................................................................. 16
3.7 Connecting the Power Supply ............................................................ 17
3.8 Cable Assembly ................................................................................. 18
4 Operation 19
4.1 Before Starting ................................................................................... 19
4.2 Operating Water Level ..................................................................... 21
4.3 Emergency Shutdown Procedure ....................................................... 21
5 Maintenance 22
5.1 Periodic Maintenance Schedule ......................................................... 22
5.2 Maintenance and Inspection .............................................................. 23
5.3 Storage ............................................................................................... 23
5.4 Replacement Parts ............................................................................. 24
5.5 Disassembly and Reassembly ........................................................... 25
5.6 Disassembly ....................................................................................... 26
5.7 Reassembly ........................................................................................ 27
5.8 Troubleshooting .................................................................................. 28

6 wc_bo5000187941_03TOC.fm
Table of Contents PSG2 500
6 Technical Data 29
6.1 Standard Specifications .......................................................................29
6.2 Operating Specifications (60 Hz) .........................................................30
6.3 Dimensions ..........................................................................................31
7 Schematics 32
8 AEM Safety Manual 33

PSG2 500 Safety Information
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1 Safety Information
1.1 Signal Words Used in this Manual
This manual contains DANGER, WARNING, CAUTION, NOTICE, and
NOTE signal words which must be followed to reduce the possibility
of personal injury, damage to the equipment, or improper service.
NOTICE: Used without the safety alert symbol, NOTICE indicates a
situation which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
fObey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
fTo avoid death or serious injury from this type of hazard, obey all safety messages that
follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
fTo avoid possible death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
fTo avoid possible minor or moderate injury from this type of hazard, obey all safety
messages that follow this signal word.

Safety Information PSG2 500
8wc_si000249gb.fm
1.2 Machine Description and Intended Use
This machine is a submersible water pump. The Wacker Neuson
Submersible Pump consists of an electric motor, an impeller, a strainer,
and a metal casing with ports for water suction and discharge. Power is
supplied to the pump through a corded plug or a hard-wired connection,
depending on the installation. The operator connects hoses to the pump
and routes them so that water is pumped from the work area and
discharged into an appropriate location.
This machine is intended to be used for general de-watering applications.
This machine is intended for the pumping of clear water, or water
containing solids up to the size stated within the products specifications,
and up to the flow, head, and suction lift limits also stated within the
product specifications.
This machine has been designed and built strictly for the intended use
described above. Using the machine for any other purpose could
permanently damage the machine or seriously injure the operator or other
persons in the area. Machine damage caused by misuse is not covered
under warranty.
The following are some examples of misuse:
• Pumping flammable, explosive, or corrosive fluids
• Pumping hot or volatile fluids that result in pump cavitation
• Operating the pump outside of product specifications due to
incorrect diameter hoses, incorrect length hoses, other inlet or
outlet restrictions, or excessive suction lift or head
• Using the machine as a ladder, support, or work surface
• Using the machine to carry or transport passengers or equipment
• Operating the machine outside of factory specifications
• Operating the machine in a manner inconsistent with all warnings
found on the machine and in the Operator’s Manual.
This machine has been designed and built in accordance with the latest
global safety standards. It has been carefully engineered to eliminate
hazards as far as practicable and to increase operator safety through
protective guards and labeling. However, some risks may remain even
after protective measures have been taken. They are called residual
risks. On this machine, they may include exposure to:
• Electric shock from improper electrical connections or high
voltage
• Personal injury from improper lifting techniques
• Projectile hazard from discharge

PSG2 500 Safety Information
wc_si000249gb.fm 9
To protect yourself and others, make sure you thoroughly read and
understand the safety information presented in this manual before
operating the machine.
Operator qualifications
Only trained personnel are permitted to start, operate, and shut down
the machine. They also must meet the following qualifications:
• have received instruction on how to properly use the machine
• are familiar with required safety devices
The machine must not be accessed or operated by:
•children
• people impaired by alcohol or drugs
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while
operating this machine:
• Close-fitting work clothes that do not hinder movement
• Safety glasses with side shields
• Hearing protection
• Safety-toed footwear
Replacement parts
When replacement parts are required for this machine, use only
Wacker Neuson replacement parts or those parts equivalent to the
original in all types of specifications, such as physical dimensions,
type, strength, and material.
1.3 Operating and Electrical Safety
To reduce risk of electric shock, connect only to a properly grounded,
grounding-type receptacle.
Risk of electric shock—this pump has not been investigated for use in
swimming pool areas.
An acceptable motor-control switch shall be provided at the time of
installation according to local codes and regulations.
To reduce risk of electric shock, follow instructions in this manual for
proper installation.
CAUTION: This pump may automatically restart. Prior to working on
the pump or control panel, all supply circuits must be disconnected.
CAUTION: Risk of shock—do not remove cord and strain relief.
WARNING

Safety Information PSG2 500
10 wc_si000249gb.fm
1.4 Service Safety
Service training
Before servicing or maintaining the machine:
• Read and understand the instructions contained in all manuals
delivered with the machine.
• Familiarize yourself with the location and proper use of all
controls and safety devices.
• Only trained personnel shall troubleshoot or repair problems
occurring with the machine.
• Contact Wacker Neuson for additional training if necessary.
When servicing or maintaining this machine:
• Do not allow improperly trained people to service or maintain the
machine. Personnel servicing or maintaining the machine must
be familiar with the associated potential risks and hazards.
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while
servicing or maintaining this machine:
• Close-fitting work clothes that do not hinder movement
• Safety glasses with side shields
• Hearing protection
• Safety-toed footwear
In addition, before servicing or maintaining the machine:
• Tie back long hair.
• Remove all jewelry (including rings).
Replacing parts and labels
• Replace worn or damaged components.
• Replace all missing and hard-to-read labels.
• When replacing electrical components, use components that are
identical in rating and performance as the original components.
• When replacement parts are required for this machine, use only
Wacker Neuson replacement parts or those parts equivalent to
the original in all types of specifications, such as physical
dimensions, type, strength, and material.

PSG2 500 Safety Information
wc_si000249gb.fm 11
1.5 Labels
A nameplate listing the model number, item number, revi-
sion number, and serial number is attached to each unit.
Please record the information found on this nameplate so it
will be available should the nameplate become lost or dam-
aged. When ordering parts or requesting service informa-
tion, you will always be asked to specify the model number,
item number, revision number, and serial number of the
unit.
CAUTION
Do not attempt to operate this product before reading the
Operator’s Manual and understanding its contents.
Mishandling of this product may result in explosion, fire, or
electrical shock.
Do not pull on the power cord or use the power cord to lift
the pump.
Always use a dedicated ground leakage circuit breaker.
Be sure to install the ground wire securely.
Be sure to disconnect the power supply before handling
or inspecting the pump.
Never insert your hand into the pump inlet holes while the
pump is connected to the power supply.
Menomonee Falls, WI 53051 USA
Model ItemNo. Rev.
SerialNo.
VHz
kWkgMax.L/minMax.m
HPlbsMax.GPMMax.ft
CUS
L
I
S
T
E
D
R
Phase
C22.2 No.108-M89
2001993
Conforms toULStd.778
Cert.to CAN/CSA Std.
Amp.
Man.Y/M
THERMALLY PROTECTED
INDOORSOR OUTDOORS
CSA ENCLOSURE 3
Wacker Neuson Corporation

Lifting and Transporting PSG2 500
12 wc_tx001962gb.fm
2 Lifting and Transporting
Do not under any circumstances install or move the pump by
suspending it from the cable assembly. The cable may be damaged,
causing electrical leakage, shock, or fire.
When installing the pump, pay close attention to its center of gravity
and weight. If it is not lowered into place correctly, it may fall and be
damaged or cause injury.
When transporting the pump by hand, be sure to employ manpower
commensurate with the weight of the pump. To avoid back injury when
lifting the pump, bend the knees to pick it up rather than bending your
back only.
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
handle.
WARNING
CAUTION

PSG2 500 Installation
wc_tx001977gb.fm 13
3 Installation
3.1 Components
Ref. Description Ref. Description
1 Lifting handle 9 Lubricant
2 Coupling 10 Shaft
3 Oil lifter 11 Shaft sleeve
4 Oil plug 12 Oil casing
5 Suction cover 13 V-ring
6 Strainer 14 Impeller
7 Cable assembly 15 Stud bolt
8 Mechanical seal 16 Pump casing
1
2
7
8
9
10 11
12
13
15
16
14
3
4
5
6
wc_gr004637

Installation PSG2 500
14 wc_tx001977gb.fm
3.2 Preparing the Machine for First Use
When the pump is delivered, first perform the following checks:
• Inspection
While unpacking, inspect the product for damage during shipment, and
make sure all bolts and nuts are tightened properly.
• Specification check
Check the model number to make sure it is the product that was
ordered. Be certain it is the correct voltage and frequency.
Note: If there is any problem with the product as shipped, contact your
nearest dealer or Wacker Neuson representative at once.
• Product specifications
Do not operate this product under any conditions other than those for
which it is specified. Failure to observe this precaution can lead to
electrical shock, current leakage, fire, water leakage or other
problems.
3.3 Application Area
If the pump is used for outdoor fountains, garden ponds and similar
places, or to drain a swimming pool, the pump must be supplied by an
isolating transformer or connected to a Residual Current Device (RCD)
with a residual operating current not exceeding 30 mA.
The pump must not be used when people are in the water.
Leakage of pump lubricants may cause pollution of water.
Proper plug must be provided according to local codes and standards.
Refer to wiring diagram.
Do not use this pump in liquids other than water, such as oil, 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, electrical leakage or shock.
Do not use in the vicinity of explosive or flammable materials.
Use only in fully assembled state.
Note: Consult your local dealer or Wacker Neuson representative
before using with any liquids other than those indicated in this manual.
3.3.1 Install the pump in a location with sufficient water level, where water
collects readily.
CAUTION
WARNING

PSG2 500 Installation
wc_tx001977gb.fm 15
Note: See “Operating Water Level” for the water level necessary for
operation. 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.
3.3.2 The hose should be run as straight as possible, since excessive
bending will hinder the water flow, preventing sufficient lift, and can
even cause the hose to become clogged with earth. If the hose is
crimped near the pump, air can become trapped in the pump and
cause idle running.
If large quantities of earth are sucked up, damage resulting from
friction in the pump can lead to electrical leakage and shock.
3.3.3 Use the pump in the upright position. To prevent the pump from
becoming submerged in mud, mount it on a block or other firm base if
necessary.
3.3.4 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.
3.4 Preparing for Installation
Before installing the pump at a work site, you will need to have the
following tools and instruments ready:
• Insulation resistance tester (megohmmeter)
• AC voltmeter
• AC ammeter (clamp-on type)
• Bolt and nut tighteners
• Power supply connection tools (screwdriver or box wrench)
Note: Please also read the instructions that come with each of the test
instruments.
CAUTION

Installation PSG2 500
16 wc_tx001977gb.fm
3.5 Checks to Make Before Installation
• When a grounded plug is used:
Use the megohmmeter to measure the insulation resistance between
the cable assembly prongs and ground.
• When connection leads are used:
With the megohmmeter, measure the insulation resistance between
each core lead and the ground lead.
Reference insulation resistance: 20MΩor greater
Note: The reference insulation resistance (20M Ω or greater) is the
value when the pump is new or has been repaired. For the reference
value after installation, see “Periodic Maintenance Table.”
3.6 Electrical Wiring
Performing electrical wiring
Electrical wiring should be performed by a qualified person in accord
with all applicable regulations. Failure to observe this precaution not
only 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 asto preventelectricalshock 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.
Do not attach the grounding wire to a gas pipe, water pipe, lightning
arrester or telephone grounding wire. Improper grounding can result in
electrical shock.
WARNING
WARNING
CAUTION

PSG2 500 Installation
wc_tx001977gb.fm 17
3.7 Connecting the Power Supply
Before connecting leads to the terminal strip, 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.
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.
NOTICE:Be sure to use a dedicated power supply with a ground
leakage circuit breaker.
Grounded plug
Connect only to receptacle of proper voltage and current rating
matching that of the plug provided with the cable assembly.
Without Plug
Tighten the ends of the cable assembly securely against the terminal
board. If installation of a grounded plug is required, use only a properly
rated and approved CEE plug and secure the ends of the cable
assembly securely to power and ground terminals in accordance with
the plug manufacturer’s instructions.
WARNING
CAUTION
Br
L
L1 L2
G/Y
wc
_
gr000309
G

Installation PSG2 500
18 wc_tx001977gb.fm
3.8 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.
Make 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 6 m (20 ft.).
CAUTION

PSG2 500 Operation
wc_tx001992gb.fm 19
4 Operation
4.1 Before Starting
4.1.1 Make sure once again that the product is of the correct voltage and
frequency rating.
NOTICE:Using the product at other than rated voltage and frequency
will not only lower its performance but may damage the product.
Note: Confirm the rated voltage and frequency on the model
nameplate.
4.1.2 Confirm the wiring, supply voltage, circuit breaker capacity, and motor
insulation resistance.
Reference insulation resistance = 20 MΩor greater.
Note: The reference insulation resistance (20 MΩor greater) is the
value when the pump is new or has been repaired. For the reference
value after installation see “Periodic Maintenance Table.”
4.1.3 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.
4.1.4 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.
Non-Automatic Model
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:
• Using an ammeter (clamp-on type), measure the operating
current at the L1 and L2 phase wires on the terminal.
COUNTERMEASURE: If the operating current exceeds the rated
value, pump motor overload may be a cause. Make sure the pump has
been installed under proper conditions as described in Installation.
• Using an AC voltmeter (tester), measure voltage at the terminals.
Supply voltage tolerance: within ±5% of rated voltage.
WARNING
WARNING

Operation PSG2 500
20 wc_tx001992gb.fm
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 Neuson
representative. Continuing to operate the pump under abnormal
conditions may result in electrical shock, fire, or current leakage.
Operation
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.
Paycareful attentionto thewater level while the pump is operating. Dry
operation may cause the pump to malfunction.
Note: See section Operating water level, for the water level necessary
for operation.
If the protection system operates due to an overload or malfunction,
causing the pump to stop, disconnect the power supply to the pump.
Make sure that the power is completely shut off before proceeding.
Next, unplug the cable assembly from the receptacle or detach it from
the terminals. Then, investigate and remove the cause of the
malfunction before restarting the pump.
CAUTION
WARNING
CAUTION
WARNING