Wacker Neuson PST2-400 User manual

Operator’s Manual
Pump
PST2-400, PSTF2-400
Type PST2-400, PSTF2-400
Document 5000188001
Date 1215
Version 06
Language EN
5000188001

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.

Foreword
wc_tx001173gb.fm 3
Foreword
Machines covered in this manual
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 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.
Machine Item Number
PST2 400 0009112
PSTF2 400 0620435

Foreword
wc_tx001173gb.fm 4

PST2/PSTF2 400 Table of Contents
wc_bo0154618en_005TOC.fm 5
Foreword 3
1. Safety Information 7
1.1 Operating and Electrical Safety ............................................................ 8
1.2 Informational Labels ............................................................................. 8
2. Operation 9
2.1 Names of Parts ..................................................................................... 9
2.2 Prior to Operation ............................................................................... 10
2.3 Installation .......................................................................................... 10
2.4 Installing the Float (if equipped) ......................................................... 13
2.5 Electrical Wiring .................................................................................. 15
2.6 Electrical Circuit Diagrams ................................................................. 17
2.7 Operation ............................................................................................ 19
2.8 Automatic Operation (PSTF2 400 only) ............................................. 22
2.9 Residue Plate ..................................................................................... 23
3. Maintenance 24
3.1 Periodic Maintenance Table ............................................................... 24
3.2 Maintenance and Inspection .............................................................. 25
3.3 Disassembly and Reassembly ........................................................... 27
3.4 Disassembly ....................................................................................... 28
3.5 Impeller Inspection ............................................................................. 29
3.6 Impeller Reassembly .......................................................................... 30
3.7 Troubleshooting .................................................................................. 31
4. Technical Data 32
4.1 Standard Specifications ...................................................................... 32
4.2 Operating Specifications .................................................................... 33
4.3 Dimensions ......................................................................................... 34

Table of Contents PST2/PSTF2 400
wc_bo0154618en_005TOC.fm 6

PST2/PSTF2 400 Safety Information
wc_si000034gb.fm 7
1. Safety Information
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.
DANGER
WARNING
CAUTION

Safety Information PST2/PSTF2 400
wc_si000034gb.fm 8
1.1 Operating and Electrical Safety
To reduce risk of electric shock, connect only to a properly grounded,
grounding-type receptacle.
Risk of electric shock—this pump has not been investigated for use in
swimming pool areas.
An acceptable motor-control switch shall be provided at the time of
installation according to local codes and regulations.
To reduce risk of electric shock, 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.
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-
tion found on this plate so it will be available
should the nameplate become lost or damaged.
When ordering parts or requesting service infor-
mation, you will always be asked to specify the
model number, item number, revision number,
and serial number of the unit.
WARNING
Wacker Neuson Corporation
Menomonee Falls, WI 53051 USA
Model ItemNo. Rev.
SerialNo.
VHz
kWkgMax.L/minMax.m
MADEIN TAIWAN
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 St d.
Amp.
Man.Y/MTHERMALLY PROTECTED
INDOORSOR OUTDOORS
CSA ENCLOSURE 3

PST2/PSTF2 400 Operation
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2. Operation
2.1 Names of Parts
See Graphic: wc_gr001699
Ref Description Ref Description
1 Lifting handle 9 Oil plug
2 Mechanical seal 10 Dust seal
3 Lubricant 11 Sleeve
4 Oil housing 12 Impeller
5 Coupling 13 Stirrer nut
6 Volute 14 Strainer
7 Gasket 15 Oil lifter
8 Cable assembly
wc_gr001699
8
1
9
10
12
13
14
6
11
15
2
53

Operation PST2/PSTF2 400
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2.2 Prior to Operation
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.
2.3 Installation
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.
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, 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.
CAUTION
WARNING

PST2/PSTF2 400 Operation
wc_tx000111gb.fm 11
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.
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 two power wires.
Reference insulation resistance: 20MW or greater.
Note: The reference insulation resistance (20MWor 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.
2.3.1 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
shock.
WARNING
CAUTION
CAUTION

Operation PST2/PSTF2 400
wc_tx000111gb.fm 12
2.3.2 Install the pump in a location with sufficient water level, where water
collects readily.
Note: See Operation (“Operating Water Level”) for the water level
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.
2.3.3 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.
2.3.4 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.
CAUTION

PST2/PSTF2 400 Operation
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2.4 Installing the Float (if equipped)
See graphic: wc_gr005664
2.4.1 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.
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.
Pump model Length “L”
PSTF2 400 150 mm (5.9 in.)
wc_gr005664

Operation PST2/PSTF2 400
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Notes:

PST2/PSTF2 400 Operation
wc_tx000111gb.fm 15
2.5 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 astopreventelectricalshockfrom
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.
Connecting the power supply
Beforeconnectingwirestotheterminal, 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.
• The 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.
WARNING
WARNING
CAUTION
WARNING
CAUTION

Operation PST2/PSTF2 400
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See Graphic: wc_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.
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 twenty feet.
CAUTION

PST2/PSTF2 400 Operation
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2.6 Electrical Circuit Diagrams
See Graphic: wc_gr006190
If connected to a circuit protected by a fuse, use a time-delay fuse with
this pump.
Ref. Description Ref. Description
1 Capacitor 5 Frame grounding
2 Main coil 6 Ground
3 Auxiliary coil 8 Float switch (normally open
contact)
4 Miniature protector
wc_gr006190
PSTF2 400
PST2 400
W
W (L)
6
5
8
1
3
2
4
R(Br) R
Y/G
B
LL
RR1
WWBL
3
2
5
4
6
G
G/Y
G/Y
CAUTION

Operation PST2/PSTF2 400
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Wire Colors
B Black V Violet Or Orange
G Green W White Pr Purple
L Blue Y Yellow Sh Shield
P Pink Br Brown LL Light Blue
R Red Cl Clear G/Y Green/Yellow
TTan GrGray

PST2/PSTF2 400 Operation
wc_tx000111gb.fm 19
2.7 Operation
Before starting
2.7.1 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.
2.7.2 Confirm the wiring, supply voltage, circuit breaker capacity, and motor
insulation resistance.
Reference insulation resistance = 20 MW or greater.
Note: The reference insulation resistance (20 MWor greater) is the
value when the pump is new or has been repaired. For the reference
value after installation see “Periodic Maintenance Table.”
2.7.3 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.
2.7.4 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.
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 PST2/PSTF2 400
wc_tx000111gb.fm 20
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.
Paycareful attention to the water 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.
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.
CAUTION
WARNING
CAUTION