Wayne PC4 Service manual

620003-001 B 08/18© 2018, WAYNE/Scott Fetzer Company.
Self-Priming* Portable Multi-Use Pump
www.waynepumps.com
Please read and save these instructions. Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself and others by observing all safety
information. Failure to comply with instructions could result in personal injury and/or property
damage! Retain instructions for future reference.
Operating Instructions and Parts Manual PC4
SPECIFICATIONS
POWER SUPPLY REQUIREMENTS 120 V, 60 Hz
MOTOR Brush Type
HORSEPOWER 1/2 HP
CIRCUIT REQUIREMENT 15 A (minimum)
LIQUID TEMPERATURE RANGE 40° F- 120° F
CONSTRUCTION
MOTOR HOUSING Cast Iron
MOTOR SHAFT Stainless Steel
IMPELLER Thermoplastic
VOLUTE Cast Iron
PUMP SUCTION 3/4 in. Brass Hose Fittings
PUMP DISCHARGE 3/4 in. Brass Hose Fittings
PERFORMANCE
Model HP Discharge Head 10 ft. 20 ft. 40 ft. 60 ft. 80 ft.
PC4 1/2 Gal/hr 1600 1500 1240 950 660

Operating Instructions and Parts Manual
2
PC4
REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.
GENERAL SAFETY INFORMATION
CALIFORNIA PROPOSITION 65
This product can expose you to chemicals, including DEHP,
which is known to the State of California to cause cancer,
birth defects and reproductive harm. For more information,
go to www.P65Warnings.ca.gov.
AVERTISSEMENT
Ce produit peutvous exposer à des produits chimiques,
notamment du DOP, reconnus par l’État de Californie comme
étant cancérigènes et à l’origine d’anomalies congénitales
et de problèmes de l’appareil reproductif. Pour plus de
renseignements, visiter le site www.P65Warnings.ca.gov.
Do not submerge motor or allow motor to be
exposed to water. Personal injury and/or death WILL result, and void
warranty.
Ne pas submerger le moteur ni laisser le
moteur exposé à l'eau. Des blessures corporelles et/ou la mort
pourraient en découler.
Do NOT use to pump flammable or explosive
fluids such as gasoline, fuel oil, kerosene, etc. Do NOT use in explosive
atmospheres. Pump only clear water. Failure to follow this warning WILL
result in personal injury and/or property damage.
NE PAS utiliser pour pomper des
fluides inflammables ou explosifs tels que l'essence,
le mazout, le kérosène, etc. NE PAS utiliser dans des
atmosphères explosives. Pomper uniquement de l'eau claire. Le non-
respect de cet avertissement entraînera des blessures corporelles et/ou
des dégâts matériels.
Risk of Electrical Shock! All wiring SHOULD be
performed by a licensed or certified electrician.
Risque de choc électrique! Tout le câblage DOIT
être effectué par un électricien qualifié ou certifié.
DESCRIPTION
This *self-priming portable Multi-Use pump is designed to be used
as a transfer pump for such applications as emptying water heaters,
livestock tanks, etc. The motor is air cooled; it is not designed to
operate under water. This pump is not suitable for drinking water.
NOTE: This pump is not intended for permanent installation or long,
extended periods of continuous operation.
*Self-Priming if used with a foot valve on suction hose or if gravity fed.
UNPACKING
After unpacking the Multi-Use pump, carefully inspect for any
damage that may have occurred during transit. Check for loose,
missing or damaged parts. If you need assistance, call our
Customer Support Department at 1-800-237-0987.
SAFETY SIGNAL WORDS
This manual contains information that is very important
to know and understand. This information is provided for
SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help
recognize this information, observe the following symbols.
Danger indicates an imminently hazardous
situation which, if NOT avoided, WILL result in death or serious injury.
La mention Danger indique une situation
dangereuse imminente qui, si elle n’est pas évitée, ENTRAÎNE la mort ou
des blessures graves.
Warning indicates a potentially hazardous
situation which, if NOT avoided, COULD result in death or serious injury.
La mention avertissement indique une
situation potentiellement dangereuse qui, si elle n’est pas évitée, risque
d’entraîner des lésions corporelles graves ou même la mort.
Caution indicates a potentially hazardous
situation which, if NOT avoided, MAY result in minor or moderate injury.
MISE EN GARDE La mention mise en garde indique une
situation potentiellement dangereuse qui, si elle n’est pas évitée,
pourrait entraîner des blessures mineures ou modérées.
Notice indicates important information, that if
NOT followed, MAY cause damage to equipment.
This is the safety alert symbol. It is used to alert you to
potential bodily injury hazards. Obey all safety messages
that follow this symbol to avoid possible harm.
NOTE: Information that requires special attention.

Operating Instructions and Parts Manual
3
GENERAL SAFETY INFORMATION (CONT’T)
Do NOT walk on wet areas until ALL power is
turned off. Failure to follow this warning WILL result in fatal
electrical shock.
Ne PAS marcher sur les zones
humides jusqu'à ce que le courant est coupé. Le défaut de
suivre cet avertissement entraînera une décharge électrique mortelle.
1. Read all instructions before operation.
2. Disconnect power and release all pressure within
the system before servicing any component.
3. Drain all liquids from system before servicing.
Secure the discharge line before starting the
pump. An unsecured discharge line MAY whip. Personal injury and/or
property damage COULD result.
Fixer la conduite de décharge avant le
démarrage de la pompe. Toute conduite de décharge non fixée pourrait
donner fouetter. Des blessures corporelles et/ou des dégâts matériels
pourraient en résulter.
4. Before each use inspect pump and system components,
checking for weak and/or worn hoses. Insure all connections
are secure.
Pump motor is equipped with an automatic
resetting thermal protector and MAY restart unexpectedly. Protector
tripping is an indication of motor overheating because of operating
pump at low heads (low discharge restriction), excessively high or low
voltage, inadequate wiring, excessive surrounding air temperature,
inadequate ventilation, and/or defective motor or pump.
Le moteur de la pompe est doté d'un
protecteur thermique à réinitialisation automatique et POURRAIT
redémarrer de manière imprévue. Le déclenchement du protecteur est
une indication de surchauffe du moteur à cause d'une utilisation de
la pompe à faible hauteur de chute (restriction de faible décharge),
d'une tension excessivement haute ou basse, d'un câblage inadéquat,
d'un branchement incorrect du moteur, d'une température ambiante
excessive, d'une ventilation inadéquate ou d'une pompe ou d'un moteur
défectueux.
5. Provide a means of pressure relief in the case of an obstructed
discharge line.
6. Protect electrical cord from sharp objects, hot surfaces, oil and
chemicals. Do not operate with damaged or kinked cord.
INSTALLATION
ALWAYS disconnect power source before
attempting to operate, service, or maintain the pump. NEVER handle a
pump with wet hands or when standing on wet or damp
surface or in water. Fatal electrical shock WILL occur.
TOUJOURS débrancher le cordon
d'alimentation avant d'essayer d'installer, de réparer ou de
faire l'entretien de la pompe. Ne JAMAIS manipuler de pompe avec les
mains humides ou debout sur une surface humide ou mouillée, ou dans
l'eau. RISQUE de choc électrique mortel!
1. A ground fault circuit interrupter (GFCI) is required.
Risk of electrical shock! This pump is supplied
with a grounding conductor and grounding type attachment plug. A
grounded receptacle in conformance with current NEC and local codes
must be used.
Risque de choc électrique! Cette
pompe est fournie avec un conducteur de mise à la terre et
une fiche de terre. Utiliser une prise de courant mise à la
terre conforme au CNE et aux codes locaux en vigueur.
2. This pump operates on 115V.
3. Use an extension cord only if necessary. Contact Customer
Support (800-237-0987) for guidance.
Risk of fatal electrical shock. NEVER cut off the
round grounding prong. Cutting the cord or plug WILL void the warranty
and make the pump inoperable.
Risque de choc électrique mortel. Ne JAMAIS
couper la broche de terre ronde sur le cordon. Couper le cordon ou
les bornes de la batterie ANNULERA la garantie et rendra la pompe
inutilisable.
4. Figure 1 shows a typical installation. Threaded adapters are
furnished for attaching garden hose where conditions permit its
use. In no case should the pump be more than 15 feet above
or away from water source. Install a foot valve to keep it self-
priming.
5. The inlet line may be galvanized pipe, plastic pipe, or reinforced
hose. Small leaks in suction line greatly reduce efficiency of
pump and may prevent priming.

Operating Instructions and Parts Manual
4
PC4
INSTALLATION (CONTINUED)
Ordinary garden hose will collapse under
suction pressure and should not be used for the inlet line.
6. Use a foot valve when pumping from a creek, pond, or source
where foreign objects may be sucked into the pump. The foot
valve should prevent solids from entering the inlet line.
7. A regular garden hose may be used as a discharge line.
Protect the pipe from damage by swimmers,
wildlife, and debris.
Protéger le tuyau contre les dommages causés
par les nageurs, les animaux et les débris.
PRIME PLUG
OUTLET
INLET
HOSE
ADAPTERS
Figure 1
OPERATION
Pump must be filled with water before
operation. Running the pump dry will cause damage to the shaft seal.
1. This unit is not waterproof or weatherproof and is not
intended to be used in showers, saunas, or other potentially
wet locations. The motor is designed to be used in a clean,
dry location with access to adequate cooling air. Ambient
temperatures around the motor should not exceed 104˚F
(40˚C).
2. Remove priming plug and fill with water. Replace plug
(plumbers seal tape should be used on priming plug to prevent
air leaks).
3. Plug power cord into GFCI protected electrical outlet. The
pump will prime in a few minutes depending on suction line
length. Use of foot valve on suction line is recommended for
self-priming.
4. Unplug cord to turn unit off.
MAINTENANCE
Let pump cool for at least 20 minutes before
attempting to service. Motor MAY be extremely hot. Personal injury MAY
result.
Laisser refroidir la pompe pendant au moins
20 minutes avant d'essayer de la réparer. Le moteur PEUT être
extrêmement chaud. Des blessures PEUVENT en résulter.
1. Pump should be checked before each use for proper
operation.
ALWAYS disconnect the electrical supply
before attempting to operate, service, or perform any maintenance. If
the power source is out of sight, lock and tag in the open (off) position
to prevent unexpected power application. Failure to do so WILL result
in fatal electrical shock. Only qualified electricians SHOULD repair this
unit. Improper repair WILL result in fatal electrical shock.
TOUJOURS débrancher l'alimentation électrique
avant d'essayer de faire fonctionner, d'entretenir ou d'effectuer toute
opération de maintenance. Si la source d'alimentation est hors de
vue, verrouiller et étiqueter en position ouverte (off) pour éviter une
décharge électrique inattendue. Ne pas le faire ENTRAÎNERA un choc
électrique mortel. Seuls les électriciens qualifiés DOIVENT réparer cet
appareil. Une réparation incorrecte ENTRAÎNERA un choc électrique
mortel.
BRUSH REPLACEMENT
Brushes for this pump should be inspected
after 100 hours of operation.
Pumps with excess of 100 hours of operation may stop operating
or fail to start. This could be due to worn brushes or carbon build-
up. The brushes should be removed and carbon removed. Worn
brushes are not covered under warranty. Replacement brushes may
be available online.
1) Disconnect electrical cord from power supply.
2) Remove brush caps with screwdriver.
3) Remove old brush assembly.
4) Replace brushes, make sure springs do not pinch during
assembly. Align/center tabs on the back of the brush spring
with the flats on the brush hlder. Ref. fig 2.
5) Replace brush caps.
For other problems, consult troubleshooting chart.

Operating Instructions and Parts Manual
5
SERVICE PART REPLACEMENT
Instructional video available at www.waynepumps.com
1. Make sure the pump is unplugged and cooled down before
disassembling the pump.
2. Release any pressure from the pump then disconnect any
hoses or plumbing and drain the product.
3. Remove brush holder caps and brushes (make note of which
side of the pump the brush was in also the orientation of the
brush as you will want to put them back the same way they
came out). Ref fig.3. Remove the (4) ¼-20 screws and lock
washers holding the volute to the motor housing. Ref fig.3
BRUSH HOLDER CAP
BRUSH
ALIGN TABS ON BRUSH
WITH FLATS ON BRUSH HOLDER
Figure 2
Figure 3
1/4-20 SCREW
WASHER
GASKET
VOLUTE
PRIMING FEATURE
MOTOR HOUSING
4. Remove the volute.
5. Remove the gasket and discard.
6. Remove the rotor assembly from the motor housing. There is
a thrust washer in the bearing pocket at the back of the motor
housing, if the thrust washer falls out make sure it is put back
into the pocket before reassembling. Ref fig. 4
LOOSE
TIGHT
THRUST WASHER
ROTOR ASSEMBLY
HEAD SEAL
CERAMIC SEAL
IMPELLER
Figure 4
7. Holding the rotor assembly with one hand unscrew the impeller
from the rotor shaft (do not use a vise or other such device to
hold the rotor as it may damage the rotor).
8. Remove both parts of the seal assembly from the back head
and impeller.
9. Push the new head seal (part with the blue metal housing) over
the rotor shaft and into the back head making sure the flange
on the seal seats against the back head and making sure the
black carbon side of the seal is facing away from the back
head towards the impeller.
10. Push the ceramic seal into the impeller pocket making sure the
white ceramic surface faces away from the back of the impeller.
11. Holding the rotor with one hand thread the new impeller onto
the rotor shaft making sure it is tight on the shaft and the white
face of the ceramic seal contacts the black carbon face of the
head seal.
12. Make sure the thrust washer is in the bearing pocket in the
back of the motor housing and guide the rotor assembly back
into the motor housing. Make sure the priming feature on the
back head is on the bottom of the pump, the pump won’t
prime properly if this isn’t in the correct location. Ref. fig. 3
13. Put the new gasket on the motor housing then reattach the
volute to the motor housing using the four ¼-20 screws and
lock washers. Torque the screws to 75 in. lbs.
14. Replace the brushes and caps, make sure to put them back
in the same way they came out. Make sure the springs do not
pinch during assembly and align/center the tabs on the back of
the brush spring with the flats on the brush holder. Ref. fig. 2
15. Test thoroughly and check for leaks before use.

Operating Instructions and Parts Manual
6
PC4
For Replacement Parts or Customer Support, Call 1-800-237-0987
Address any correspondence to:
WAYNE Water Systems
101 Production Drive
Harrison, OH 45030 U.S.A.
Please provide following information:
- Model number
- Serial number (if any)
- Part description and number as shown in parts list
2
1
Ref.
No. Description Part Number Qty.
1Brush kit 62015-WYN1 1
2Impeller and seal kit 56671-WYN1 1
Note: Replacement parts are available in kit form only

Operating Instructions and Parts Manual
7
LIMITED WARRANTY
For one year for PC4 model from the date of purchase, from an authorized dealer, Wayne Water Systems will repair or replace, at its option for the original purchaser,
any part or parts of its Multi-Use Pumps or Water Pumps (“Product”) found upon examination by Wayne Water Systems to be defective in materials or workmanship.
Please call Wayne Water Systems (800-237-0987) for warranty instructions. Be prepared to provide the model number and the serial number when exercising this
warranty. All transportation charges on Products or parts submitted for repair or replacement must be paid by purchaser.
This Limited Warranty does not cover Products which have been damaged as a result of accident, abuse, misuse, neglect, improper installation, improper maintenance,
or failure to operate in accordance with Wayne Water Systems’ written instructions.
THIS WARRANTY IS IN LIEU OF ANY AND ALL OTHER WARRANTIES, OBLIGATIONS OR AGREEMENTS, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE, AND ANY RIGHTS OR REMEDIES AGAINST ANY PERSON OR ENTITY UNDER THE UNIFORM
COMMERCIAL CODE OR OTHERWISE WITH RESPECT TO THE SALE OF THE PRODUCT. THE REMEDIES AND OBLIGATIONS STATED IN THIS WARRANTY ARE THE SOLE
AND EXCLUSIVE REMEDIES OF AND OBLIGATIONS TO THE OWNER FOR ANY AND ALL MATTERS ARISING WITH RESPECT TO OR IN ANY WAY CONNECTED WITH
THE PRODUCT, REGARDLESS OF THE SOURCE OR PROVIDER OF SUCH GOODS. IN NO EVENT, WHETHER AS A RESULT OF BREACH OF CONTRACT, WARRANTY TORT
(INCLUDING NEGLIGENCE) OR OTHERWISE, SHALL WAYNE WATER SYSTEMS OR ANY AFFILIATE BE LIABLE FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
You MUST retain your purchase receipt along with this form. In the event you need to exercise a warranty claim, you MUST send a copy of the purchase receipt along
with the material or correspondence. Please call Wayne Water Systems (800-237-0987) for return authorization and instructions.
DO NOT MAIL THIS FORM TO Wayne Water Systems.Use this form only to maintain your records.
MODEL NO._____________________ SERIAL NO._________________________ INSTALLATION DATE __________________________
ATTACH YOUR RECEIPT HERE

8
NOTES
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