Wayne PC4 Operating Instructions Manual

Self-Priming Portable Utility Pump

OPERATING INSTRUCTIONS & PARTS MANUAL

READ, UNDERSTAND AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL - DO NOT DISCARD. Failure to follow these instructions could result in property damage, serious injury or death.

PC4

DESCRIPTION

This self-priming portable utility pump is designed to be used as a transfer pump for such applications as emptying water heaters, livestock tanks, etc. Pump can also be used for an intermittent pressure boost for applications such as washing cars, cleaning driveways, etc. The motor is air cooled; it is not designed to operate under water.

NOTE: This pump is not intended for permanent installation or long, extended periods of continuous operation.

UNPACKING

After unpacking the utility 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 Service Department at 1-800-237-0987.

SAFETY GUIDELINES

To help recognize this information, observe the following signal words/hazard classiﬁcations.

Danger indicates an imminently hazardous

situation which, if not avoided, WILL result in death or serious injury. Warning indicates a potentially hazardous

situation which, if not avoided, COULD result in death or serious injury. Caution indicates a potentially hazardous

situation which, if not avoided, MAY result in minor or moderate injury. 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.

GENERAL SAFETY INFORMATION

CALIFORNIA PROPOSITION 65

This product or its power cord contains

chemicals, including lead, known to the State of California to cause cancer and birth defects or other reproductive harm. Wear gloves when handling this product, and wash hands after handling.

GENERAL SAFETY

Do not submerge motor or allow motor to be

exposed to water. Personal injury and/or death WILL result.

Do NOT use to pump ﬂammable or explosive ﬂuids such as gasoline, fuel oil, kerosene, etc. Do NOT use in a ﬂammable and/or explosive atmosphere. Pump SHOULD only be used to pump clear water. Personal injury and/or death WILL result. Risk of electrical shock. ALL wiring must be

performed by a qualiﬁed electrician.

Do NOT walk on wet areas until ALL power is turned off. Failure to follow this warning WILL result in fatal electrical shock.

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.

4. Periodically inspect pump and system components, checking

for weak and/or worn hoses. Insure all connections are secure.

Motor

Impeller

Motor Housing

Shaft and Volute Seal

Maximum Fluid Temperature

REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.

Single Phase - 115V, 60 Hz, 8,000 RPM

Series Wound (brush type) AC/DC Operation

Thermoplastic

Cast iron

Buna-N

120°F

For parts, product & service information visit www.waynepumps.com

Specications

Horsepower

Inlet/Outlet Openings

Pump Housing

Motor Shaft

Motor Bearings

1/2 HP

3/4 inch NPT

Cast iron

Cold rolled steel

Permanently lubricated Rolling element bearings

3213 07 -001 6/16

Operating Instructions and Parts Manual

GENERAL SAFETY INFORMATION (CONTINUED)

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.

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. Avoid kinking the cord and replace damaged cords immediately.

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.

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 (See Figure 1).

PRIME PLUG

INLET

OUTLET

Figure 2

HOSE ADAPTERS

4. Figure 2 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 when suction lift is over 10 feet or when suction line is over 10 feet long.

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.

Ordinary garden hose WILL collapse under

suction pressure and SHOULD NOT be used for

the inlet line, except in pressure boosting applications.

6. Use a strainer when pumping from a creek, pond, or source where foreign objects may be sucked into the pump. The strainer should prevent solids from entering the inlet line.

7. A regular garden hose may be used as a discharge line.

RESET

TEST

GROUNDING BLADE

Figure 1

GFCI RECEPTACLE

2. This pump operates on 115V, 60 Hz AC, single phase or 115V DC.

3. Use an extension cord only if necessary. Follow the Extension Cord Length Table for proper gage of 3-wire, grounding type extension cord.

Extension Cord Length Table

Wire Size #18 #16 #14 #12

Length 25 ft 50 ft 100 ft 150 ft

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.

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.

4. In the case of pressure boosting, turn water on before starting pump. This force primes the pump. Then, plug power cord into GFCI protected electrical outlet.

5. Unplug cord to turn unit off.

www.waynepumps.com

MAINTENANCE

Let pump cool for at least 20 minutes before

attempting to service. Motor MAY be extremely

hot. Personal injury MAY result.

1. Pump should be checked periodically 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.

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 buildup. The brushes should be removed and carbon removed. Worn brushes are not covered under warranty. Replacement brushes may be available from WAYNE Pumps. Call 1-800-237-0987 to order.

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. ﬁg3.

5) Replace brush caps. For other problems, consult troubleshooting chart.

PC4

NOTES

__________________________________________________________

www.waynepumps.com

Operating Instructions and Parts Manual

SERVICE PART REPLACEMENT

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.4

IMPELLER

HEAD SEAL

CERAMIC SEAL

LOOSE

ROTOR ASSEMBLY

THRUST WASHER

BRUSH HOLDER CAP

BRUSH

ALIGN TABS ON BRUSH

WITH FLATS ON BRUSH HOLDER

Figure 3

VOLUTE

GASKET

Figure 4

1/4-20 SCREW

WASHER

PRIMING FEATURE

MOTOR HOUSING

Figure 5

TIGHT

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.

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.3

15. Test thoroughly and check for leaks before use.

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.5

www.waynepumps.com

PC4

TROUBLESHOOTING CHART

Symptom Possible Cause(s) Corrective Action

Pump will not start or run 1. Blown fuse 1. If blown, replace with proper sized fuse or reset

2. Low line voltage 2. Contact an electrician

3. Worn brushes 3. Replace brushes

4. Impeller blocked 4. Remove blockage

5. Defective motor 5. Replace pump

Pump will not prime or retain prime after operating

Flow rate is too low 1. Piping or hose is fouled or damaged 1. Clean or replace

Seal leaks 1. Worn seal 1. Replace seal

Thermal Protector Tripping 1. Damage or misalignment causing rotating

1. Air leak in suction line 1. Repair or replace suction line (use plumbers

2. Impeller blocked 2. Remove blockage

3. Worn seal 3. Replace seal

4. Suction lift too high 4. Lower pump

5. Hose kinked or looped 5. Straighten hose

6. Fittings not tight 6. Tighten ﬁttings

7. Suction hose out of water 7. Submerge suction hose end

8. Clogged inlet 8. Clean inlet

2. Low line voltage 2. Contact an electrician

2. Backhead damaged or cracked 2. Replace backhead

3. Pump head loose on motor 3. Insure proper assembly and no obstruction,

parts to bind

2. High surrounding temperature 2. Provide a shaded, well-ventilated area for pump

3. Low line voltage 3. Contact an electrician

4. Motor housing air-vents blocked 4. Remove air-vent blockage

breaker

tape to install garden hose adpater ﬁttings and priming plug onto pump body)

tighten bolts

1. Take to motor repair shop or locate and repair mechanical binding

www.waynepumps.com

+ 11 hidden pages

Wayne PC4 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual