Wayne PC4, PC4K Operating Instructions And Parts Manual

Operating Instructions and Parts Manual PC4, PC4K

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.

Self-Priming Portable Utility Pump

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

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.

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.

NOTE: Information that requires special attention.

General Safety Information

CALIFORNIA PROPOSITION 65

This product

contains chemicals, including lead, known to the State of California to cause birth defects and other reproductive harm. 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.

Specifications

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

Motor. . . . . . . . . .Series Wound (brush type) AC/DC Operation

Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermoplastic

Motor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cast iron

Shaft and Volute Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . .Buna-N

Maximum Fluid Temperature. . . . . . . . . . . . . . . . . . . . . . . 120°F

REMINDER: Keep your dated proof of purchase for warranty purposes!

Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 HP

Inlet/Outlet Openings. . . . . . . . . . . . . . . . . . . . . . . . . . 3/4” NPT

Pump Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast iron

Motor Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . .Cold rolled steel

Motor Bearings . . . . . . . . . . . . . . . . . . .Permanently lubricated

Rolling element bearings

Attach it to this manual or file it for safekeeping.

For parts, product & service information

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Operating Instructions and Parts Manual

General Safety Information (Continued)

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.

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.

Extension Cord Length Table

Wire Size #18 #16 #14 #12

Length 25 ft 50 ft 100 ft 150 ft

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

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.

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.

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.

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.

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).

PRIME PLUG

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).

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INLET

HOSE ADAPTERS

OUTLET

Figure 2

PC4, PC4K

Operation (Continued)

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.

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 build-up. 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) Insert new brush assembly.

5) Replace brush caps.

For other problems, consult troubleshooting chart.

ADDITIONAL REPAIRS

To replace bearings, shaft seal, or gaskets, follow the instructions listed below.

1. Disconnect electrical cord from power supply.

2. Relieve pressure in system.

3. Disconnect inlet and outlet lines.

4. Empty water from pump housing.

5. Place pump on bench with motor end up and remove brushes as described in BRUSH REPLACEMENT instructions. If brushes are to be reused, mark the location from which each came. Replace brushes in original orientation upon completion of repair.

6. Remove the four cap screws holding motor housing and pump housing together. Motor housing is now free and can be removed. Take care not to lose commutator bearing finger spring.

7. With a screwdriver, pry the rotorbackhead assembly out of the pump housing.

8. Remove the impeller by turning counter clockwise (righthand thread on shaft).

9. Remove backhead (the bearing is press fit into the backhead).

10. Place backhead on flat surface with impeller side down and press out shaft seal.

11. Place impeller on flat surface with vane side down and with screwdriver and hammer break ceramic seal ring into several pieces and remove. Next, remove rubber seal ring cup from impeller.

12. Remove bearing from armature shaft (press-fit on shaft). (Impeller side bearing is the only serviceable bearing).

13. Inspect the armature commutator bars. The environment in which the unit has been operating will have influence on the condition of the commutator. Airborne dust an dirt will accelerate wear. A rough or scarred appearance may dictate having commutator reconditioned before reassembly.

14. To reassemble, install new bearing on the shaft. Always press against the inner race to prevent bearing damage. Make sure bearing is tight against the shaft shoulders.

15. Press shaft seal into backhead. When pressing shaft seal into place, apply force to the cup flange. Avoid touching the polished seal surface; oil or scratches on this surface may cause premature failure of the seal.

16. Press ceramic side of seal into impeller, ceramic side out. Avoid touching ceramic with hands as oil may cause premature failure of the seal. Wipe oil off both sides of seal with a soft, lint-free cloth.

17. Reassemble unit in reverse order, beginning with Step 9.

18. After reassembly check shaft for free rotation with screwdriver in fan through air exit openings.

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Operating Instructions and Parts Manual

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 breaker

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

1. Air leak in suction line 1. Repair or replace suction line (use plumbers tape to install garden hose adpater fittings and priming plug onto pump body)

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, tighten bolts

1. Take to motor repair shop or locate and

rotating parts to bind

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

3. Low line voltage 3. Contact an electrician

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

repair mechanical binding

pump

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PC4, PC4K

For Replacement Parts or Technical Assistance,

Call 1-800-237-0987

Please provide following information: Address any correspondence to:

- Model number WAYNE Water Systems

- Serial number (if any) 101 Production Drive

- Part description and number as shown in parts list Harrison, OH 45030 U.S.A.

5, 8

4,8

FINGER SPRING

4,8

4, 7,8

Replacement Parts List

Ref. No.

1 Brush kit 62007-002 1 2 Brush and holder kit 62008-002 1 3 Fittings kit 62009-001 1 4 Impeller and seal kit 62010-001 1 5 Bearing kit 62011-002 1 6 Cord kit 62012-001 1 7 Volute kit 62013-001 1 8 Backhead kit 62026-001 1

Note: Replacement parts are available in kit form only

Description Part Number Qty.

PAR

1, 2

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Operating Instructions and Parts Manual

Limited Warranty

For one year from the date of purchase, WAYNE Water Systems ("WAYNE") will repair or replace, at its option, for the original purchaser any part or parts of its Sump Pumps or Water Pumps (“Product”) found upon examination by WAYNE to be defective in materials or workmanship. Please call WAYNE (800-237-0987) for instructions or see your dealer. Be prepared to provide the model 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's written instructions.

THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR FROM THE DATE OF PURCHASE. THIS IS THE EXCLUSIVE REMEDY AND ANY LIABILITY FOR ANY AND ALL INDIRECT OR CONSEQUENTIAL DAMAGES OR EXPENSES WHATSOEVER IS EXCLUDED.

Some states do not allow limitations on how long an implied warranty lasts, or do not allow the exclusions or limitations of incidental or consequential damages, so the above limitations might not apply to you. This limited warranty gives you specific legal rights, and you may also have other legal rights which vary from state to state.

In no event, whether as a result of breach of contract warranty, tort (including negligence) or otherwise, shall WAYNE or its suppliers be liable for any special, consequential, incidental or penal damages including, but not limited to loss of profit or revenues, loss of use of the products or any associated equipment, damage to associated equipment, cost of capital, cost of substitute products, facilities, services or replacement power, downtime costs, or claims of buyer’s customers for such 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 (800-237-0987) for return authorization and instructions.

DO NOT MAIL THIS FORM TO WAYNE. Use this form only to maintain your records.

MODEL NO. _____________________ SERIAL NO. ________________________ INSTALLATION DATE _____________________

ATTACH YOUR RECEIPT HERE

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Wayne PC4, PC4K Operating Instructions And Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual