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Table of Contents 1. 2. Foreword Safety Information 2.1 2.2 3. 41 Inspection of Lubrication Oil ..........................................................................41 43 Special Tools for Pump Disassembly, Testing and Reassembly ..................43 PS2 400 (1–2HP) ..........................................................................................44 PS2 500, PSA2 500 (2–3HP) ........................................................................64 PS2 750 (1HP) ...........................
Table of Contents wc_bo0154618001enTOC.
Foreword 1. Foreword This manual provides information and procedures to safely operate and maintain this Wacker 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 Corporation. This machine is built with user safety in mind; however, it can present hazards if improperly operated and serviced.
Safety Information 2. Safety Information This manual contains DANGER, WARNING, CAUTION, 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.
Safety Information 2.2 Information Labels Label Meaning Wacker Corporation Menomonee Falls, WI 53051 USA Model Item No. Man.Y/M Serial No. V Hz Max.m Phase Max.L/min kg Rev. THERMALLY PROTECTED INDOORS OR OUTDOORS CSA ENCLOSURE 3 Amp. Conforms to UL Std. 778 Cert. to CAN/CSA St d. C22.2 No.108-M89 kW R Max. ft Max.GPM lbs HP C L IS TED 2001992 US MADE IN JAPAN A nameplate listing the Model Number, Item Number, Revision, and Serial Number is attached to each unit.
Safety Information wc_si000034gb.
PS2 400 3. Technical Data Technical Data 3.1 PS2 400 3.1.1 Applicable Liquids, Consistency and Temperature Pump Motor Connection Standard Specifications – PS2 400 Rain Water, Ground Water, Sand-Carrying Water 0–40°C (32–104°F) Impeller Semi-vortex type Shaft seal Double mechanical seal Bearing Shielded ball bearing Specification Dry submersible induction motor (2-Pole) Insulation Class B Protection system Miniature protector Lubricant 160ml (5.
Technical Data 3.1.2 PS2 400 Operating Specifications – PS2 400 (60Hz) Model No. PS2 400 Part No. 0009112 Pump Discharge 50mm (2in) Phase 1 Starting Method Capacitor Run Output 0.40kW (1-2HP) Full Load Amps 5.4A Starting Amps 12.5A Voltage 110V Max. Head 12m (39ft) Max. Capacity 200 ltr/min (53gpm) C.W.L. 90mm (3.5in) Weight* 11.3Kg (25 lb) *The weight (mass) given above is the operating weight of the pump itself, not including the cable assembly. wc_td000034gb_spec.
PS2 400 Technical Data 3.1.3 Operating Specifications – PS2 400 (50Hz) Model No. Part No. PS2 400 0008785 0008786 0008788 0008789 0009173 0009174 0009175 Pump Discharge 50mm (2in) Phase 1 Starting Method Capacitor Run Output 0.40kW (1-2HP) Full Load Amps 2.6A 5.5A Starting Amps 7.0A 14.0V Voltage 230V 110V Max. Head 12m (39ft) Max. Capacity 200 ltr/min (53gpm) C.W.L. 90mm (3.5in) Weight* 13.
Technical Data 3.2 PS2 500, PSA2 500 PS2 500, PSA2 500 3.2.1 Standard Specifications – PS2 500, PSA2 500 Applicable Liquids, Consistency and Temperature Pump Motor Rain Water, Fountain Water, Ground Water, Sand-Carrying Water 0–40°C (32–104°F) Impeller Semi-vortex type Shaft seal Double mechanical seal Bearing Shielded ball bearing Specification Dry submersible induction motor (2-Pole) Insulation Class B Protection System Miniature protector Lubricant 160ml (5.
PS2 500, PSA2 500 3.2.2 Technical Data Operating Specifications – PS2 500, PSA2 500 (60 Hz) Model No. Part No. PS2 500 0009113 PSA2 500 0009172 0009114 Pump Discharge 50mm (2in) Phase 1 Starting Method Capacitor Run Output 0.48kW (2-3HP) Full Load Amps 6.1A 3.3A 6.1A Starting Amps 12.5A 8.0A 12.5A Voltage 110V 220V 110V Max. Head Max. Capacity 12m (39.5ft) 236 ltr/min (62.4gpm) C.W.L. 50mm (2in) Weight* 9.
Technical Data PS2 500, PSA2 500 Operating Specifications – PS2 500, PSA2 500 (50 Hz) Model No. Part No. PS2 500 0008793 0008794 0008795 0008796 0009176 0009177 PSA2 500 0009178 0009179 0009180 0008787 0008790 0008791 0008792 0009181 Pump Discharge 50mm (2in) Phase 1 Starting Method Capacitor Run Output 0.40kW (1–2HP) Full Load Amps 2.9A 6.2A 2.9A 6.2A Starting Amps 7.0A 14.0A 7.0A 14.0A Voltage 230V 110V 230V 110V Max. Head 11m (36ft) Max. Capacity 220 ltr/min (58gpm) C.
PS2 750 3.3 Technical Data PS2 750 3.3.1 Standard Specifications – PS2 750 Applicable Liquids, Consistency and Temperature Pump Motor Rain Water, Fountain Water, Ground Water, Sand-Carrying Water 0–40°C (32–104°F) Impeller Open type Shaft Seal Double mechanical seal Bearing Shielded ball bearing Specification Dry submersible induction motor (2-Pole) Insulation Class E Protection System Circle Thermal Protector Lubricant 210ml (7.
Technical Data 3.3.2 PS2 750 Operating Specifications – PS2 750 (60 Hz) Model No. Part No. PS2 750 0009115 0009116 Pump Discharge 50mm (2in) Phase 1 Starting Method Capacitor Run Output 0.75kW (1HP) Full Load Amps 11.5A 6.5A Starting Amps 43.0A 25.5A Voltage 110V 220V Max. Head 18m (60ft) Max. Capacity 276 ltr/min (73gpm) C.W.L. 100mm (4in) Weight* 19.5Kg (43 lb) *The weight (mass) given above is the operating weight of the pump itself, not including the cable assembly.
PS2 750 Technical Data 3.3.3 Operating Specifications – PS2 750 (50 Hz) Model No. Part No. PS2 750 0008797 0008798 0008799 0008800 0009182 0009183 0009184 Pump Discharge 50mm (2in) Phase 1 Starting Method Capacitor Run Output 0.75kW (1HP) Full Load Amps 6.3A 13.9A Starting Amps 21.0A 46.0A Voltage 230V 110V Max. Head 16m (52.5ft) Max. Capacity 276 ltr/min (73gpm) C.W.L. 100mm (4in) Weight* 19.
Technical Data 3.4 PS3 1500, PS3 2200 PS3 1500, PS3 2200 3.4.1 Standard Specifications – PS3 1500, PS3 2200 Applicable Liquids, Consistency and Temperature Pump Motor Rain Water, Fountain Water, Ground Water, Sand-Carrying Water 0–40°C (32–104°F) Impeller Semi-vortex type Shaft Seal Double mechanical seal Bearing Shielded ball bearing Specification Dry submersible induction motor (2-Pole) Insulation Class B Protection System Circle thermal protector Lubricant 270ml (9.
PS3 1500, PS3 2200 3.4.2 Technical Data Operating Specifications – PS3 1500, PS3 2200 (60 Hz) Model No. Part No. PS3 1500 PS3 2200 0009117 0009118 0009119 Pump Discharge 80mm (3in) Phase Starting Method 1 Capacitor Run Output Capacitor Run Capacitor Start Capacitor Run 0.48kW (2HP) 0.75kW (3HP) Full Load Amps 23.0A 11.5A 13.0A Starting Amps 136A 68.0A 70.0A Voltage 110V Max. Head Max. Capacity 220V 21m (69ft) 26m (85ft) 420 ltr/min (111gpm) 493 ltr/min (130gpm) C.W.L.
Technical Data 3.5 PS2 1503, PS3 1503 PS2 1503, PS3 1503 3.5.1 Standard Specifications – PS2 1503, PS3 1503 Applicable Liquids, Consistency and Temperature Pump Motor Discharge wc_td000034gb_spec.
PS2 1503, PS3 1503 3.5.2 Operating Specifications – PS2 1503, PS3 1503 (60 Hz) Model No. Part No. Technical Data PS2 1503 0009120 PS3 1503 0009121 0009122 0009123 0009124 0009125 Pump Discharge 50mm (2in) 80mm (3in) Phase 3 Starting Method Direct Online Output 1.5kW (2HP) Full Load Amps 6.1A 3.1A 2.3A 6.1A 3.1A 2.3A Starting Amps 42A 21A 16A 42A 21A 16A Voltage 220V 440V 575V 220V 440V 575V Max. Head Max. Capacity 23m (75ft) 14.
Technical Data 3.5.3 PS2 1503, PS3 1503 Operating Specifications – PS2 1503, PS3 1503 (50 Hz) Model No. PS2 1503 PS3 1503 Part No. 0009186 0008801 0008802 0008803 0008804 0008805 0008806 0008807 0008808 0008809 0008810 0008811 0009188 0008812 Pump Discharge 50mm (2in) 80mm (3in) Phase 3 Starting Method Direct Online Output 1.5kW (2HP) Full Load Amps 3.4/3.3A Starting Amps 20/21A Voltage Max. Head Max. Capacity 400/415V 21.5m (71ft) 14.
PS2 2203, PS3 2203 3.6 Technical Data PS2 2203, PS3 2203 3.6.1 Standard Specifications – PS2 2203, PS3 2203 Applicable Liquids, Consistency and Temperature Pump Motor Connection wc_td000034gb_spec.
Technical Data 3.6.2 PS2 2203, PS3 2203 Operating Specifications – PS2 2203, PS3 2203 (60 Hz) Model No. Part No. PS2 2203 0009126 0009127 PS3 2203 0009128 0009129 0009130 0009131 Pump Discharge 50mm (2in) 80mm (3in) Phase 3 Starting Method Direct Online Output 2.2kW (3HP) Full Load Amps 9.3A 4.7A 3.5A 9.3A 4.7A 3.5A Starting Amps 73A 37A 28A 73A 37A 28A Voltage 220V 440V 575V 220V 440V 575V Max. Head Max. Capacity 30.5m (100ft) 20.
PS2 2203, PS3 2203 3.6.3 Technical Data Operating Specifications – PS2 2203, PS3 2203 (50 Hz) Model No. PS2 2203 PS3 2203 Part No. 0008813 0008814 0008815 0008816 0008817 0008818 0009190 0008819 0008820 0008821 0008822 0008823 0008824 0009192 Pump Discharge 50mm (2in) 80mm (3in) Phase 3 Starting Method Direct Online Output 1.5kW (2HP) Full Load Amps 5.5/5.6A Starting Amps 36/37.5A Voltage 400/415V Max. Head Max. Capacity 26m (85ft) 20.
Technical Data 3.7 PS2 3703, PS3 3703, PS4 3703 PS2 3703, PS3 3703, PS4 3703 3.7.1 Standard Specifications – PS2 3703, PS3 3703, PS4 3703 Applicable Liquids, Consistency and Temperature Pump Motor Connection wc_td000034gb_spec.
PS2 3703, PS3 3703, PS4 3703 3.7.2 Model No. Part No. Technical Data Operating Specifications – PS2 3703, PS3 3703, PS4 3703 (60 Hz) PS2 3703 PS3 3703 PS4 3703 0009132 0009133 0009134 0009135 0009136 0009137 0009138 0009139 0009140 Pump Discharge 60mm (2in) 80mm (3in) Phase 100mm (4in) 3 Starting Method Direct Online Output 3.7kW (5HP) Full Load Amps 13.4A 6.8A 5.3A 13.4A 6.8A 5.3A 13.4A 6.8A 5.
Technical Data 3.7.3 PS2 3703, PS3 3703, PS4 3703 Operating Specifications – PS2 3703, PS3 3703, PS4 3703 (50 Hz) Model No. PS2 3703 PS3 3703 PS4 3703 Part No. 0008825 0008826 0008827 0008828 0008829 0008830 0009194 0008831 0008832 0008833 0008834 0008835 0008836 0009196 0008837 0008838 0008839 0008840 0008841 0008842 0009198 80mm (3in) 100mm (4in) Pump Discharge 50mm (2in) Phase 3 Starting Method Direct Online Output 3.7kW (5HP) Full Load Amps 7.5/7.
PS3 5503, PS4 5503 3.8 Technical Data PS3 5503, PS4 5503 3.8.1 Standard Specifications – PS3 5503, PS4 5503 Applicable Liquids, Consistency and Temperature Pump Motor Connection wc_td000034gb_spec.
Technical Data 3.8.2 PS3 5503, PS4 5503 Operating Specifications – PS3 5503, PS4 5503 (60 Hz) Model No. Part No. PS3 5503 0009141 0009142 PS4 5503 0009143 0009144 0009145 0009146 Pump Discharge 80mm (3in) 100mm (4in) Phase 3 Starting Method Direct Online Output 5.5kW (7.5HP) Full Load Amps 19.5A 9.8A 7.3A 19.5A 9.8A 7.3A Starting Amps 162A 81A 62A 162A 81A 62A Voltage 220V 440V 575V 220V 440V 575V Max. Head Max.
PS3 5503, PS4 5503 3.8.3 Technical Data Operating Specifications – PS3 5503, PS4 5503 (50 Hz) Model No. PS3 5503 PS4 5503 Part No. 0008843 0008844 0008845 0008846 0008847 0008848 0009200 0008849 0008850 0008851 0008852 0008853 0008854 0009202 Pump Discharge 80mm (3in) 100mm (4in) Phase 3 Starting Method Direct Online Output 5.5kW (7.5HP) Full Load Amps 10.8/10.5A Starting Amps 86/89A Voltage Max. Head Max. Capacity 400/415V 32.0m (105ft) 22.
Technical Data 3.9 PS4 7503HH, PS4 7503HF PS4 7503HH, PS4 7503HF 3.9.1 Standard Specifications – PS4 7503HH, PS4 7503HF Applicable Liquids, Consistency and Temperature Pump Motor Rain Water, Fountain Water, Ground Water, Sand-Carrying Water 0–40°C (32–104°F) Impeller Open type Shaft Seal Double mechanical seal Bearing Sealed ball bearing Type, Poles Dry type submersible induction motor (2-Pole) Insulation Class B Protection System Circle thermal protector Lubricant 760ml (25.
PS4 7503HH, PS4 7503HF 3.9.2 Operating Specifications – PS4 7503HH, PS4 7503HF (60 Hz) Model No. Part No. Technical Data PS4 7503HH 0009147 0009148 PS4 7503HF 0009149 0009150 0009151 0009152 Pump Discharge 100mm (4in) Phase 3 Starting Method Direct Online Output 7.5kW (10HP) Full Load Amps 25.5A 12.8A 9.7A 25.5A 12.8A 9.7A Starting Amps 226A 113A 85A 226A 113A 85A Voltage 220V 440V 575V 220V 440V 575V Max. Head Max.
Technical Data 3.9.3 Model No. Part No. PS4 7503HH, PS4 7503HF Operating Specifications – PS4 7503HH, PS4 7503HF (50 Hz) PS4 7503HH PS4 7503HF 0008855 0008856 0008857 0008858 0008859 0008860 0009204 0008861 0008862 0008863 0008864 0008865 0008866 0009206 Pump Discharge 100mm (4in) Phase 3 Starting Method Direct Online Output 7.5kW (10HP) Full Load Amps 14.3/13.8A Starting Amps 117/121A Voltage 400/415V Max. Head Max.
PS4 11003HH, PS4 11003HF Technical Data 3.10 PS4 11003HH, PS4 11003HF 3.10.1 Standard Specifications – PS4 11003HH, PS4 11003HF Applicable Liquids, Consistency and Temperature Pump Motor Rain Water, Fountain Water, Ground Water, Sand-Carrying Water 0–40°C (32–104°F) Impeller Open Type Shaft Seal Double Mechanical Seal Bearing Sealed Ball Bearing Type, Poles Dry Type Submersible Induction Motor (2-Pole) Insulation Class B Protection System Circle Thermal Protector Lubricant 760ml (25.
Technical Data PS4 11003HH, PS4 11003HF 3.10.2 Operating Specifications – PS4 11003HH, PS4 11003HF (60 Hz) Model No. Part No. PS4 11003HH 0009153 0009154 PS4 11003HF 0009155 0009156 0009157 0009158 Pump Discharge 100mm (4in) Phase 3 Starting Method Direct Online Output 11kW (15HP) Full Load Amps 38.0A 19.0A 14.3A 38.0A 19.0A 14.3A Starting Amps 297A 149A 120A 297A 149A 120A Voltage 220V 440V 575V 220V 440V 575V Max. Head Max. Capacity 51m (167ft) 32.
PS4 11003HH, PS4 11003HF 3.10.3 Model No. Part No. Technical Data Operating Specifications – PS4 11003HH, PS4 11003HF (50 Hz) PS4 11003HH PS4 11003HF 0008867 0008868 0008869 0008870 0008876 0008877 0009208 0008871 0008872 0008873 0008874 0008878 0008879 0009210 Pump Discharge 100mm (4in) Phase 3 Starting Method Direct Online Output 11kW (15HP) Full Load Amps 21.0/20.5A Starting Amps 152/158A Voltage 400/415V Max. Head Max. Capacity 48.5m (159ft) 32.
General Operation 4. General Operation 4.1 Introduction The information in General Operation does not in any way replace the model specific Operator’s Manual and Parts Book that accompany each pump. It is included in this repair manual as a general overview of operation. Always refer to the specific model pump Operator’s Manual and Parts Book for: 4.
General Operation 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 32–104°F (0– 40°C) which can lead to failure, current leakage or shock.
General Operation 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.
General Operation CAUTION 4.3.2 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. 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.
General Operation WARNING Connecting the power supply Before connecting wires to the terminal, 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.
General Operation 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. 4.4 Operation Before starting 4.4.1 Make sure once again that the product is of the correct voltage and frequency rating. CAUTION: Using the product at other than rated voltage and frequency will not only lower its performance but may damage the product.
General Operation • CAUTION WARNING Using an AC voltmeter (tester), measure voltage at the terminals. Supply voltage tolerance: within ±5% of rated voltage. COUNTERMEASURE: If the supply voltage is outside the tolerance, possible causes are the power supply capacity or an inadequate extension cable. Look again at Electrical Wiring and make sure the conditions are proper.
Elementary Maintenance 5. Elementary Maintenance 5.1 Inspection of Lubrication Oil 1. Drain the lubrication oil into a clean container and transfer to a transparent container to check for deterioration or water leaking into the oil. 2. Check the sealing system for replacement if the following conditions exists: —Oil volume is below 70% of correct volume. —Excessive discoloration or deterioration. —Water comprises over 5% of total oil capacity. —Abrasive materials visible.
Elementary Maintenance Elem-Maintenance.
PS Series Submersible Pumps 6. Repair Repair 6.1 Special Tools for Pump Disassembly, Testing and Reassembly 6.1.1 Machinery and Tools • Standard hand tools for disassembly and assembly • Tools to remove and mount bearings • Dial gauge (0.01mm and up) • Dial caliper (0.
Repair 6.2 PS2 400 PS2 400 (1–2HP) 6.2.1 Power Supply Disassembly, Inspection, Testing and Reassembly 6.2.1.1 Power Supply Disassembly Note: Draining oil is not required to simply disassemble, inspect or test power supply. However, if further disassembly and testing of motor is required, drain oil. 2. Clean cover housing (l) before disassembly. Pay particular attention to areas around cover (s) and hose coupling (b). 3. Prior to working on pump, all electrical power supply circuits must be disconnected.
PS2 400 Repair 9. Remove three bolts (j), three washers (k) and housing cover (l). 10. Disconnect red, black and blue wire connections (wc) to capacitor (o). See graphic wc_gr000603. o wc wc_gr000603 6.2.1.2 Power Supply Inspection 1. Measure cable length. The specified cable length is 627.3cm (247in), subject to user’s specific application requirements. —Replace cable if measured length is less than 503cm (198in). 2.
Repair PS2 400 1 = Frame Grounding 2 = Main Coil 3 = Capacitor 4 = Aux. Coil 5 = Protector 6 = Ground R = Red Br = Brown L = Blue Repair.
PS2 400 Repair 6.2.1.3 Power Supply Testing Air Test Cable Air test cable insulation for resistance using a Megger tester between conductors. —Replace power supply cable if readings fall below 30 MΩ. wc_gr000436 Water Test Cable 1. Water test cable insulation for resistance using a water tank. This testing method may detect minute insulation flaws that air test will not. 2. Submerse cable in a water tank with conductors on both ends of cable above water level.
Repair PS2 400 —Replace capacitor when test indicator shakes continuously and comes back quickly. o wc_gr000438 6.2.1.4 Power Supply Reassembly Note: If, upon inspection and testing, a pump component requires replacement, use only original manufacturer’s replacement cables complete with anti-wicking block assembly and certified for submersible use. Note: Use only new gaskets and o-rings when reassembling pump. 1. Properly align rubber gasket (m) over top of motor bracket (n).
PS2 400 Repair See graphic wc_gr000439. o m n wc_gr000439 2. Reposition capacitor (o) inside two tangs of motor bracket (n). Note: A thin piece of double-sided tape between motor bracket (n) and capacitor (o) temporarily holds capacitor (o) in proper position and eases reassembly. 3. Connect black, blue and red wire connections (wc) to capacitor (o). See graphic wc_gr000603. o wc wc_gr000603 4. Reposition single ground wire (h) to motor bracket (n) and secure with screw (i). Repair.
Repair PS2 400 5. Feed red, green and white wires, up through opening of housing cover (l). 6. Align three holes of housing cover and assemble (finger tight) with three washers (k) and three bolts (j). Alternately tighten each bolt one-quarter turn until tight. 7. Connect red, green and white wire connection to matching colored wires of power cable (p). 8. Holding power cable (p) slightly above housing cover (l), push wires inside protruding boss until cover (s) is flush with boss. 9.
PS2 400 Repair See graphic wc_gr00439. Note: Make note of orientation to motor bracket . m n wc_gr000439 4. If not done already, disconnect two (blue and black) wire connections to capacitor (o). 5. Remove motor bracket (n) from motor frame (t), allowing motor wires to pass through oblong opening. 6. Remove spring washer (al). —Leave upper bushing (am) in place. 7. Remove three nuts (af) so strainer (ac) and volute (aa) remain on the workbench in an upright position.
Repair PS2 400 13. Pull rotor (an) with upper and lower ball bearings (am & ap) still attached. an ap wc_gr000604 14. Again, tuck motor leads inside motor frame (t) and turn motor and motor frame upside down. Make sure wires are not pinched and motor frame (t) sits on a clean, flat surface. 15. Remove three hex socket bolts (ak), oil housing (ag) and o-ring (ae). Remove rubber plug (xx) from top side of oil housing (ag). ag xx ad ae wc_gr000440 16. Remove three piece portion of mechanical seal (ad).
PS2 400 Repair cw rp wc_gr000441 zz 18. Make note of thin metal piece (cw) and white plastic bushing (zz) that are separate parts of rubber plug (rp). 6.2.2.2 Motor Inspection 1. Visually inspect rotor (an) for corrosion, wear or damaged threads. 2. Measure rotor (an) for deflection using a dial gauge. Record measurements with rotor supported by upper and lower bearings. —Deflection at center of rotor should not exceed 0.10mm (0.0039in). —Deflection at pump end of shaft should not exceed 0.08mm (0.
Repair PS2 400 5. Visually inspect mechanical seal (ad) for wear, cracks or damage. Look carefully at flexible components, replace if deformed. Note: Pay particular attention to sealing faces that butt up against each other. They are divided by a thin oil film which prevents water from entering motor.Replace entire mechanical seal (ad) if worn, damaged or cracked. Replace every 6,000 hours of service or one year, whichever comes first. 6.2.2.3 Motor Testing Test Stator Insulation Resistance 1.
PS2 400 Repair 3. Hold the vacuum position for 10 seconds. The gauge should remain absolutely stable. —Replace mechanical seal upon failing vacuum test. 6.2.2.4 Motor Reassembly Note: If, upon inspection and testing, a pump component requires replacement, use only original manufacturer’s replacement cables complete with anti-wicking block assembly and certified for submersible use. Note: Use only new gaskets and o-rings when reassembling pump. 1.
Repair PS2 400 See graphic wc_gr000605. rp t wc_gr000605 5. Center three-piece portion of mechanical seal (ad) on top of rubber plug. See graphic wc_gr000443. ad t ae wc_gr000443 6. Install rubber washer (rw) to top side of oil housing (ag). See graphic wc_gr000607. rw ag wc_gr000607 7. Apply clean pump oil to o-ring (ae) and lay into motor frame (t). Pick up oil housing (ag). Turn it upside down, line up three mounting holes and gently set in place. See graphic wc_gr000445.
PS2 400 Repair ag t wc_gr000445 8. Gently insert three hex socket bolts (ak) and apply downward hand pressure to oil housing (ag) while aligning holes. Assemble finger tight. 9. Alternately tighten each of bolt one-quarter turn until oil housing (ag) is secure. 10. Assemble strainer (ac), volute (aa) and volute gasket (ah) in upright position. Pick up motor and turn to an upright position. Lay motor over three protruding bolts (ab). Do not attach nuts at this time. 11.
Repair PS2 400 13. Apply a drop of clean pump oil to white plastic washer (wb) and insert it inside lip so it is flush. Use a blunt screw driver to press fit washer in place. Note: It is important these pieces are assembled correctly before proceeding. v u wb wc_gr000446 14. Sub-assemble dust seal and sleeve (u & v) and slide assembled pieces onto rotor shaft. See graphic wc_gr000446. IMPORTANT: DO NOT apply oil to surface where dust seal contacts sleeve. 15.
PS2 400 Repair 21. Properly align rubber gasket (m) over top of motor bracket (n). Make sure knob located on under side of rubber gasket (m) is aligned with hole in motor bracket (n). Press gasket flush to motor bracket (n). o m n wc_gr000439 22. Reposition capacitor (o) inside two tangs of motor bracket (n). Note: A thin piece of double-sided tape between motor bracket (n) and capacitor (o) temporarily holds capacitor (o) in proper position and eases reassembly. 23.
Repair PS2 400 See graphic wc_gr000408. R = Red L = Blue B = Black 24. Reposition single ground wire (h) to motor bracket (n) and secure with screw (i). 25. Feed red, green and white wires, and guide them through opening of housing cover (l). 26. Align three holes of housing cover and assemble (finger tight) with three washers (k) and three bolts (j). Alternately tighten each bolt one-quarter turn until tight. 27. Connect red, green and white wire connection to matching colored wires of power cable (p).
PS2 400 Repair 6.2.3 Impeller Disassembly, Inspection, Testing and Reassembly 6.2.3.1 Impeller Disassembly 1. 2. 3. 4. 5. 6. Note: It is not necessary to drain the oil for disassembly and inspect ion of the impeller (w) or volute (aa). However, drain oil if further disassembly and testing is required. Turn pump on its side. Remove three nuts (af) and the suction strainer (ac). Remove volute (aa) and volute gasket (ah).
Repair PS2 400 6.2.3.3 Impeller Clearance PS2 400 is equipped with a semi-vortex impeller and has no specific clearance requirements. 6.2.3.4 Impeller Reassembly Note: If, upon inspection and testing, a pump component requires replacement, use only original manufacturer’s replacement parts. 4. Turn pump on its side. 5. Pre-assemble the dust seal (u) and sleeve (v). Slide the two pieces (u & v) onto the rotor shaft.
PS2 400 Repair 10. Replace gasket (ah) on top of volute (aa). 11. Lift and hold remaining pump assembly in an upright position, align three mounting flanges and lower into place. 12. Assemble and secure three nuts (af). 13. Tighten three nuts (af). 14. Pre-test pump to verify proper operation. 15. Performance test pump. Test results should be: Maximum head Maximum volume Repair.fm > > 63 10.06m (33ft) 170.
Repair 6.3 PS2 500, PSA2 500 PS2 500, PSA2 500 (2–3HP) 6.3.1 Power Supply Disassembly, Inspection, Testing and Reassembly 6.3.1.1 Power Supply Disassembly Note: Draining oil is not required to simply disassemble, inspect or test power supply. However, if further disassembly and testing of the motor is required, drain oil. 1. Clean top of outer cover housing (r) thoroughly. 2. Prior to working on the pump, all electrical power supply circuits must be disconnected. 3. Coil up excess power cable. 4.
PS2 500, PSA2 500 Repair 6.3.1.2 Power Supply Inspection 1. Measure cable length. The specified cable length is 996 cm (392"), subject to user’s specific application requirements. —Replace cable if measured length is less than 797 cm (314"). 2. Inspect insulation materials of the power supply cable and wires for cuts, cracking, hardening, abrasive wear or any other condition where short circuit or water leaks are possible. 3. Inspect power supply cable and wires for broken connectors.
Repair Repair.fm PS2 500, PSA2 500 1 = Ground 2 = Frame Grounding 3 = Transformer 4 = Level Relay Unit 5 = Triac 6 = Electrode 7 = Capacitor 8 = Aux.
PS2 500, PSA2 500 Repair 6.3.1.3 Power Supply Testing Air Test Cable Air test the cable insulation for resistance using a Megger tester between conductors. —Replace power supply cable if readings fall below 30 MΩ. wc_gr0000436 Water Test Cable 1. Water test the cable insulation for resistance using a water tank. This testing method may detect minute insulation flaws that air test will not. 2. Submerse the cable in a water tank with conductors on both ends of cable above water level.
Repair PS2 500, PSA2 500 —Capacitor can be re-used when the test indicator shakes once and comes back slowly. —Replace capacitor when the test indicator shakes continuously and comes back quickly. q wc_gr0000438 Test Relay Unit–PSA2 500 Only The pump starts operating when there is current flowing between the two relay unit electrodes. Hold a screw driver so it touches both electrodes simultaneously, then test resistance using a Megger tester. wc_gr000449 6.3.1.
PS2 500, PSA2 500 Repair 1. Properly align rubber gasket (n) over top of motor bracket (o). Make sure knob located on the under side of gasket (n) is aligned with hole in motor bracket (o). Press gasket flush to motor bracket. Rotate both rubber gasket and motor bracket until the three crescent shaped protrusions line up properly with motor housing. Repair.
Repair PS2 500, PSA2 500 See graphic wc_gr000439. q n o wc_gr000439 2. Connect black, blue and red wire connections to capacitor (q). 3. Reposition capacitor (q) inside two tangs of motor bracket (o). Note: A thin piece of double-sided tape between motor bracket (o) and capacitor (q) temporarily holds the capacitor in the proper position and ease reassembly. 4. Reposition single ground wire (j) to motor bracket (o) and secure with screw (k). 5.
PS2 500, PSA2 500 Repair 16. Install oil plug gasket (ad) over oil plug (ae) in the correct orientation. See graphic wc_gr000450. ae ad wc_gr000450 17. Screw plug with gasket (ad & ae) into oil housing. Tighten oil plug (ae). 18. Pre-test pump to verify proper operation. 19. Performance test pump. Test results should be: PS2 500 Maximum head Maximum volume > > Amperage @110V < Amperage @ 220V < 10.36m (34ft) 200.6 ltr/min (53gpm) full load 6.4A start 13.1A full load 3.2A start 8.
Repair PS2 500, PSA2 500 6.3.2 Motor Disassembly, Inspection, Testing and Reassembly 6.3.2.1 Motor Disassembly 1. Motor disassembly requires disassembly of entire pump. 2. Remove oil. 3. Disassemble power supply. See Power Supply Disassembly on page 64). 4. With pump in upright position, remove rubber gasket (n) from motor bracket (o). 5. Disconnect blue and black wire connections to capacitor (q). 6.
PS2 500, PSA2 500 Repair 16. Remove wear ring (an) if damaged or worn. 17. Remove dust seal and sleeve as one piece (ao & ap). 18. Remove white plastic washer from recess in motor frame (l). wc_gr000451 19. Remove three bolts (al), oil housing (ak) and o-ring (as). 20. Remove mechanical seal (am). 21. Remove rotor (av). A puller tool may be required. Note: Take note of the correct sequence of assembly and how the individual parts are oriented. 6.3.2.2 Motor Inspection 1.
Repair PS2 500, PSA2 500 4. Visually inspect the upper and lower bearing (au & ax) for wear, corrosion or rust. Manually test lower ball bearing (ax) for any side to side movement, vibration or damage to the inside or outside diameter. —Replace every 6,000 hours of service or one year, whichever comes first. 5. Visually inspect mechanical seal (am) for wear, cracks or damage. Look carefully at flexible components, replace if deformed.
PS2 500, PSA2 500 Repair Test Oil Chamber Pressure 1. After installing mechanical seal, attach a vacuum pump to oil housing. 2. Raise negative pressure inside the oil chamber to 60 cmHg (11.6 in.Hg). IMPORTANT: DO NOT exceed 60 cmHg (11.6 in.Hg). 3. Hold the vacuum position for 10 seconds. The gauge should remain absolutely stable. —Replace mechanical seal upon failing vacuum test. 6.3.2.
Repair PS2 500, PSA2 500 14. Secure impeller with flat washer (ac), lockwasher (ad) and acorn nut (ae). 15. While keeping the impeller and rotor shaft from rotating, tighten the acorn nut (ae). 16. Slide volute (af), rubber suction plate (ag) and metal suction cover (ah), lining up three holes with three stud bolts protruding from oil housing. 17. Lay strainer (ai) over top and secure with three shoulder bolts (aj). 18.
PS2 500, PSA2 500 Repair PS2 500 Maximum head Maximum volume > > Amperage @ 110V < Amperage @ 220V < 10.36m (34ft) 200.6 ltr/min (53gpm) full load 6.4A start 13.1A full load 3.2A start 8.4A PSA2 500 6.3.3 Repair.fm Maximum head Maximum volume > > Amperage @ 110V < 10.36m (34ft) 200.6 ltr/min (53gpm) full load 6.4A start 13.
Repair PS2 500, PSA2 500 6.3.3.1 Impeller Disassembly 1. 2. 3. 4. 5. 6. Note: Draining oil is not required to disassemble and inspect the impeller (aq) or volute (af). However, drain oil if further disassembly and testing is required. Turn pump on its side. Remove three bolts (aj) and the strainer (ai). Remove suction cover (ah), suction plate (ag) and volute (af). While keeping the impeller and rotor shaft from rotating, remove acorn nut (ae), lockwasher (ad) and washer (ac).
PS2 500, PSA2 500 Repair 6.3.3.4 Impeller Reassembly Note: If, upon inspection and testing, a pump component requires replacement, use only original manufacturer’s replacement parts. 1. Turn pump on its side. 2. Pre-assemble dust seal (ao) and sleeve (ap). Slide the two pieces (ao & ap) onto the rotor shaft. IMPORTANT: DO NOT apply oil to the surface where the dust seal (ao) contacts the sleeve (ap). 3. Replace wear ring (an). — The side with the protrusions around the edge faces the volute (af). 4.
Repair 6.4 PS2 750 PS2 750 (1HP) 6.4.1 Power Supply Disassembly, Inspection, Testing and Reassembly 6.4.1.1 Power Supply Disassembly 1. 2. 3. 4. 5. 6. 7. 8. Note: Draining oil from oil housing is not required to simply disassemble, inspect or test power supply. However, if further disassembly and testing of motor is required, drain oil. Clean top of outer cover housing (d) thoroughly. Prior to working on pump, all electrical power supply circuits must be disconnected. Coil up excess power cable (p).
PS2 750 Repair 9. Prior to removing the housing cover (i) mark where both housing cover (i) and stator (v) line up with each other. This aids reassembly. See graphic wc_gr000619. 10. Remove four acorn nuts (g) and four washers (h) from housing cover (i). 11. Remove housing cover (i) to gain access to capacitor (k). 12. Label two blue wires (zz) connecting to capacitor (k). This aids reassembly. k zz wc_gr000452 13.
Repair PS2 750 1 = Ground 2 = Frame Grounding 3 = Circle Thermal Protector 4 = Aux. Coil 5 = Heater 6 = Main Coil 7 = Centrifugal Switch 8 = Capacitor R = Red Br = Brown L = Blue Repair.
PS2 750 Repair 6.4.1.3 Power Supply Testing Air Test Cable Air test cable insulation for resistance using a Megger tester between conductors. —Replace power supply cable if readings fall below 30 MΩ. p wc_gr000453 Water Test Cable 1. Water test cable insulation for resistance using a water tank. This testing method may detect minute insulation flaws that air test will not. 2. Submerse cable in a water tank with conductors on both ends of cable above water level.
Repair PS2 750 k wc_gr000454 6.4.1.4 Power Supply Reassembly Note: If, upon inspection and testing, a pump component requires replacement, use only original manufacturer’s replacement cables complete with anti-wicking block assembly and certified for submersible use. Note: Use only new gaskets and o-rings when reassembling pump. 1. Correctly position capacitor (k), butting it up against metal tang of cover assembly. Secure capacitor (inside clamp of cover assembly) with screw (not shown). 2.
PS2 750 Repair 7. Replace large diameter o-ring (e) on outside diameter of bearing housing (not shown). Lower outer cover (d) over pump, aligning cutouts of cover housing. 8. Reconnect red, green and white connectors power cable to identically colored wire connectors protruding from top of pump. 9. Holding power cable (p) directly above housing cover (i), push three wire connections inside pump, guiding seal over two threaded studs until seal (q) sits flush with boss. 10. Secure with two acorn nuts (o).
Repair PS2 750 6.4.2 Motor Disassembly, Inspection, Testing and Reassembly 6.4.2.1 Motor Disassembly Note: Motor disassembly requires disassembly of entire pump. 1. Remove oil. 2. Disassemble power supply. See Power Supply Disassembly on page 80). 3. Label two blue wires (zz) connecting to capacitor. This aids reassembly. k ah zz ag ai wc_gr000452 wc_gr000455 4. Remove screw (ad) and capacitor (k). 5. 6. 7. 8. Remove two screws (af) and cover (ae). Remove pin (ag) and spring washer (ah).
PS2 750 Repair —The other wire can remain attached. 10. Remove two screws (aa) along with two spacers (ac) from thermal switch (ab). 11. Remove two screws (x), bearing cover (y) and spring washer (bh). 12. Remove four long screws (u) that secure stator (v) to bearing housing (az). y bh v wc_gr000456 13. Remove stator (v) with thermal switch (ab) and ground wire (t) still attached and set aside. 14. Turn pump on its side. 15.
Repair PS2 750 16. While keeping impeller from rotating, remove nut (au), lockwasher (at) and thread cover (as). as am wc_gr000457 17. Remove impeller (am) from rotor shaft. Note: Impeller vanes may be very sharp due to excessive wear. Handle with care. 18. Remove volute (bb) and o-ring (ba). 19. Remove key (be), any shims (al), sleeve (aj) and oil seal (ak) from rotor shaft. aj be ak az al av wc_gr000577 20. Remove three pieces of mechanical seal (av). 21.
PS2 750 Repair 22. Carefully remove rubber seal (rs) and plastic bushing (pb) from bearing housing (az). az pb rs wc_gr000578 23. If damaged, remove upper seal (us) from top of volute (bb) casting. ai us ls wc_gr000579 wc_gr000580 24. Turn volute (bb) upside down and examine lower seal (ls), remove if damaged. 6.4.2.2 Motor Inspection 1. Visually inspect rotor (bj) for corrosion, wear or damaged threads. 2. Measure rotor (bj) for deflection using a dial gauge.
Repair PS2 750 4. Visually inspect upper and lower rotor bearing (bi & ay) for wear, corrosion or rust. Manually test for any side to side movement or vibration. —Replace every 6,000 hours of service or one year, whichever comes first. 5. Visually inspect mechanical seal (not shown) for wear, cracks or damage. Look carefully at flexible components, replace if deformed. Note: Pay particular attention to sealing faces that but up against each other.
PS2 750 Repair Test Wire Resistance Measure resistance of each phase using Megger tester. —Replace stator if test results fluctuate more that ±5% of manufacturer’s specification. Locked Rotor Current Test Lock rotor (bj) and apply 25% of rated voltage by lock transformer or regulator. —Current measurement test results should be similar to rated current. Test Oil Chamber Pressure 1. After installing mechanical seal, attach a vacuum pump to oil housing. 2.
Repair PS2 750 1. Using wooden fixture or equivalent, turn bearing housing (az) upright and install rotor (bj) with upper and lower bearings attached. 2. Holding two mating pieces together, turn upside down in wooden fixture so lower end of rotor shaft points upward. 3. Press black rubber seal (rs) into bearing housing (az) then press white plastic bushing (pb) in recessed area of rubber seal so it creates a flush surface. az pb rs wc_gr000578 4.
PS2 750 Repair 8. Press lower seal (ls) in underside of volute (bb) if necessary. bb us ls wc_gr000579 wc_gr000580 9. Align and install impeller (am) over keyway of rotor shaft. 10. Install thread cover (as), lockwasher (at) and nut (au). 11. Holding impeller and rotor shaft from rotating, tighten nut (au). 12. Position suction cover gasket (an) on suction cover (ao) and secure with three stud bolts (aq). 13. Position strainer (ap) over three protruding stud bolts and secure with three hex nuts (ar).
Repair PS2 750 18. Install bearing cover (y) and secure with two screws (x). Note: Alternately tighten each screw one-quarter turn until bearing cover compresses spring washer and screws are tight. 19. Secure thermal switch (ab) using two spacers (ac) and two screws (aa). 20. Position lower half of centrifugal switch (w) over bearing cover (y) and attach with two screws (r). 21. Position upper half of centrifugal switch (ai) over keyway of rotor shaft.
PS2 750 Repair 29. Position gasket (f) over bolts and boss of housing cover (i). 30. Replace large diameter o-ring (e) on outside edge of bearing housing. Lower outer cover (d) over pump, aligning cutout with cover housing. 31. Connect red, green and white connectors power cable to identically colored wire connectors from motor. 32. Holding power cable (p) directly above housing cover (i), push three wire connections inside pump, guiding seal over two threaded studs until seal (q) sits flush with boss.
Repair PS2 750 39. Performance test pump. Test results should be: 6.4.3 Maximum head Maximum volume > > Amperage @ 110V < Amperage @ 220V < 15.5m (51ft) 234.7 ltr/min (62gpm) full load 12.1A start 45.2A full load 6.8A start 26.8A Impeller Disassembly, Inspection, Testing and Reassembly 6.4.3.1 Impeller Disassembly 1. 2. 3. 4. 5. Repair.fm Note: Draining oil from oil housing is not required to disassemble, inspect and replace impeller alone.
PS2 750 Repair 6. Pull impeller (am). A puller, part number 0151079, may be required. Remove key (be) from rotor shaft for inspection. be wc_gr000583 6.4.3.2 Impeller Inspection 1. Visually inspect impeller (am) for corrosion, wear or damage. Worn impellers compromise peak performance. 2. Visually inspect impeller key (be) and rotor shaft keyway for signs of uneven wear. 3. Visually inspect volute (bb) casting for cracks, wear and damage.
Repair PS2 750 6.4.3.4 Impeller Reassembly Note: If, upon inspection and testing, a pump component requires replacement, use only original manufacturer’s replacement parts. be wc_gr000583 1. With pump on its side, replace key (be) properly in keyway of rotor shaft. 2. Align and install impeller (am) over keyway of rotor shaft. 3. Install thread cover (as). as am wc_gr000457 4. Install lockwasher (at) and nut (au). 5. Holding impeller and rotor shaft from rotating, tighten nut (au). 6.
PS2 750 Repair 7. Measure distance between impeller and volute after assembly. Keep a recommended clearance of 0.3–0.5mm (0.118–0.196in). —If measured distance between impeller is greater than 0.5mm (0.196in), pumping capacity drops. —If measured distance between impeller is less than 0.3mm (0.118in), impeller may contact volute and slow rotation, overload motor causing premature failure. 8. Position strainer (ap) over three protruding stud bolts and secure with three nuts (ar). 9.
Repair 6.5 PS3 1500, PS3 2200 PS3 1500, PS3 2200 (2–3HP) 6.5.1 Power Supply Disassembly, Inspection, Testing and Reassembly 6.5.1.1 Power Supply Disassembly 2. 3. 4. 5. 6. Repair.fm Note: Draining oil is not required to simply disassemble, inspect or test power supply. However, if further disassembly and testing of the motor is required, drain oil. Clean top of cover housing (j) thoroughly. Prior to working on the pump, all electrical power supply circuits must be disconnected.
PS3 1500, PS3 2200 Repair 7. It is not necessary to remove hose coupling (h) or lift handle (a) unless they are damaged and need to be replaced. 8. Remove four bolts (c), lockwashers (d) and flat washers (e) that secure housing cover (j) to motor bracket. 9. Lift housing cover (j) off and remove o-ring (w). j mb w wc_gr000584 10. Remove two wire connections (wc) going to capacitor (o). Note: If keyring (kr) and warning plate (wp) are damaged or illegible, replace it.
Repair PS3 1500, PS3 2200 p q n o wc_gr000585 6.5.1.2 Power Supply Inspection 1. Measure the cable length. The specified cable length is 9.8m (32ft), subject to user’s specific application requirements. —Replace cable if measured length is less than 8m (26ft). 2. Inspect insulation materials of the power supply cable and wires for cuts, cracking, hardening, abrasive wear or any other condition where short circuit or water leaks are possible. 3.
PS3 1500, PS3 2200 Repair 3 = Heater 4 = Main Coil 5 = Aux. Coil 6 = Capacitor 7 = Centrifugal Switch R = Red Br = Brown L = Blue 1 = Bi-metal (to power supply) 2 = Protector 3 = Heater 4 = Centrifugal Switch 5 = Main Coil 6 = Aux. Coil Repair.
Repair PS3 1500, PS3 2200 R = Red Br = Brown L = Blue Repair.
PS3 1500, PS3 2200 Repair 6.5.1.3 Power Supply Testing 1. Air test the cable insulation for resistance using a Megger tester between conductors. —Replace power cable (S) if readings fall below 30 MΩ. s wc_gr000586 2. Water test the cable insulation for resistance using a water tank. This testing method may detect minute insulation flaws that the air test will not. 3. Submerse the cable in a water tank with conductors on both ends of cable above the water level.
Repair PS3 1500, PS3 2200 6.5.1.4 Power Supply Reassembly Note: If, upon inspection and testing, a pump component requires replacement, use only original manufacturer’s replacement cables complete with anti-wicking block assembly and certified for submersible use. Note: Use only new gaskets and o-rings when reassembling pump. p q n o wc_gr000585 —PS3 1500, slide capacitor (o) into cover (p) until rear of capacitor contacts “L” shaped stop.
PS3 1500, PS3 2200 Repair 5. If not done previously, seat cone shaped rubber end of power cable (s) inside cable casing. Tighten casing clamp with two screws (t) when power cable (s) is fully seated inside the cable casing. —PS3 1500, slide new inner and outer shrink tubes (hs) over each of the three power cable wires before connecting the motor leads to the power cable leads. Attach identical colored wires and secure connection with screw (xx) and nut (yy).
Repair PS3 1500, PS3 2200 6. Holding the power cable (s) directly above housing cover (j), push three wires inside the pump, aligning the four mounting holes of the cable casing. Secure with four bolts (k) and four washers (l). 7. If lift handle (a) is not already attached, put one leg of the lifting handle through the keyring/warning plate, then align mounting holes to top of the housing cover (j). Secure with two bolts (b).
PS3 1500, PS3 2200 Repair pg op wc_gr000591 10. Screw oil plug (op) with plug gasket (pg) into the oil housing and tighten. 11. Pre-test pump to verify proper operation. 12. Performance test pump. Test results should be: PS3 1500 Maximum head Maximum volume > > Amperage @ 110V < Amperage @ 220V < 17.9m (59ft) 355.8 ltr/min (94gpm) full load 24.2A start 142.8A full load 12.1A start 71.4A PS3 2200 Repair.fm Maximum head Maximum volume > > Amperage @ 220V < 109 21.9m (72ft) 416.
Repair PS3 1500, PS3 2200 6.5.2 Motor Disassembly, Inspection, Testing and Reassembly 6.5.2.1 Motor Disassembly Note: Motor disassembly for the PS3 1500 and PS3 2200 requires disassembly of the entire pump. 1. Lay pump on its side and remove oil plug and gasket. Rotate pump so all oil can drain from oil housing. Slide gasket over oil plug and screw oil plug back into oil housing during servicing. 2. Prior to working on pump, all electrical power supply circuits must be disconnected. 3.
PS3 1500, PS3 2200 Repair 6. Remove key (bi) from rotor shaft. 7. Remove dust seal and sleeve (ak & al) as one piece. 8. Remove wear ring (aj) exposing oil housing (af) and the oil housing mounting bolts (ag). 9. Remove four hex socket bolts (ag) and oil housing (af). 10. Remove two screws (ar) and oil lifter (as). as at ls af au wc_gr000592 11. Remove two screws (at) and retaining plate (au). 12. Examine lower seal (ls). Remove only if worn or damaged. 13.
Repair PS3 1500, PS3 2200 14. Remove three piece portion of mechanical seal (aq). aq wc_gr000593 15. Turn pump upright and clean top of cover housing (j) thoroughly. 16. Coil up excess power cable (s). 17. Remove four bolts (k) and four lockwashers (l) that secure cable casing (u) in place. 18. Pull power cable (s) up exposing the red, white and green wire connections. —PS3 1500, remove three outer shrink tubes and three inner shrink tubes to access screw (xx) and nut (yy) connections.
PS3 1500, PS3 2200 Repair —PS3 2200, separate the motor wires from the power cable wires. 19. Remove four bolts (c), lockwashers (d) and flat washers (e) that secure housing cover (j) to motor bracket (not shown). 20. Lift housing cover (aq) off and remove o-ring (au). 21. Remove two wire connections going to capacitor (au). o q p n wc_gr000585 22. Remove capacitor (o) for inspection and testing.
Repair PS3 1500, PS3 2200 25. Remove motor bracket (mb). Note: First loosen screw of any wire connections to terminal box (q). Bundle wires before passing through hole in motor bracket (mb). 26. Remove spring washer (bf). 27. Pull rotor (bh) with upper bearing (bg) and lower bearing (bk) attached. Note: A puller tool may be required. 6.5.2.2 Motor Inspection 1. Visually inspect rotor (bh) for corrosion, wear or damaged threads. 2. Measure the rotor (bh) for deflection using a dial gauge.
PS3 1500, PS3 2200 Repair 6. Visually inspect the Circle Thermal Protector (CTP) for damage to insulation materials, water or oil intrusion, heat discoloration of bi-metal disc, or damage to bi-metal disc. —Check to assure the lead wires of the stator windings are correctly and securely connected to the protector. —Check for disconnection of lead wires, short-circuit, coil-burn, or incorrect wiring. 7. Visually inspect oil lifter (as).
Repair PS3 1500, PS3 2200 Test Oil Chamber Pressure 1. After installing mechanical seal, attach a vacuum pump to oil housing. 2. Raise negative pressure inside the oil chamber to 60 cmHg (11.6 in.Hg). IMPORTANT: DO NOT exceed 60 cmHg (11.6 in.Hg). 3. Hold the vacuum position for 10 seconds. The gauge should remain absolutely stable. —Replace mechanical seal upon failing vacuum test. Test Thermal Protection (CTP) 1. Clean the points of the circle thermal protector (CTP). 2.
PS3 1500, PS3 2200 Repair bl bm bn mb wc_gr000594 5. Secure lower half of centrifugal switch (bp) with two screws (bo). 6. Secure upper half of centrifugal switch (bn) with washer (bm) and hex nut (bl). 7. While keeping the rotor shaft from rotating, tighten nut (bl). 8. Position insulated bushing (bs) in clearance hole so wires do not contact motor bracket. 9. Secure cover (p) to motor bracket (mb) with four screws (z). Note: Use marks on cover and motor bracket for proper orientation. 10.
Repair PS3 1500, PS3 2200 13. Slide capacitor (o) into cover (p) until rear of capacitor contacts “L” shaped stop. Note: To tighten screw (n), first gain access by removing two screws (r) that secure terminal box (j) to cover (p) and pull terminal box out of the way. 14. Reconnect two (previously labelled) wire connections to capacitor (o). 15. Install o-ring (w) to base of motor bracket (mb). x bs bc bt wc_gr000588 16. Verify that gasket (x) and gasket (bs) is in place.
PS3 1500, PS3 2200 Repair 23. Position o-ring (w) to lip of motor frame (bc). 24. Place oil housing in upright position. —Replace seal (ls) if damaged or worn. au st ls wc_gr000627 25. Secure retaining plate (au) with two screws (at). Note: Small tab (st) on inside diameter of plate must face downward. 26. Secure oil lifter (as) to retaining plate with two screws (ar). 27. Slide assembled oil housing over rotor shaft, aligning four mounting holes and cutout for gasket (av). 28.
Repair PS3 1500, PS3 2200 35. While keeping impeller and rotor shaft from rotating, tighten hex nut (ao) and acorn nut (ap). 36. Align three holes of retainer plate (ab) with volute (aa). 37. Secure strainer (ac) using four bolts (ae) and four washers (ad). 38. Before turning pump upright, remove oil plug (op) and plug gasket (pg). —Pour 270ml (9.1fl-oz) of clean oil into oil housing. Note: Use SAE 10W/20W oil, Turbine oil VG32 or equivalent. 39.
PS3 1500, PS3 2200 Repair —PS3 1500, slide heat shrinks back over each the three exposed wire connections and apply heat to collapse insulation material around connection. Make sure any exposed wire or metal is completely insulated. Allow time to cool before proceeding. IMPORTANT: DO NOT use electrical tape in place of heat shrink. —PS3 2200, attach identical colored wires and secure each connection with wire nut (m). IMPORTANT: DO NOT use electrical tape in place of heat shrink. 42.
Repair PS3 1500, PS3 2200 6.5.3 Impeller Disassembly, Inspection, Testing and Reassembly 6.5.3.1 Impeller Disassembly 1. 2. 3. 4. 5. 6. Note: Draining oil is not required to disassemble, inspect or replace the impeller. However, if further disassembly and testing is required, drain oil. Prior to working on the pump, all electrical power supply circuits must be disconnected. With pump on its side, remove four bolts (ae) and four washers (ad) and strainer (ac).
PS3 1500, PS3 2200 Repair 3. Visually inspect volute (aa) for wear and damage. Look for signs of wear on volute cutwaters and surfaces facing impeller. am wc_gr000597 6.5.3.3 Impeller Clearance 1. Measure the distance between impeller and volute after assembly. Keep a recommended clearance of 0.3–0.5mm (0.118–0.196in). —If measured distance between impeller is greater than 0.5mm (0.196in), pumping capacity drops. —If measured distance between impeller is less than 0.3mm (0.
Repair PS3 1500, PS3 2200 3. Install washer (an) and hex nut (ao). 4. Holding the impeller and rotor shaft from rotating, tighten hex nut (ao). 5. Install acorn nut (ap). 6. Holding the impeller and rotor shaft from rotating, tighten acorn nut (ap). 7. Align three holes of retainer plate (ab) with volute (aa). 8. Measure the distance between the impeller (am) and the volute (aa) after assembly. Keep a recommended clearance of 0.3– 0.5mm (0.118–0.196in).
PS2 1503, PS3 1503, PS2 2203, PS3 2203 6.6 Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203 (2–5HP) 6.6.1 Power Supply Disassembly, Inspection, Testing and Reassembly 6.6.1.1 Power Supply Disassembly Note: Draining oil is not required to disassemble, inspect or replace the impeller. However, if further disassembly and testing is required, drain oil. 1. Clean top of cover housing (n) thoroughly. 2. Prior to working on the pump, all electrical power supply circuits must be disconnected. 3.
Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203 10. Lift housing cover (n) and tip it on its side, allowing it to rest on top of the motor frame (aa). 11. Loosen two screws (r) and remove thermal switch (q) from underside of housing cover (n). See graphic wc_gr000629. Note: Leave three wire connections to thermal switch (q) attached. r q p o n wc_gr000629 12. Remove large diameter o-ring (o) from outside diameter and o-ring (p) from the inside diameter of cover housing (n). 13.
PS2 1503, PS3 1503, PS2 2203, PS3 2203 Repair 4. Inspect the sheath for cuts, gouges, cracking, hardening or abrasive wear. —Replace the power supply cable if the outer sheath is damaged or exposing interior insulation or protective materials. No tape repair is permitted. G = Green B = Black W = White R = Red 1 = Coil 2 = Circle Thermal Protector 6.6.1.3 Power Supply Testing Air Test Cable 1. Air test the cable insulation for resistance using a Megger tester between conductors.
Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203 3. Submerse the cable in a water tank with conductors on both ends of cable above the water level. After 24 hours, test the cable insulation using a Megger tester between conductors and metal container. —Replace power cable (x) if readings fall below 30 MΩ. 6.6.1.
PS2 1503, PS3 1503, PS2 2203, PS3 2203 Repair See graphic wc_gr000630. a ab b wc_gr000630 8. Position plate (b) on top of stator. Line up cutouts in plate with protruding wires. 9. Gather loose wires and guide them through hole while at the same time lowering cover housing. Align with upper bearing, being careful not to damage spring washer (a). Do not force. 10. Carefully lower housing cover into place. Note: Cover housing and rotor assembly must be perpendicular for the housing to slide into place.
Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203 18. If lift handle (c) was removed, obtain keyring/warning plate combination and trap around one of the legs of lift handle before securing to cover housing with two bolts (h). Note: If keyring/warning plate is damaged, illegible or missing, replace it. 19. Turn pump on its side and remove oil plug (op) and plug gasket (pg). 20. Pour 270ml (9.1fl-oz) of clean oil into the oil housing. Note: Use SAE 10W/20W oil, Turbine oil VG32 or equivalent.
PS2 1503, PS3 1503, PS2 2203, PS3 2203 Repair PS2 2203 Maximum head Maximum volume > > Amperage @ 200V < Amperage @ 440V < Amperage @ 575V < 30.5m (100 ft) 500 ltr/min (132gpm) full load 9.3A start 73A full load 4.7A start 36A full load 3.5A start 28A PS3 2203 6.6.2 Maximum head Maximum volume > > Amperage @ 200V < Amperage @ 440V < Amperage @ 575V < 20.4m (67 ft) 500 ltr/min (132gpm) full load 9.3A start 73A full load 4.7A start 36A full load 3.
Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203 3. With pump on its side, remove three bolts (bb), three washers (ba) and strainer (az). 4. Remove three bolts (ay), three washers (ax) and suction cover (aw). Note: Remove any gaskets (av) between suction cover and volute. These gaskets are used as shims to adjust impeller clearance. 5. While holding the impeller (bf) and rotor shaft from rotating, remove acorn nut (au), lockwasher (at) and thread cover (as).
PS2 1503, PS3 1503, PS2 2203, PS3 2203 Repair 7. Remove key (aq), shim (be) and sleeve (bd) from rotor shaft. See graphic wc_gr000639. bd be aq wc_gr000639 8. Turn pump around and remove four bolts (ai) and four lockwashers (aj) that secure the volute (al) to the motor frame (aa). 9. Remove volute (al), o-ring (ak) and gasket (ah). 10. Remove two screws (ac) and oil lifter (ad). 11. Remove four screws (ae) and retaining plate (af).
Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203 ms-1 ms-2 ms-3 ms-4 wc_gr000641 14. Carefully pull rotor (ap) from stator (am) with upper bearing (ao) and lower bearing (ar) assembled. Note: Use caution when pulling rotor to avoid scratching the outer surface of the rotor. If necessary, position pump in vertical position and use puller or other means to draw the rotor up and out of the stator without any side to side movement. 6.6.2.2 Motor Inspection ao ar ap wc_gr000645 1.
PS2 1503, PS3 1503, PS2 2203, PS3 2203 Repair Note: Pay particular attention to the sealing faces that butt up against each other. They are divided by a thin oil film which prevents water from entering the motor. Replace entire mechanical seal if worn, damaged or cracked. Replace every 6,000 hours of service or one year, whichever comes first. q wc_gr000644 6.
Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203 —Replace stator (az) if test results fall below 20 MΩ. Test Stator Continuity Test continuity between phase wire ends. —Replace stator if any breaks are found. Test Wire Resistance Measure resistance of each phase using Megger tester. —Replace stator if test results fluctuate more that ±5% of manufacturer’s specification. Note: Allow for temperature induced variations in winding resistance. Note: Contacts of imbedded thermoprotector can affect test results.
PS2 1503, PS3 1503, PS2 2203, PS3 2203 Repair ap am aa wc_gr000642 1. With stator (am) inside motor frame (aa), set motor frame upright on a wooden fixture or equivalent. Note: Fixture must provide 40cm (4in) clearance for rotor shaft. 2. With upper and lower ball bearings attached, lower rotor (ap) until lower bearing rests inside casting. 3. Replace gasket (ab). 4. Replace large diameter o-ring (o) to outside diameter of cover housing (n). r q j p i o n wc_gr000629 5.
Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203 Note: Cover housing and rotor assembly must be perpendicular for the housing to slide into place. 13. Assemble four bolts (k) and four lockwashers (l) to cover housing. Assemble “L” bracket (m) in one of the four mounting holes. —Sequentially turn each bolt (k) one-quarter turn until all four bolts are tight and the torque is distributed evenly. 14. Position the power cable (x) direct above the motor leads and secure the four wire connections.
PS2 1503, PS3 1503, PS2 2203, PS3 2203 Repair bc al wc_gr000635 23. Turn volute (al) over so it sits rightside up on a clean, flat surface. 24. Assemble o-ring (ak) to outside diameter of volute (al). 25. If necessary, replace seal (ag) to inside diameter of volute (al). See graphic wc_gr000637. af ag al wc_gr000636 wc_gr000637 26. Align retaining plate (af) and secure with four screws (ae). —Line up cutout in seal (ag) with small tab of retaining plate (af). 27.
Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203 ms 29 wc_gr000638 29. Pick-up assembled volute and assemble to motor frame (aa) with four bolts (ai) and four lockwashers (aj). 30. Slide sleeve (bd) onto rotor shaft. Press into place. Sleeve should fit inside oil seal (bc) previously assembled to volute. 31. Slide thin shim (be) onto rotor shaft. 32. Apply oil to key (aq) then place into keyslot of rotor shaft. 33. Align impeller key with rotor shaft keyway and slide impeller (bf) onto rotor shaft. 34.
PS2 1503, PS3 1503, PS2 2203, PS3 2203 Repair op pg wc_gr00591 39. Pour 740ml (25.1fl-oz) of clean oil into oil housing. Note: Use SAE 10W/20W oil, Turbine oil VG32 or equivalent. 40. Screw oil plug (op) with plug gasket (pg) into oil housing and tighten. 41. Pre-test pump to verify proper operation. 42. Performance test pump. Test results should be: PS2 1503 Maximum head Maximum volume > > Amperage @ 220V < Amperage @ 440V < Amperage @ 575V < 21.5m (71ft) 430 ltr/min (114gpm) full load 6.
Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203 PS2 2203 Maximum head Maximum volume > > Amperage @ 200V < Amperage @ 440V < Amperage @ 575V < 30.5m (100 ft) 500 ltr/min (132gpm) full load 9.3A start 73A full load 4.7A start 36A full load 3.5A start 28A PS3 2203 6.6.4 Maximum head Maximum volume > > Amperage @ 200V < Amperage @ 440V < Amperage @ 575V < 20.4m (67 ft) 500 ltr/min (132gpm) full load 9.3A start 73A full load 4.7A start 36A full load start 3.
PS2 1503, PS3 1503, PS2 2203, PS3 2203 Repair 1. Prior to working on the pump, all electrical power supply circuits must be disconnected. 2. With pump on its side, remove four bolts (ae) and four washers (ad) and strainer (ac). 3. Remove retainer plate (ab) and volute (aa). 4. While keeping the impeller (am) from rotating, remove acorn nut (ap), hex nut (ao) and washer (an). Note: Impeller vanes may be very sharp due to excessive wear. Handle with care. 5. Remove impeller (am).
Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203 —If measured distance between impeller is greater than 0.5mm (0.196in), pumping capacity drops. —If measured distance between impeller is less than 0.3mm (0.118in), impeller may contact volute, slow rotation, overload motor and cause premature failure. 6.6.4.3 Impeller Reassembly Note: Draining oil is not required to disassemble, inspect and replace impeller. However, if further disassembly and testing is required, drain oil.
PS2 1503, PS3 1503, PS2 2203, PS3 2203 Repair 3. Install washer (an) and hex nut (ao). 4. Holding the impeller and rotor shaft from rotating, tighten hex nut (ao). 5. Install acorn nut (ap). 6. Holding the impeller and rotor shaft from rotating, tighten acorn nut (ap). 7. Align three holes of retainer plate (ab) with volute (aa). 8. Measure the distance between the impeller (am) and the volute (aa) after assembly. Keep a recommended clearance of 0.3– 0.5mm (0.118–0.196in).
Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203 PS2 2203 Maximum head Maximum volume > > Amperage @ 200V < Amperage @ 440V < Amperage @ 575V < 30.5m (100 ft) 500 ltr/min (132gpm) full load 9.3A start 73A full load 4.7A start 36A full load 3.5A start 28A PS3 2203 Repair.fm Maximum head Maximum volume > > Amperage @ 200V < Amperage @ 440V < Amperage @ 575V < 146 20.4m (67 ft) 500 ltr/min (132gpm) full load 9.3A start 73A full load 4.7A start 36A full load start 3.
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 6.7 Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 (5–10HP) 6.7.1 Power Supply Disassembly, Inspection, Testing and Reassembly 6.7.1.1 Power Supply Disassembly Note: Draining oil is not required to simply disassemble, inspect or test power supply. However, if further disassembly and testing of the motor is required, drain oil. 1. Clean top of cover housing (m) thoroughly. 2.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 l ak y aj ac m u g wc_gr000647 9. Remove four bolts (s) , four lockwashers (t) and “L” bracket (u) secured to the housing cover (m). —PS3 5503 & PS4 5503 only, remove one hex-socket bolt (b) and one lockwasher (c) securing the housing cover (m) to the motor frame (g). 10. It is not necessary to remove hose coupling (j) or lift handle (l) unless they are damaged and need to be replaced. 11.
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 Repair d a e wc_gr000630 6.7.1.2 Power Supply Inspection 1. Measure the cable length. The specified cable length is 15.3m (50ft), subject to user’s specific application requirements. —Replace cable if measured length is less than 11.4m (38ft). 2. Inspect insulation materials of the power supply cable and wires for cuts, cracking, hardening, abrasive wear or any other condition where short circuit or water leaks are possible. 3.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 6.7.1.3 Power Supply Testing Air Test Cable Air test the cable insulation for resistance using a Megger tester between conductors. —Replace power cable (ag) if readings fall below 30 MΩ. ag wc_gr000643 Water Test Cable 1. Water test the cable insulation for resistance using a water tank. This testing method may detect minute insulation flaws that the air test will not. 2.
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 Repair 1. Replace gasket (a). 2. Replace large diameter o-ring (w) to outside diameter of cover housing (m). q p v o w m n wc_gr000629 3. Replace o-ring (v) to inside diameter of cover housing (m). 4. Turn cover housing on its side, so it rests on the motor frame (g). 5. Secure thermal switch (p) to inside of cover housing with two screws (q). 6. Verify that ground wire (n) is securely attached with screw (o). 7.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 d a e wc_gr000630 8. Position plate (e) on top of stator. Line up cutouts in plate with protruding wires. 9. Gather loose wires and guide them through hole while at the same time lowering cover housing. Align with upper bearing, being careful not to damage spring washer (d). Do not force. 10. Carefully lower housing cover into place. Note: Cover housing and rotor assembly must be perpendicular for the housing to slide into place. 11.
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 Repair 16. If hose coupling (j) was removed, reposition gasket (k) and hose coupling (j) to cover housing (m) and secure with four bolts (h) and lockwashers (i). 17. If lift handle (l) was removed, obtain keyring/warning plate combination and trap around one of the legs of lift handle before securing to cover housing with two bolts (r). Note: If keyring/warning plate is damaged, illegible or missing, replace it. 18.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 PS4 3703 Maximum head Maximum volume > > Amperage @ 220V < Amperage @ 440V < 15.8m (52ft) 124.6 ltr/min (328gpm) full load 14.1A start 117.6A full load 7.1A start 58.8A PS3 5503 Maximum head Maximum volume > > Amperage @ 220V < Amperage @ 440V < 32.6m (107ft) 836.5 ltr/min (221gpm) full load 20.5A start 170.1A full load 10.3A start 85.1A PS4 5503 6.7.2 Maximum head Maximum volume > > Amperage @ 220V < Amperage @ 440V < 19.
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 Repair 6. Unscrew hook (ai) and release chain (ah) from “L” bracket (u). 7. Pull power cable (ag) up exposing the red, white, black and green wire connections. 8. Remove four outer and four inner shrink tubes (ac). 9. Separate the motor wires from the power cable wires by loosening the set screw (ak) on each of the four terminal posts (aj). See graphic wc_gr000647. l ak y aj ac m u g wc_gr000647 10.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 13. Loosen two screws (q) and remove thermal switch (p) from underside of housing cover (m). See graphic wc_gr000629. Note: Leave three wire connections to thermal switch (p) attached. q p v w m wc_gr000629 14. Remove large diameter o-ring (w) from outside diameter and o-ring (v) from the inside diameter of cover housing (m). 15. Remove gasket (a), plate (e) and spring washer (d). See graphic wc_gr000630. d a e wc_gr000630 16.
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 Repair 17. Remove three stud bolts (ar) and three washers (aq) holding suction cover (ap) to volute (av). Remove three bolts (by), three washers (bx) and suction cover (ap). Note: Remove any gaskets (ao) between suction cover and volute. These gaskets are used as shims to adjust impeller clearance. 18. Using a pneumatic wrench, remove acorn nut (an). Remove lockwasher (am) and thread cover (al). Note: Impeller vanes may be very sharp due to excessive wear.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 21. Remove oil seal (ax) and shim (ay). See graphic wc_gr000639. ax ay bb wc_gr000639 22. Remove four bolts (bl) and four lockwashers (bm) that secures the volute (av) to the motor frame (g). 23. Remove the volute (av) from the motor frame (g) and set right side up on a clean, flat surface. 24. Remove o-ring (bn) and gasket (bk) from motor frame (g). 25. With volute upright, remove two screws (bh) and oil lifter (bd). 26.
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 Repair be av bj wc_gr000648 27. Flip the volute (av) over and remove the oil seal (aw). bc wc_gr000649 28. Remove four part portion of mechanical seal (bc) from rotor shaft. See graphic wc_gr000649. 29. Carefully pull rotor, bearings and bearing housing as an assembly from stator (f). Note: Use caution when pulling rotor to avoid scratching the outer surface of the rotor.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 bp bq bu bv bs bt wc_gr000650 30. Remove four bolts (ba) and bearing housing (bp). 31. Remove o-ring (bq) and two part seal (bx) from bearing housing (bp). See graphic wc_gr000651. bx bp wc_gr000651 6.7.2.2 Motor Inspection bw bs bv wc_gr000645 1. Visually inspect rotor (bv) for corrosion, wear or damaged threads. 2. Measure the rotor (bv) for deflection using a dial gauge. —Deflection at the center of the rotor should not exceed 0.10mm (0.
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 Repair 4. Visually inspect the upper bearing (bw) and lower bearing (bs) for wear, corrosion or rust. Manually test the for any side to side movement or vibration. —Replace every 6,000 hours of service or one year, whichever comes first. 5. Visually inspect mechanical seal (bc) for wear, cracks or damage. Look carefully at flexible components, replace if deformed. Note: Pay particular attention to the sealing faces that butt up against each other.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 bd wc_gr000595 Repair.
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 6.7.3 Repair Motor Testing Test Stator Insulation Resistance 1. Dry stator thoroughly and allow it to cool before testing. 2. Measure resistance between stator’s lead wire and motor frame using Megger tester. —Replace stator if test results fall below 20 MΩ. Test Stator Continuity Test continuity between phase wire ends. —Replace stator if any breaks are found. Test Wire Resistance Measure resistance of each phase using Megger tester.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 6.7.3.1 Motor Reassembly Note: If, upon inspection and testing, a pump component requires replacement, use only original manufacturer’s replacement cables complete with anti-wicking block assembly and certified for submersible use. Note: Use only new gaskets and o-rings when rebuilding pump. 1. Lay the bearing cover (bt) over the shaft of the rotor (bv). 2. Slide lower bearing (bs) onto shaft of rotor (bv) and secure with locking ring (br).
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 Repair bp bv bs bt wc_gr000699 bp bq bu bv bs bt wc_gr000650 6. Secure the bearing cover (bt) to the bearing housing (bp) with four bolts (bu). See graphic wc_gr000650. 7. Assemble mechanical seal (bc) to rotor shaft. See graphic wc_gr000649. bc wc_gr000649 8. With the stator inside the motor frame, take the assembled rotor (bg) and carefully slide it inside the stator (f). 9.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 10. Set volute (av) rightside up on a clean, flat surface. 11. Install o-ring (bn) and gasket (bk) to volute (av). 12. Install seal (bj) to volute (av). See graphic wc_gr000648. be av bj wc_gr000648 13. Secure retaining plate (be) to volute using four screws (bi). 14. Secure oil lifter (bd) to retaining plate (be) using two screws (bh). 15. Install the assembled volute over rotor shaft and mechanical seal.
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 Repair ax ay bb wc_gr000639 17. Position the key (bb) properly in the keyway of the rotor shaft. 18. Align and install impeller (az) over keyway of rotor shaft. Note: Impeller vanes may be very sharp due to excessive wear. Handle with care. 19. Install thread cover (al), lockwasher (am) and acorn nut (an). 20. Using a pneumatic wrench, tighten acorn nut (an). 21. Install gasket (ao), and suction cover (ap) to volute (av). 22.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 24. Add or remove additional gaskets (ao) to obtain recommended clearance. 25. Secure suction strainer (as) with three stud bolts (ar) and three washers (aq). 26. Position pump in upright position. 27. Install upper bearing (bw) to rotor shaft. 28. Replace gasket (a). 29. Replace large diameter o-ring (w) to outside diameter of cover housing (m). q p v o w m n wc_gr000629 30. Replace o-ring (v) to inside diameter of cover housing (m). 31.
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 Repair 37. Carefully lower housing cover into place. Note: Cover housing and rotor assembly must be perpendicular for the housing to slide into place. 38. Assemble four bolts (s) and four lockwashers (t) to cover housing. Assemble “L” bracket (u) in one of the four mounting holes. —Sequentially turn each bolt (ag) one-quarter turn until all four bolts are tight and the torque is distributed evenly.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 43. If hose coupling (j) was removed, reposition gasket (k) and hose coupling (j) to cover housing (m) and secure with four bolts (h) and lockwashers (i). 44. If lift handle (l) was removed, obtain keyring/warning plate combination and trap around one of the legs of lift handle before securing to cover housing with two bolts (r). Note: If keyring/warning plate is damaged, illegible or missing, replace it. 45.
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 Repair PS4 3703 Maximum head Maximum volume > > Amperage @ 220V < Amperage @ 440V < 15.8m (52ft) 1241.6 ltr/min (328gpm) full load 14.1A start 117.6A full load 7.1A start 58.8A PS3 5503 Maximum head Maximum volume > > Amperage @ 220V < Amperage @ 440V < 32.6m (107ft) 836.5 ltr/min (221gpm) full load 20.5A start 170.1A full load 10.3A start 85.1A PS4 5503 6.7.4 Repair.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 6.7.4.1 Impeller Disassembly 1. 2. 3. 4. 5. 6. Note: Draining oil is not required to disassemble, inspect or replace the impeller. However, if further disassembly and testing is required, drain oil. Prior to working on pump, all electrical power supply circuits must be disconnected. With pump on its side, remove three nuts (au), three washers (at) and suction strainer (as). Remove three stud bolts (ar) and three washers (aq) from volute (av).
PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 Repair —If measured distance between impeller is greater than 0.5mm (0.196in), pumping capacity drops. —If measured distance between impeller is less than 0.3mm (0.118in), impeller may contact volute, slow rotation, overload motor and cause premature failure. 6.7.4.4 Impeller Reassembly Note: If, upon inspection and testing, a pump component requires replacement, use only original manufacturer’s replacement parts. 1.
Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 7. Measure the distance between the impeller (az) and the volute (av) after assembly. Keep a recommended clearance of 0.3–0.5mm (0.118–0.196in). —If the measured distance between the impeller is greater than 0.5mm (0.196in), the pumping capacity drops. —If the measured distance between the impeller is less than 0.3mm (0.118in), the impeller may contact the volute and slow rotation, overload the motor causing premature failure. 8.
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF 6.8 Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF (10–15HP) 6.8.1 Power Supply Disassembly, Inspection, Testing and Reassembly 6.8.1.1 Power Supply Disassembly Note: Draining oil is not required to simply disassemble, inspect or test power supply. However, if further disassembly and testing of the motor is required, drain oil. 1. Clean top of cover housing (ap) thoroughly. 2.
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF ap e o wc_gr000701 —PS4 7503HH & PS4 7503HF, remove o-ring (h) from cable casing (g). —PS4 11003HH & PS4 11003HF, remove o-ring (t) from cable casing (s). —PS4 7503HH & PS4 7503HF, remove three bolts (ao), one bolt (au), one lockwasher (av) and “L” bracket (aw) secured to the housing cover (ap). —PS4 11003HH & PS4 11003HF, remove six bolts (au), six lockwashers (av) and “L” bracket (aw) secured to the housing cover (ap). See graphic wc_gr000433. 8.
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair 11. Loosen two screws (at) and remove thermal switch (as) from underside of housing cover (ap). See graphic wc_gr000629. Note: Leave three wire connections to thermal switch (as) attached. at as aq ar ap wc_gr000629 12. Remove large diameter o-ring (ar) from outside diameter and o-ring (aq) from the inside diameter of cover housing (ap). 13. Remove gasket (aa), plate (ac) and spring washer (ab). See graphic wc_gr000630. ab aa ac wc_gr000630 6.8.
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF —Replace the power supply cable if the outer sheath is damaged or exposing interior insulation or protective materials. No tape repair is permitted. G = Green B = Black W = White R = Red 1 = Coil 2 = Circle Thermal Protector 6.8.1.3 Power Supply Testing 1. Air test the cable insulation for resistance using a Megger tester between conductors. —Replace power cable (k) if readings fall below 30 MΩ. k wc_gr000643 2.
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair 6.8.1.4 Power Supply Reassembly Note: If, upon inspection and testing, a pump component requires replacement, use only original manufacturer’s replacement cables complete with anti-wicking block assembly and certified for submersible use. Note: Use only new gaskets and o-rings when rebuilding pump. 1. Replace gasket (aa). 2. Replace large diameter o-ring (ar) to outside diameter of cover housing (ap). at as aq am ar ap al wc_gr000629 3.
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF ab aa ac wc_gr000630 8. Position plate (ac) on top of stator. Line up cutouts in plate with protruding wires. 9. Gather loose wires and guide them through hole while at the same time lowering cover housing. Align with upper bearing, being careful not to damage spring washer (ab). Do not force. 10. Carefully lower housing cover into place. Note: Cover housing and rotor assembly must be perpendicular for the housing to slide into place.
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair 11. Sequentially turn each bolt one-quarter turn until all bolts are tight and the torque is distributed evenly. —PS4 7503HH & PS4 7503HF only, assemble one socket-hex bolt (aj) and one lockwasher (ak) to cover housing. Tighten so torque is distributed evenly. —PS4 7503HH & PS4 7503HF, replace o-ring (h) to the underside of cable casing (g). —PS4 11003HH & PS4 11003HF, replace o-ring (t) to the underside of cable casing (s).
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF 13. Push wires and their connections into the hole of the protruding boss, lining up cable cover (g) or (s) with four mounting holes. —PS4 7503HH & PS4 7503HF, press cable cover (g) down and secure with four bolts (f). Alternately tighten each bolt one-quarter turn until cable cover (g) is securely sealed and the torque is evenly distributed. —PS4 11003HH & PS4 11003HF, press cable cover (s) down and secure with four bolts (r).
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair PS4 7503HF Maximum head Maximum volume > > Amperage @ 220V < Amperage @ 440V < 26.51m (87ft) 1767.5 ltr/min (467gpm) full load 26.8A start 237A full load 13A start 118.7A PS4 11003HH Maximum head Maximum volume > > Amperage @ 220V < Amperage @ 440V < 43.28m (142ft) 1211.1 ltr/min (320gpm) full load 39.9A start 311.9A full load 19.9A start 156.5A PS411003HF 6.8.
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF —PS4 7503HH & PS4 7503HF, remove four bolts (f) that secure cable casing (g) in place. —PS4 11003HH & PS4 11003HF, remove four bolts (r) that secure cable casing (t) in place. 5. Unscrew hook (q) and release chain (p) from “L” bracket (aw). 6. Pull power cable (k) up exposing the red, white, black and green wire connections. 7. Remove four outer shrink tubes (d) and four inner shrink tubes (c). 8.
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair —PS4 11003HH & PS4 11003HF, remove six bolts (au), six lockwashers (av) and “L” bracket (aw) secured to the housing cover (ap). 9. Remove the lift handle (an). 10. PS4 7503HH & PS4 7503HF only, remove one hex-socket bolt (aj) and one lockwasher (ak) securing the housing cover (ap) to the motor frame (ae). 11. It is not necessary to remove hose coupling (ah) or (ay) unless they are damaged and need to be replaced. 12.
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF ab aa ac wc_gr000630 16. Turn pump on its side, remove three nuts (bm), three washers (bh), plate (bk) and suction strainer (bj). 17. Remove three stud bolts (bi) and three washers (bh). Remove three bolts (bb), three washers (ba) and suction cover (bg). —Remove any gaskets (bf) between suction cover and volute. These gaskets are used as shims to adjust impeller clearance. 18. Using a pneumatic wrench, remove acorn nut (be).
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair 20. Remove the key (bs) from the rotor shaft for inspection. bn bp bq bs wc_gr000703 wc_gr000708 21. Remove four bolts (cc) and four lockwashers (cd) that secures the volute (bn) from the top. Remove two long bolts (cp) and two lockwashers (co) that secures the volute (bn) from the bottom. 22. Remove the volute (bn) from the motor frame (ae) and set right side up on a clean, flat surface. 23. Remove gasket (cb) from motor frame (ae). 24.
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF cl bx by cm cn wc_gr000435 wc_gr000702 27. Flip the oil housing (cn) over and remove the oil seal (cm). 28. Remove four part portion of mechanical seal (cj) from rotor shaft. See graphic wc_gr000704. cj wc_gr000704 29. Carefully pull rotor, bearings and bearing housing as an assembly (cr) from stator. Note: Use caution when pulling rotor to avoid scratching the outer surface of the rotor.
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair bu cf ch ce wc_gr000706 30. Remove four bolts (ce) and bearing cover (cf). 6.8.2.2 Motor Inspection cv cu cs wc_gr000645 1. Visually inspect rotor (cs) for corrosion, wear or damaged threads. 2. Measure the rotor (cs) for deflection using a dial gauge. —Deflection at the center of the rotor should not exceed 0.10mm (0.0039in). —Deflection at the pump end of the shaft should not exceed 0.08mm (0.0031in). 3. Measure shaft diameter of rotor (cs).
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF as wc_gr000644 6. Visually inspect the thermal switch (as) for damage to insulation materials, water or oil intrusion, heat discoloration of bi-metal disc, or damage to bi-metal disc. —Check to assure the lead wires of the stator windings are correctly and securely connected to the protector. —Check for disconnection of lead wires, short-circuit, coil-burn, or incorrect wiring. 7. Visually inspect oil lifter (ck).
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair Test Wire Resistance Measure resistance of each phase using Megger tester. —Replace stator if test results fluctuate more that ±5% of manufacturer’s specification. Locked Rotor Current Test Lock rotor and apply 25% of rated voltage by lock transformer or regulator. —Current measurement test results should be similar to rated current. Test Oil Chamber Pressure 1. After installing mechanical seal, attach a vacuum pump to oil housing. 2.
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF See graphic wc_gr000702. cl bx by cm cn wc_gr000702 wc_gr000435 4. Secure retaining plate (bx) to oil housing (cn) using six screws (cl). 5. Secure oil lifter (ck) to retaining plate (bx) using two screws (bw). The assembly is complete. Set the oil housing assembly (cz) aside in a clean, dust free area. 6. Second, assemble the bearing housing assembly (bg). Place the bearing housing (ch) upside down on a clean, flat surface.
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair ct cs cf cu wc_gr000698 9. Slide lower bearing (cu) onto shaft of rotor (cs) and secure with locking ring (ct). 10. Take the bearing housing (ch) and guide it through the shaft of the rotor (cs). See graphic wc_gr000699. ch ce cf wc_gr000699 wc_gr000706 11. Secure the bearing cover (cf) to the bearing housing (ch) with four bolts (ce). 12.
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF 14. Sequentially turn each bolt (bv) one-quarter turn until all four bolts are tight and the torque is distributed evenly. 15. Assemble mechanical seal (cj) to rotor shaft. 16. Pick up the pre-assembled oil housing (cz) and slide over rotor shaft. Secure with four bolts (ca) and four lockwashers (bz). 17. Sequentially turn each bolt (ca) one-quarter turn until all four bolts are tight and the torque is distributed evenly. 18.
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair bn bp bq bs wc_gr000708 22. Align and install impeller (br) over keyway of rotor shaft. Note: Impeller vanes may be very sharp due to excessive wear. Handle with care. 23. Install thread cover (bc), lockwasher (bd) and acorn nut (be). 24. Using a pneumatic wrench, tighten acorn nut (be). 25. Install gasket (bf), and suction cover (bg) to volute (bn). 26. Secure suction cover (bg) with three bolts (bb) and three washers (ba). 27.
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF 28. Add or remove additional gaskets (bf) to obtain recommended clearance. 29. Secure suction strainer (bj) with three stud bolts (bi) and three washers (bh). —Longest threaded end goes into volute. 30. Position pump in upright position. 31. Replace gasket (aa). 32. Replace large diameter o-ring (ar) to outside diameter of cover housing (ap). at as aq am ar ap al wc_gr000629 33. Replace o-ring (aq) to inside diameter of cover housing (ap). 34.
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair ab aa ac wc_gr000630 38. Position plate (ac) on top of stator. Line up cutouts in plate with protruding wires. 39. Gather loose wires and guide them through hole while at the same time lowering cover housing. Align with upper bearing, being careful not to damage spring washer (ab). Do not force. 40. Carefully lower housing cover into place. Note: Cover housing and rotor assembly must be perpendicular for the housing to slide into place. 41.
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF 42. Sequentially turn each bolt one-quarter turn until all bolts are tight and the torque is distributed evenly. —PS4 7503HH & PS4 7503HF only, assemble one socket-hex bolt (aj) and one lockwasher (ak) to cover housing. Tighten so torque is distributed evenly. —PS4 7503HH & PS4 7503HF, replace o-ring (h) to the underside of cable casing (g). —PS4 11003HH & PS4 11003HF, replace o-ring (t) to the underside of cable casing (s).
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair 44. Push wires and their connections into the hole of the protruding boss, lining up cable cover (g) or (s) with four mounting holes. —PS4 7503HH & PS4 7503HF, press cable cover (g) down and secure with four bolts (f). Alternately tighten each bolt one-quarter turn until cable cover (g) is securely sealed and the torque is evenly distributed. —PS4 11003HH & PS4 11003HF, press cable cover (s) down and secure with four bolts (r).
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF PS4 7503HF Maximum head Maximum volume > > Amperage @ 220V < Amperage @ 440V < 26.51m (87ft) 1767.5 ltr/min (467gpm) full load 26.8A start 237.3A full load 13.4A start 118.7A PS4 11003HH Maximum head Maximum volume > > Amperage @ 220V < Amperage @ 440V < 43.28m (142ft) 1211.1 ltr/min (320gpm) full load 39.9A start 311.9A full load 19.9A start 156.5A PS4 11003HF 6.8.
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair 3. Remove three stud bolts (bi) and three washers (bh). Remove three bolts (bb), three washers (ba) and suction cover (bg). —Remove any gaskets (bf) between suction cover and volute. These gaskets are used as shims to adjust impeller clearance. 4. Using a pneumatic wrench, remove acorn nut (be). Remove lockwasher (bd) and thread cover (bc). Note: Impeller vanes may be very sharp due to excessive wear. Handle with care. 5. Remove impeller (br).
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF 3. Visually inspect volute (bn) for wear and damage. Look for signs of wear on volute cutwaters and surfaces facing impeller. br wc_gr000709 6.8.3.3 Impeller Clearance 1. Measure the distance between impeller and volute after assembly. Keep a recommended clearance of 0.3–0.5mm (0.118–0.196in). —If measured distance between impeller is greater than 0.5mm (0.196in), pumping capacity drops. —If measured distance between impeller is less than 0.3mm (0.
PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF Repair 4. Using a pneumatic wrench, tighten acorn nut (be). 5. Install gasket (bf), and suction cover (bg) to volute (bn). 6. Secure suction cover (bg) with three bolts (bb) and three washers (ba). 7. Measure the distance between the impeller (br) and the volute (bn) after assembly. Keep a recommended clearance of 0.3–0.5mm (0.118–0.196in). —If the measured distance between the impeller is greater than 0.5mm (0.196in), the pumping capacity drops.
Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF 12. Performance test pump. Test results should be: PS4 7503HH Maximum head Maximum volume > > 35.36m (116ft) 1124.0 ltr/min (297gpm) > > 26.51m (87ft) 1767.5 ltr/min (46gpm) > > 43.28m (142ft) 1211.1 ltr/min (320gpm) PS4 7503HF Maximum head Maximum volume PS4 11003HH Maximum head Maximum volume PS4 11003HF Maximum head Maximum volume Repair.fm > > 204 27.
Troubleshooting 7. Troubleshooting Problem Possible Causes Pump fails to start. 1. No power is supplied (i.e. power outage). 1. Contact electric power company or an electrical repair shop. 2. Open circuit or poor connection of the cable assembly 2. Check if there is an open circuit in the cable assembly or wiring. 3. Impeller is obstructed. 3. Inspect the pump and remove the obstruction. 1. Impeller is obstructed. 1. Inspect the pump and remove the obstruction. 2. Voltage drop. 2.
Troubleshooting Problem The pump’s head and pumping volume is decreased. Possible Causes 3. The strainer is obstructed 3. Remove the obstruction. or buried. Place a concrete block under the pump to prevent the pump from picking up debris. 4. The motor rotates in reverse. The pump generates noise 1. The bearing of the motor or vibration. may be damaged. Troubleshooting.fm Measures 206 4. Interchange the power supply terminal leads. 1.
Threadlock and Sealant 8. Threadlock and Sealant Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker equipment. 8.
Torque Values 9. Metric Fasteners (DIN) Torque Values 9.1 Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) 8.8 Size 10.9 WRENCH SIZE 12.9 ft lb N•m ft lb N•m ft lb N•m Inch Metric Inch Metric M3 *11 1.2 *14 1.6 *19 2.1 7/32 5.5 – 2.5 M4 *26 2.9 *36 4.1 *43 4.9 9/32 7 – 3 M5 *53 6.0 6 8.
Inch Fasteners (SAE) 9.2 Torque Values Inch Fasteners (SAE) Size ft lb N•m ft lb N•m ft lb N•m Inch Metric Inch Metric No.4 *6 0.7 *14 1.0 *12 1.4 1/4 5.5 3/32 – No.6 *12 1.4 *17 1.9 *21 2.4 5/16 8 7/64 – No.8 *22 2.5 *31 3.5 *42 4.7 11/32 9 9/64 – No.10 *32 3.6 *45 5.1 *60 6.8 3/8 – 5/32 – 1/4 6 8.
Torque Values 8-Sealants-Torque.
PS2 400 Electrical Schematics 10. Electrical Schematics 10.1 PS2 400 1 = Frame Grounding 2 = Main Coil 3 = Capacitor 4 = Aux. Coil 5 = Protector 6 = Ground R = Red Br = Brown L = Blue ESchem.
Electrical Schematics PS2 500, PSA2 500 10.2 PS2 500, PSA2 500 1 = Ground 2 = Frame Grounding 3 = Main Coil 4 = Capacitor 5 = Aux. Coil 6 = Miniature Protector ESchem.
PS2 500, PSA2 500 ESchem.fm Electrical Schematics 1 = Ground 2 = Frame Grounding 3 = Transformer 4 = Level Relay Unit 5 = Triac 6 = Electrode 7 = Capacitor 8 = Aux.
Electrical Schematics PS2 750 10.3 PS2 750 1 = Ground 2 = Frame Grounding 3 = Circle Thermal Protector 4 = Aux. Coil 5 = Heater 6 = Main Coil 7 = Centrifugal Switch 8 = Capacitor R = Red Br = Brown L = Blue ESchem.
PS3 1500 Electrical Schematics 10.4 PS3 1500 1 = Bi-metal (to power supply) 2 = Protector 3 = Heater 4 = Main Coil 5 = Aux. Coil 6 = Capacitor 7 = Centrifugal Switch R = Red Br = Brown L = Blue ESchem.
Electrical Schematics PS3 2200 10.5 PS3 2200 1 = Bi-metal (to power supply) 2 = Protector 3 = Heater 4 = Centrifugal Switch 5 = Main Coil 6 = Aux. Coil R = Red Br = Brown L = Blue ESchem.
PS2 1503, PS3 1503 Electrical Schematics 10.6 PS2 1503, PS3 1503 G = Green B = Black W = White R = Red ESchem.
Electrical Schematics PS2 2203, PS2 2203 10.7 PS2 2203, PS2 2203 G = Green B = Black W = White R = Red ESchem.
PS2 3703, PS3 3703, PS4 3703 Electrical Schematics 10.8 PS2 3703, PS3 3703, PS4 3703 G = Green B = Black W = White R = Red ESchem.
Electrical Schematics PS3 5503, PS4 5503 10.9 PS3 5503, PS4 5503 G = Green B = Black W = White R = Red ESchem.
PS4 7503HH, PS4 7503HF Electrical Schematics 10.10 PS4 7503HH, PS4 7503HF G = Green B = Black W = White R = Red ESchem.
Electrical Schematics PS4 11003HH, PS4 11003HF 10.11 PS4 11003HH, PS4 11003HF G = Green B = Black W = White R = Red ESchem.
Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-354 02 - 0 · Fax: +49 - (0)89-354 02-390 Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : +1-(1)(262) 255-0500 · Fax: +1-(1)(262) 255-0550 · Tel. : (800) 770-0957 Wacker Asia Pacific Operations · Sunley Center, Unit 912, 9/F · 9 Wing Qin Street, Kwai Chung, N.T. · Hong Kong · Tel.
