Wacker Neuson PS 2 500 Repair Manual

www.wackergroup.com1 Phase Submersible Pumps3 Phase Submersible PumpsPS2 400PS2 500PSA2 500PS2 750PS3 1500PS3 2200PS2 1503PS3 1503PS2 2203PS3 2203PS3

Technical Data PS2 400wc_td000034gb_spec.fm 63.1.2 Operating Specifications – PS2 400 (60Hz)*The weight (mass) given above is the operating weight of

Repair PS2 750Repair.fm 9639.Performance test pump. Test results should be:6.4.3 Impeller Disassembly, Inspection, Testing andReassembly6.4.3.1 Impell

PS2 750 RepairRepair.fm 976. Pull impeller (am). A puller, part number 0151079, may berequired. Remove key (be) from rotor shaft for inspection.6.4.3.

Repair PS2 750Repair.fm 986.4.3.4 Impeller ReassemblyNote: If, upon inspection and testing, a pump component requiresreplacement, use only original ma

PS2 750 RepairRepair.fm 997. Measure distance between impeller and volute after assembly.Keep a recommended clearance of 0.3–0.5mm (0.118–0.196in).—If

Repair PS3 1500, PS3 2200Repair.fm 1006.5 PS3 1500, PS3 2200 (2–3HP)6.5.1 Power Supply Disassembly, Inspection, Testing andReassembly6.5.1.1 Power Sup

PS3 1500, PS3 2200 RepairRepair.fm 1017. It is not necessary to remove hose coupling (h) or lift handle (a)unless they are damaged and need to be repl

Repair PS3 1500, PS3 2200Repair.fm 1026.5.1.2 Power Supply Inspection1. Measure the cable length. The specified cable length is 9.8m (32ft),subject to

PS3 1500, PS3 2200 RepairRepair.fm 1033 = Heater4 = Main Coil5=Aux.Coil6 = Capacitor7 = Centrifugal SwitchR=Red W=WhiteBr = Brown G = GreenL = Blue G/

Repair PS3 1500, PS3 2200Repair.fm 104R=Red W=WhiteBr = Brown G = GreenL = Blue G/Y = Green/Yellow

PS3 1500, PS3 2200 RepairRepair.fm 1056.5.1.3 Power Supply Testing1. Air test the cable insulation for resistance using a Megger testerbetween conduct

PS2 400 Technical Datawc_td000034gb_spec.fm 73.1.3 Operating Specifications – PS2 400 (50Hz)*The weight (mass) given above is the operating weight of

Repair PS3 1500, PS3 2200Repair.fm 1066.5.1.4 Power Supply ReassemblyNote: If, upon inspection and testing, a pump component requiresreplacement, use

PS3 1500, PS3 2200 RepairRepair.fm 1075. If not done previously, seat cone shaped rubber end of power cable(s) inside cable casing. Tighten casing cla

Repair PS3 1500, PS3 2200Repair.fm 1086. Holding the power cable (s) directly above housing cover (j), pushthree wires inside the pump, aligning the f

PS3 1500, PS3 2200 RepairRepair.fm 10910.Screw oil plug (op) with plug gasket (pg) into the oil housing andtighten.11.Pre-test pump to verify proper o

Repair PS3 1500, PS3 2200Repair.fm 1106.5.2 Motor Disassembly, Inspection, Testing andReassembly6.5.2.1 Motor DisassemblyNote: Motor disassembly for t

PS3 1500, PS3 2200 RepairRepair.fm 1116. Remove key (bi) from rotor shaft.7. Remove dust seal and sleeve (ak & al) as one piece.8. Remove wear rin

Repair PS3 1500, PS3 2200Repair.fm 11214.Remove three piece portion of mechanical seal (aq).15.Turn pump upright and clean top of cover housing (j) th

PS3 1500, PS3 2200 RepairRepair.fm 113—PS3 2200, separate the motor wires from the power cable wires.19.Remove four bolts (c), lockwashers (d) and fla

Repair PS3 1500, PS3 2200Repair.fm 11425.Remove motor bracket (mb).Note: First loosen screw of any wire connections to terminal box (q).Bundle wires b

PS3 1500, PS3 2200 RepairRepair.fm 1156. Visually inspect the Circle Thermal Protector (CTP) for damage toinsulation materials, water or oil intrusion

Technical Data PS2 500, PSA2 500wc_td000034gb_spec.fm 83.2 PS2 500, PSA2 5003.2.1 Standard Specifications – PS2 500, PSA2 500OIL HOUSING LUBRICANTUse

Repair PS3 1500, PS3 2200Repair.fm 116Test Oil Chamber Pressure1. After installing mechanical seal, attach a vacuum pump to oilhousing.2. Raise negati

PS3 1500, PS3 2200 RepairRepair.fm 1175. Secure lower half of centrifugal switch (bp) with two screws (bo).6. Secure upper half of centrifugal switch

Repair PS3 1500, PS3 2200Repair.fm 11813.Slide capacitor (o) into cover (p) until rear of capacitor contacts “L”shaped stop.Note: To tighten screw (n)

PS3 1500, PS3 2200 RepairRepair.fm 11923.Position o-ring (w) to lip of motor frame (bc).24.Place oil housing in upright position.—Replace seal (ls) if

Repair PS3 1500, PS3 2200Repair.fm 12035.While keeping impeller and rotor shaft from rotating, tighten hex nut(ao) and acorn nut (ap).36.Align three h

PS3 1500, PS3 2200 RepairRepair.fm 121—PS3 1500, slide heat shrinks back over each the three exposedwire connections and apply heat to collapse insula

Repair PS3 1500, PS3 2200Repair.fm 1226.5.3 Impeller Disassembly, Inspection, Testing andReassembly6.5.3.1 Impeller DisassemblyNote: Draining oil is n

PS3 1500, PS3 2200 RepairRepair.fm 1233. Visually inspect volute (aa) for wear and damage. Look for signs ofwear on volute cutwaters and surfaces faci

Repair PS3 1500, PS3 2200Repair.fm 1243. Install washer (an) and hex nut (ao).4. Holding the impeller and rotor shaft from rotating, tighten hex nut(a

PS2 1503, PS3 1503, PS2 2203, PS3 2203 RepairRepair.fm 1256.6 PS2 1503, PS3 1503, PS2 2203, PS3 2203 (2–5HP)6.6.1 Power Supply Disassembly, Inspection

PS2 500, PSA2 500 Technical Datawc_td000034gb_spec.fm 93.2.2 Operating Specifications – PS2 500, PSA2 500 (60 Hz)*The weight (mass) given above is the

Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203Repair.fm 12610.Lift housing cover (n) and tip it on its side, allowing it to rest on topof the motor fra

PS2 1503, PS3 1503, PS2 2203, PS3 2203 RepairRepair.fm 1274. Inspect the sheath for cuts, gouges, cracking, hardening orabrasive wear.—Replace the pow

Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203Repair.fm 1283. Submerse the cable in a water tank with conductors on both endsof cable above the water l

PS2 1503, PS3 1503, PS2 2203, PS3 2203 RepairRepair.fm 129See graphic wc_gr000630.8. Position plate (b) on top of stator. Line up cutouts in plate wit

Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203Repair.fm 13018.If lift handle (c) was removed, obtain keyring/warning platecombination and trap around o

PS2 1503, PS3 1503, PS2 2203, PS3 2203 RepairRepair.fm 131PS2 2203PS3 22036.6.2 Motor Disassembly, Inspection, Testing andReassembly6.6.2.1 Motor Disa

Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203Repair.fm 1323. With pump on its side, remove three bolts (bb), three washers (ba)and strainer (az).4. Re

PS2 1503, PS3 1503, PS2 2203, PS3 2203 RepairRepair.fm 1337. Remove key (aq),shim(be) and sleeve (bd) from rotor shaft.See graphic wc_gr000639.8. Turn

Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203Repair.fm 13414.Carefully pull rotor (ap) from stator (am) with upper bearing (ao)and lower bearing (ar)

PS2 1503, PS3 1503, PS2 2203, PS3 2203 RepairRepair.fm 135Note: Pay particular attention to the sealing faces that butt upagainst each other. They are

Technical Data PS2 500, PSA2 500wc_td000034gb_spec.fm 10Operating Specifications – PS2 500, PSA2 500 (50 Hz)*The weight (mass) given above is the oper

Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203Repair.fm 136—Replace stator (az) if test results fall below 20 MΩ.Test Stator ContinuityTest continuity

PS2 1503, PS3 1503, PS2 2203, PS3 2203 RepairRepair.fm 1371. With stator (am) inside motor frame (aa), set motor frame uprighton a wooden fixture or e

Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203Repair.fm 138Note: Cover housing and rotor assembly must be perpendicular forthe housing to slide into pl

PS2 1503, PS3 1503, PS2 2203, PS3 2203 RepairRepair.fm 13923.Turn volute (al) over so it sits rightside up on a clean, flat surface.24.Assemble o-ring

Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203Repair.fm 14029.Pick-up assembled volute and assemble to motor frame (aa) withfour bolts (ai) and four lo

PS2 1503, PS3 1503, PS2 2203, PS3 2203 RepairRepair.fm 14139.Pour 740ml (25.1fl-oz) of clean oil into oil housing.Note: Use SAE 10W/20W oil, Turbine o

Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203Repair.fm 142PS2 2203PS3 22036.6.4 Impeller Disassembly, Inspection, Testing andReassembly6.6.4.1 Impelle

PS2 1503, PS3 1503, PS2 2203, PS3 2203 RepairRepair.fm 1431. Prior to working on the pump, all electrical power supply circuitsmust be disconnected.2.

Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203Repair.fm 144—If measured distance between impeller is greater than 0.5mm(0.196in), pumping capacity drop

PS2 1503, PS3 1503, PS2 2203, PS3 2203 RepairRepair.fm 1453. Install washer (an) and hex nut (ao).4. Holding the impeller and rotor shaft from rotatin

PS2 750 Technical Datawc_td000034gb_spec.fm 113.3 PS2 7503.3.1 Standard Specifications – PS2 750OIL HOUSING LUBRICANTUse Lightweight 32 Viscosity Tubi

Repair PS2 1503, PS3 1503, PS2 2203, PS3 2203Repair.fm 146PS2 2203PS3 2203Maximum head > 30.5m (100 ft)Maximum volume > 500 ltr/min (132gpm)Ampe

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 1476.7 PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 (5–10HP)6.7.1 Power Supply Di

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 1489. Remove four bolts (s) , four lockwashers (t) and “L” bracket (u)secured to the

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 1496.7.1.2 Power Supply Inspection1. Measure the cable length. The specified cable le

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 1506.7.1.3 Power Supply TestingAir Test CableAir test the cable insulation for resist

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 1511. Replace gasket (a).2. Replace large diameter o-ring (w) to outside diameter of

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 1528. Position plate (e) on top of stator. Line up cutouts in plate withprotruding wi

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 15316.If hose coupling (j) was removed, reposition gasket (k) and hosecoupling (j) to

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 154PS4 3703PS3 5503PS4 55036.7.2 Motor Disassembly, Inspection, Testing andReassembly

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 1556. Unscrew hook (ai) and release chain (ah) from “L” bracket (u).7. Pull power cab

Technical Data PS2 750wc_td000034gb_spec.fm 123.3.2 Operating Specifications – PS2 750 (60 Hz)*The weight (mass) given above is the operating weight o

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 15613.Loosen two screws (q) and remove thermal switch (p) fromunderside of housing co

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 15717.Removethreestudbolts(ar) and three washers (aq) holdingsuction cover (ap) to vo

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 15821.Remove oil seal (ax) and shim (ay).See graphic wc_gr000639.22.Remove four bolts

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 15927.Flip the volute (av) over and remove the oil seal (aw).28.Remove four part port

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 16030.Remove four bolts (ba) and bearing housing (bp).31.Remove o-ring (bq) and two p

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 1614. Visually inspect the upper bearing (bw) and lower bearing (bs) forwear, corrosi

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 162bdwc_gr000595

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 1636.7.3 Motor TestingTest Stator Insulation Resistance1. Dry stator thoroughly and a

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 1646.7.3.1 Motor ReassemblyNote: If, upon inspection and testing, a pump component re

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 1656. Secure the bearing cover (bt) to the bearing housing (bp) with fourbolts (bu).S

PS2 750 Technical Datawc_td000034gb_spec.fm 133.3.3 Operating Specifications – PS2 750 (50 Hz)*The weight (mass) given above is the operating weight o

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 16610.Set volute (av) rightside up on a clean, flat surface.11.Install o-ring (bn) an

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 16717.Position the key (bb) properly in the keyway of the rotor shaft.18.Align and in

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 16824.Add or remove additional gaskets (ao) to obtain recommendedclearance.25.Secure

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 16937.Carefully lower housing cover into place.Note: Cover housing and rotor assembly

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 17043.If hose coupling (j) was removed, reposition gasket (k) and hosecoupling (j) to

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 171PS4 3703PS3 5503PS4 55036.7.4 Impeller Disassembly, Inspection, Testing andReassem

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 1726.7.4.1 Impeller DisassemblyNote: Draining oil is not required to disassemble, ins

PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503 RepairRepair.fm 173—If measured distance between impeller is greater than 0.5mm(0.196in), pumping cap

Repair PS2 3703, PS3 3703, PS4 3703, PS3 5503, PS4 5503Repair.fm 1747. Measure the distance between the impeller (az) and the volute (av)after assembl

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 1756.8 PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF (10–15HP)6.8.1 Power Supply D

Technical Data PS3 1500, PS3 2200wc_td000034gb_spec.fm 143.4 PS3 1500, PS3 22003.4.1 Standard Specifications – PS3 1500, PS3 2200OIL HOUSING LUBRICANT

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 176—PS4 7503HH & PS4 7503HF, remove o-ring (h) from cablecasing (g).—PS4 11003HH

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 17711.Loosen two screws (at) and remove thermal switch (as) fromunderside of housing

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 178—Replace the power supply cable if the outer sheath is damagedor exposing interior

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 1796.8.1.4 Power Supply ReassemblyNote: If, upon inspection and testing, a pump compo

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 1808. Position plate (ac) on top of stator. Line up cutouts in plate withprotruding w

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 18111.Sequentially turn each bolt one-quarter turn until all bolts are tightand the t

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 18213.Push wires and their connections into the hole of the protrudingboss, lining up

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 183PS4 7503HFPS4 11003HHPS411003HF6.8.2 Motor Disassembly, Inspection, Testing andRea

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 184—PS4 7503HH & PS4 7503HF, remove four bolts (f) that securecable casing (g) in

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 185—PS4 11003HH & PS4 11003HF, remove six bolts (au),sixlockwashers (av) and “L”

PS3 1500, PS3 2200 Technical Datawc_td000034gb_spec.fm 153.4.2 Operating Specifications – PS3 1500, PS3 2200 (60 Hz)*The weight (mass) given above is

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 18616.Turn pump on its side, remove three nuts (bm), three washers (bh),plate (bk) an

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 18720.Remove the key (bs) from the rotor shaft for inspection.21.Remove four bolts (c

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 18827.Flip the oil housing (cn) over and remove the oil seal (cm).28.Remove four part

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 18930.Remove four bolts (ce) and bearing cover (cf).6.8.2.2 Motor Inspection1. Visual

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 1906. Visually inspect the thermal switch (as) for damage to insulationmaterials, wat

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 191Test Wire ResistanceMeasure resistance of each phase using Megger tester.—Replace

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 192See graphic wc_gr000702.4. Secure retaining plate (bx) to oil housing (cn) using s

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 1939. Slide lower bearing (cu) onto shaft of rotor (cs) and secure withlocking ring (

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 19414.Sequentially turn each bolt (bv) one-quarter turn until all four boltsare tight

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 19522.Align and install impeller (br) over keyway of rotor shaft.Note: Impeller vanes

Technical Data PS2 1503, PS3 1503wc_td000034gb_spec.fm 163.5 PS2 1503, PS3 15033.5.1 Standard Specifications – PS2 1503, PS3 1503Applicable Liquids,Co

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 19628.Add or remove additional gaskets (bf) to obtain recommendedclearance.29.Secure

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 19738.Position plate (ac) on top of stator. Line up cutouts in plate withprotruding w

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 19842.Sequentially turn each bolt one-quarter turn until all bolts are tightand the t

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 19944.Push wires and their connections into the hole of the protrudingboss, lining up

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 200PS4 7503HFPS4 11003HHPS4 11003HF6.8.3 Impeller Disassembly, Inspection, Testing &a

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 2013. Removethreestudbolts(bi) and three washers (bh).Removethree bolts (bb), three w

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 2023. Visually inspect volute (bn) for wear and damage. Look for signs ofwear on volu

PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HF RepairRepair.fm 2034. Using a pneumatic wrench, tighten acorn nut (be).5. Install gasket (bf), and su

Repair PS4 7503HH, PS4 7503HF, PS4 11003HH, PS4 11003HFRepair.fm 20412.Performance test pump. Test results should be:PS4 7503HHPS4 7503HFPS4 11003HHPS

TroubleshootingTroubleshooting.fm 2057. TroubleshootingProblem Possible Causes MeasuresPump fails to start. 1. No power is supplied(i.e. power outage)

PS2 1503, PS3 1503 Technical Datawc_td000034gb_spec.fm 173.5.2 Operating Specifications – PS2 1503, PS3 1503 (60 Hz)*The weight (mass) given above is

TroubleshootingTroubleshooting.fm 206The pump’s head andpumping volume isdecreased.3. The strainer is obstructedor buried.3. Remove the obstruction.Pl

Threadlock and Sealant8-Sealants-Torque.fm 2078. Threadlock and SealantThreadlocking adhesives and sealants are specified throughout thismanual by a n

Torque Values Metric Fasteners (DIN)8-Sealants-Torque.fm 2089. Torque Values9.1 Metric Fasteners (DIN)TORQUE VALUES (Based on Bolt Size and Hardness)

Inch Fasteners (SAE) Torque Values8-Sealants-Torque.fm 2099.2 Inch Fasteners (SAE)Size ft lb N•m ft lb N•m ft lb N•m Inch Metric Inch MetricNo.4 *6 0.

Torque Values Inch Fasteners (SAE)8-Sealants-Torque.fm 210

PS2 400 Electrical SchematicsESchem.fm 21110. Electrical Schematics10.1 PS2 4001 = Frame Grounding R = Red2 = Main Coil G = Green3 = Capacitor W = Whi

Electrical Schematics PS2 500, PSA2 500ESchem.fm 21210.2 PS2 500, PSA2 5001 = Ground L = Blue2 = Frame Grounding G = Green3 = Main Coil W = White4 = C

PS2 500, PSA2 500 Electrical SchematicsESchem.fm 2131 = Ground L = Blue2 = Frame Grounding G = Green3 = Transformer W = White4 = Level Relay Unit B =

Electrical Schematics PS2 750ESchem.fm 21410.3 PS2 7501 = Ground W = White2 = Frame Grounding B = Black3 = Circle Thermal Protector L = Blue4 = Aux. C

PS3 1500 Electrical SchematicsESchem.fm 21510.4 PS3 15001 = Bi-metal (to power supply)2=Protector3 = Heater4 = Main Coil5=Aux.Coil6 = Capacitor7 = Cen

Technical Data PS2 1503, PS3 1503wc_td000034gb_spec.fm 183.5.3 Operating Specifications – PS2 1503, PS3 1503 (50 Hz)*The weight (mass) given above is

Electrical Schematics PS3 2200ESchem.fm 21610.5 PS3 22001 = Bi-metal (to power supply)2 = Protector3 = Heater Cs = Starting Capacitor4 = Centrifugal S

PS2 1503, PS3 1503 Electrical SchematicsESchem.fm 21710.6 PS2 1503, PS3 1503G = Green 1 = CoilB = Black 2 = Circle Thermal ProtectorW=WhiteR=Red

Electrical Schematics PS2 2203, PS2 2203ESchem.fm 21810.7 PS2 2203, PS2 2203G = Green 1 = CoilB = Black 2 = Circle Thermal ProtectorW=WhiteR=Red

PS2 3703, PS3 3703, PS4 3703 Electrical SchematicsESchem.fm 21910.8 PS2 3703, PS3 3703, PS4 3703G = Green 1 = CoilB = Black 2 = Circle Thermal Protect

Electrical Schematics PS3 5503, PS4 5503ESchem.fm 22010.9 PS3 5503, PS4 5503G = Green 1 = CoilB = Black 2 = Circle Thermal ProtectorW=WhiteR=Red

PS4 7503HH, PS4 7503HF Electrical SchematicsESchem.fm 22110.10 PS4 7503HH, PS4 7503HFG = Green 1 = CoilB = Black 2 = Circle Thermal ProtectorW=WhiteR=

Electrical Schematics PS4 11003HH, PS4 11003HFESchem.fm 22210.11 PS4 11003HH, PS4 11003HFG = Green 1 = CoilB = Black 2 = Circle Thermal ProtectorW=Whi

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PS2 2203, PS3 2203 Technical Datawc_td000034gb_spec.fm 193.6 PS2 2203, PS3 22033.6.1 Standard Specifications – PS2 2203, PS3 2203Applicable Liquids,Co

Technical Data PS2 2203, PS3 2203wc_td000034gb_spec.fm 203.6.2 Operating Specifications – PS2 2203, PS3 2203 (60 Hz)*The weight (mass) given above is

PS2 2203, PS3 2203 Technical Datawc_td000034gb_spec.fm 213.6.3 Operating Specifications – PS2 2203, PS3 2203 (50 Hz)*The weight (mass) given above is

Technical Data PS2 3703, PS3 3703, PS4 3703wc_td000034gb_spec.fm 223.7 PS2 3703, PS3 3703, PS4 37033.7.1 Standard Specifications – PS2 3703, PS3 3703,

PS2 3703, PS3 3703, PS4 3703 Technical Datawc_td000034gb_spec.fm 233.7.2 Operating Specifications – PS2 3703, PS3 3703, PS4 3703 (60 Hz)*The weight (m

Technical Data PS2 3703, PS3 3703, PS4 3703wc_td000034gb_spec.fm 243.7.3 Operating Specifications – PS2 3703, PS3 3703, PS4 3703 (50 Hz)*The weight (m

PS3 5503, PS4 5503 Technical Datawc_td000034gb_spec.fm 253.8 PS3 5503, PS4 55033.8.1 Standard Specifications – PS3 5503, PS4 5503Applicable Liquids,Co

Table of Contentswc_bo0154618001enTOC.fm i1. Foreword 12. Safety Information 22.1 Operating and Electrical Safety ...

Technical Data PS3 5503, PS4 5503wc_td000034gb_spec.fm 263.8.2 Operating Specifications – PS3 5503, PS4 5503 (60 Hz)*The weight (mass) given above is

PS3 5503, PS4 5503 Technical Datawc_td000034gb_spec.fm 273.8.3 Operating Specifications – PS3 5503, PS4 5503 (50 Hz)*The weight (mass) given above is

Technical Data PS4 7503HH, PS4 7503HFwc_td000034gb_spec.fm 283.9 PS4 7503HH, PS4 7503HF3.9.1 Standard Specifications – PS4 7503HH, PS4 7503HFOIL HOUSI

PS4 7503HH, PS4 7503HF Technical Datawc_td000034gb_spec.fm 293.9.2 Operating Specifications – PS4 7503HH, PS4 7503HF (60 Hz)Model No. PS4 7503HH PS4 7

Technical Data PS4 7503HH, PS4 7503HFwc_td000034gb_spec.fm 303.9.3 Operating Specifications – PS4 7503HH, PS4 7503HF (50 Hz)*The weight (mass) given a

PS4 11003HH, PS4 11003HF Technical Datawc_td000034gb_spec.fm 313.10 PS4 11003HH, PS4 11003HF3.10.1 Standard Specifications – PS4 11003HH, PS4 11003HFO

Technical Data PS4 11003HH, PS4 11003HFwc_td000034gb_spec.fm 323.10.2 Operating Specifications – PS4 11003HH, PS4 11003HF (60 Hz)*The weight (mass) gi

PS4 11003HH, PS4 11003HF Technical Datawc_td000034gb_spec.fm 333.10.3 Operating Specifications – PS4 11003HH, PS4 11003HF (50 Hz)*The weight (mass) gi

General Operationwc_tx000111gb.fm 344. General Operation4.1 IntroductionThe information in General Operation does not in any way replace the model spe

General Operationwc_tx000111gb.fm 35Leakage of pump lubricants may cause pollution of water.Proper plug must be provided according to local codes and

Table of Contentswc_bo0154618001enTOC.fm ii

General Operationwc_tx000111gb.fm 36Preparing for InstallationBefore installing the pump at a work site, you will need to have thefollowing tools and

General Operationwc_tx000111gb.fm 37Note: On cable assembly handling, see Electrical Wiring.Avoid dry operation, which will not only lower performance

General Operationwc_tx000111gb.fm 38Connecting the power supplyBefore connecting wires to the terminal, make certain the power supplyis turned off (ci

General Operationwc_tx000111gb.fm 39Make sure the cable does not become excessively bent or twisted, anddoes not rub against a structure in a way that

General Operationwc_tx000111gb.fm 40• Using an AC voltmeter (tester), measure voltage at the terminals.Supply voltage tolerance: within ±5% of rated v

Elementary MaintenanceElem-Maintenance.fm 415. Elementary Maintenance5.1 Inspection of Lubrication Oil1. Drain the lubrication oil into a clean contai

Elementary MaintenanceElem-Maintenance.fm 42

PS Series Submersible Pumps RepairRepair.fm 436. Repair6.1 Special Tools for Pump Disassembly, Testing and Reassembly6.1.1 Machinery and Tools• Standa

Repair PS2 400Repair.fm 446.2 PS2 400 (1–2HP)6.2.1 Power Supply Disassembly, Inspection, Testing andReassembly6.2.1.1 Power Supply DisassemblyNote: Dr

PS2 400 RepairRepair.fm 459. Remove three bolts (j), three washers (k) and housing cover (l).10.Disconnect red, black and blue wire connections (wc) t

Forewordwc_tx000240gb.fm 11. ForewordThis manual provides information and procedures to safely operateand maintain this Wacker model. For your own saf

Repair PS2 400Repair.fm 461 = Frame Grounding R = Red2 = Main Coil G = Green3 = Capacitor W = White4 = Aux. Coil B = Black5=Protector L=Blue6 = Ground

PS2 400 RepairRepair.fm 476.2.1.3 Power Supply TestingAir Test CableAir test cable insulation for resistance using a Megger tester betweenconductors.—

Repair PS2 400Repair.fm 48—Replace capacitor when test indicator shakes continuously andcomes back quickly.6.2.1.4 Power Supply ReassemblyNote: If, up

PS2 400 RepairRepair.fm 49See graphic wc_gr000439.2. Reposition capacitor (o) inside two tangs of motor bracket (n).Note: A thin piece of double-sided

Repair PS2 400Repair.fm 505. Feed red, green and white wires, up through opening of housingcover (l).6. Align three holes of housing cover and assembl

PS2 400 RepairRepair.fm 51See graphic wc_gr00439.Note: Make note of orientation to motor bracket.4. If not done already, disconnect two (blue and blac

Repair PS2 400Repair.fm 5213.Pull rotor (an) with upper and lower ball bearings (am & ap) stillattached.14.Again, tuck motor leads inside motor fr

PS2 400 RepairRepair.fm 5318.Make note of thin metal piece (cw) and white plastic bushing (zz)that are separate parts of rubber plug (rp).6.2.2.2 Moto

Repair PS2 400Repair.fm 545. Visually inspect mechanical seal (ad) for wear, cracks or damage.Look carefully at flexible components, replace if deform

PS2 400 RepairRepair.fm 553. Hold the vacuum position for 10 seconds. The gauge shouldremain absolutely stable.—Replace mechanical seal upon failing v

Safety Informationwc_si000034gb.fm 22. Safety InformationThis manual contains DANGER, WARNING, CAUTION, and NOTEcallouts which must be followed to red

Repair PS2 400Repair.fm 56See graphic wc_gr000605.5. Center three-piece portion of mechanical seal (ad) on top of rubberplug.See graphic wc_gr000443.6

PS2 400 RepairRepair.fm 578. Gently insert three hex socket bolts (ak) and apply downward handpressure to oil housing (ag) while aligning holes. Assem

Repair PS2 400Repair.fm 5813.Apply a drop of clean pump oil to white plastic washer (wb) andinsert it inside lip so it is flush. Use a blunt screw dri

PS2 400 RepairRepair.fm 5921.Properly align rubber gasket (m) over top of motor bracket (n).Make sure knob located on under side of rubber gasket (m)

Repair PS2 400Repair.fm 60See graphic wc_gr000408.24.Reposition single ground wire (h) to motor bracket (n) and securewith screw (i).25.Feed red, gree

PS2 400 RepairRepair.fm 616.2.3 Impeller Disassembly, Inspection, Testing andReassembly6.2.3.1 Impeller DisassemblyNote: It is not necessary to drain

Repair PS2 400Repair.fm 626.2.3.3 Impeller ClearancePS2 400 is equipped with a semi-vortex impeller and has no specificclearance requirements.6.2.3.4

PS2 400 RepairRepair.fm 6310.Replace gasket (ah) on top of volute (aa).11.Lift and hold remaining pump assembly in an upright position, alignthree mou

Repair PS2 500, PSA2 500Repair.fm 646.3 PS2 500, PSA2 500 (2–3HP)6.3.1 Power Supply Disassembly, Inspection, Testing andReassembly6.3.1.1 Power Supply

PS2 500, PSA2 500 RepairRepair.fm 656.3.1.2 Power Supply Inspection1. Measure cable length. The specified cable length is 996 cm (392"),subject t

Safety Informationwc_si000034gb.fm 32.2 Information LabelsLabel MeaningA nameplate listing the Model Number, ItemNumber, Revision, and Serial Number i

Repair PS2 500, PSA2 500Repair.fm 661 = Ground L = Blue2 = Frame Grounding G = Green3 = Transformer W = White4 = Level Relay Unit B = Black5=Triac R=R

PS2 500, PSA2 500 RepairRepair.fm 676.3.1.3 Power Supply TestingAir Test CableAir test the cable insulation for resistance using a Megger testerbetwee

Repair PS2 500, PSA2 500Repair.fm 68—Capacitor can be re-used when the test indicator shakes onceand comes back slowly.—Replace capacitor when the tes

PS2 500, PSA2 500 RepairRepair.fm 691. Properly align rubber gasket (n) over top of motor bracket (o).Make sure knob located on the under side of gask

Repair PS2 500, PSA2 500Repair.fm 70See graphic wc_gr000439.2. Connect black, blue and red wire connections to capacitor (q).3. Reposition capacitor (

PS2 500, PSA2 500 RepairRepair.fm 7116.Install oil plug gasket (ad) over oil plug (ae) in the correctorientation.See graphic wc_gr000450.17.Screw plug

Repair PS2 500, PSA2 500Repair.fm 726.3.2 Motor Disassembly, Inspection, Testing andReassembly6.3.2.1 Motor Disassembly1. Motor disassembly requires d

PS2 500, PSA2 500 RepairRepair.fm 7316.Remove wear ring (an) if damaged or worn.17.Remove dust seal and sleeve as one piece (ao & ap).18.Remove wh

Repair PS2 500, PSA2 500Repair.fm 744. Visually inspect the upper and lower bearing (au & ax) for wear,corrosion or rust. Manually test lower ball

PS2 500, PSA2 500 RepairRepair.fm 75Test Oil Chamber Pressure1. After installing mechanical seal, attach a vacuum pump to oilhousing.2. Raise negative

Safety Informationwc_si000034gb.fm 4

Repair PS2 500, PSA2 500Repair.fm 7614.Secure impeller with flat washer (ac), lockwasher (ad) and acornnut (ae).15.While keeping the impeller and roto

PS2 500, PSA2 500 RepairRepair.fm 77PS2 500PSA2 5006.3.3 Impeller Disassembly, Inspection, Testing andReassemblyMaximum head > 10.36m (34ft)Maximum

Repair PS2 500, PSA2 500Repair.fm 786.3.3.1 Impeller DisassemblyNote: Draining oil is not required to disassemble and inspect theimpeller (aq) or volu

PS2 500, PSA2 500 RepairRepair.fm 796.3.3.4 Impeller ReassemblyNote: If, upon inspection and testing, a pump component requiresreplacement, use only o

Repair PS2 750Repair.fm 806.4 PS2 750 (1HP)6.4.1 Power Supply Disassembly, Inspection, Testing andReassembly6.4.1.1 Power Supply DisassemblyNote: Drai

PS2 750 RepairRepair.fm 819. Prior to removing the housing cover (i) mark where both housingcover (i) and stator (v) line up with each other. This aid

Repair PS2 750Repair.fm 821 = Ground W = White2 = Frame Grounding B = Black3 = Circle Thermal Protector L = Blue4 = Aux. Coil R = Red5 = Heater G = Gr

PS2 750 RepairRepair.fm 836.4.1.3 Power Supply TestingAir Test CableAir test cable insulation for resistance using a Megger tester betweenconductors.—

Repair PS2 750Repair.fm 846.4.1.4 Power Supply ReassemblyNote: If, upon inspection and testing, a pump component requiresreplacement, use only origina

PS2 750 RepairRepair.fm 857. Replace large diameter o-ring (e) on outside diameter of bearinghousing (not shown). Lower outer cover (d) over pump, ali

PS2 400 Technical Datawc_td000034gb_spec.fm 53. Technical Data3.1 PS2 4003.1.1 Standard Specifications – PS2 400OIL HOUSING LUBRICANTUse Lightweight 3

Repair PS2 750Repair.fm 866.4.2 Motor Disassembly, Inspection, Testing andReassembly6.4.2.1 Motor DisassemblyNote: Motor disassembly requires disassem

PS2 750 RepairRepair.fm 87—The other wire can remain attached.10.Remove two screws (aa) along with two spacers (ac) from thermalswitch (ab).11.Remove

Repair PS2 750Repair.fm 8816.While keeping impeller from rotating, remove nut (au), lockwasher(at) and thread cover (as).17.Remove impeller (am) from

PS2 750 RepairRepair.fm 8922.Carefully remove rubber seal (rs) and plastic bushing (pb) frombearing housing (az).23.If damaged, remove upper seal (us)

Repair PS2 750Repair.fm 904. Visually inspect upper and lower rotor bearing (bi & ay) for wear,corrosion or rust. Manually test for any side to si

PS2 750 RepairRepair.fm 91Test Wire ResistanceMeasure resistance of each phase using Megger tester.—Replace stator if test results fluctuate more that

Repair PS2 750Repair.fm 921. Using wooden fixture or equivalent, turn bearing housing (az)upright and install rotor (bj) with upper and lower bearings

PS2 750 RepairRepair.fm 938. Press lower seal (ls) in underside of volute (bb) if necessary.9. Align and install impeller (am) over keyway of rotor sh

Repair PS2 750Repair.fm 9418.Install bearing cover (y) and secure with two screws (x).Note: Alternately tighten each screw one-quarter turn until bear

PS2 750 RepairRepair.fm 9529.Position gasket (f) over bolts and boss of housing cover (i).30.Replace large diameter o-ring (e) on outside edge of bear