Maintenance - Wayne PC4 Operating Instructions And Parts Manual

Operation
(Continued)
3. Plug power cord into GFCI
protected electrical outlet. The
pump will prime in a few minutes
depending on suction line length.
Use of foot valve on suction line is
recommended.
4. In the case of pressure boosting,
turn water on before starting pump.
This force primes the pump. Then,
plug power cord into GFCI protected
electrical outlet.
5. Unplug cord to turn unit off.

Maintenance

Let pump cool for
at least 20 minutes
before attempting to service. Motor
MAY be extremely hot. Personal injury
MAY result.
1. Pump should be checked periodically
for proper operation.
ALWAYs disconnect
the electrical supply
before attempting to operate, service,
or perform any maintenance. If the
power source is out of sight, lock and
tag in the open (off) position to prevent
unexpected power application. Failure
to do so WILL result in fatal electrical
shock. only qualified electricians
shouLD repair this unit. Improper repair
WILL result in fatal electrical shock.
BrUSh rePlaCeMent
Brushes for this
pump shouLD be
inspected after 100 hours of operation.
Pumps with excess of 100 hours of
operation may stop operating or fail to
start. This could be due to worn brushes
or carbon build-up. The brushes should
be removed and carbon removed.
Worn brushes are not covered under
warranty. Replacement brushes may
be available from Wayne Pumps. Call
1-800-237-0987 to order.
1) Disconnect electrical cord from
power supply.
2) Remove brush caps with screwdriver.
3) Remove old brush assembly.
4) Insert new brush assembly.
5) Replace brush caps.
For other problems, consult
troubleshooting chart.
aDDItIOnal rePaIrS
To replace bearings, shaft seal, or
gaskets, follow the instructions listed
below.
1. Disconnect electrical cord from
power supply.
2. Relieve pressure in system.
3. Disconnect inlet and outlet lines.
4. empty water from pump housing.
5. Place pump on bench with motor
end up and remove brushes as
described in BrUSh rePlaCeMent
instructions. If brushes are to be
reused, mark the location from
which each came. Replace brushes
in original orientation upon
completion of repair.
6. Remove the four cap screws holding
motor housing and pump housing
together. Motor housing is now free
and can be removed. Take care not
to lose commutator bearing finger
spring.
7. With a screwdriver, pry the rotor-
backhead assembly out of the pump
housing.
8. Remove the impeller by turning
counter clockwise (righthand thread
on shaft).
9. Remove backhead (the bearing is
press fit into the backhead).
10. Place backhead on flat surface with
impeller side down and press out
shaft seal.
3
11. Place impeller on flat surface
with vane side down and with
screwdriver and hammer break
ceramic seal ring into several pieces
and remove. next, remove rubber
seal ring cup from impeller.
12. Remove bearing from armature
shaft (press-fit on shaft). (Impeller
side bearing is the only serviceable
bearing).
13. Inspect the armature commutator
bars. The environment in which
the unit has been operating will
have influence on the condition of
the commutator. airborne dust an
dirt will accelerate wear. a rough
or scarred appearance may dictate
having commutator reconditioned
before reassembly.
14. To reassemble, install new bearing
on the shaft. always press against
the inner race to prevent bearing
damage. Make sure bearing is tight
against the shaft shoulders.
15. Press shaft seal into backhead.
When pressing shaft seal into place,
apply force to the cup flange. avoid
touching the polished seal surface;
oil or scratches on this surface may
cause premature failure of the seal.
16. Press ceramic side of seal into
impeller, ceramic side out. avoid
touching ceramic with hands as oil
may cause premature failure of the
seal. Wipe oil off both sides of seal
with a soft, lint-free cloth.
17. Reassemble unit in reverse order,
beginning with Step 9.
18. after reassembly check shaft for
free rotation with screwdriver in fan
through air exit openings.
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