WACKER Group PDT 2 Repair Manual Download Page 2

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Summary of Contents for PDT 2

Page 1: ...www wackergroup com Pump PDT 2 PDI 2 PDT 3 PDI 3 REPAIR MANUAL 0163153en 001 0606 0 1 6 3 1 5 3 E N...

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Page 3: ...amage caused by misuse or neglect of the unit should be brought to the attention of the operator to prevent similar occurrences from happening in the future This manual provides information and proced...

Page 4: ...qualified and rated by the United States Forest Service for this purpose In order to comply with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Admi...

Page 5: ...13 2 6 Pump Machines with Wacker Engines 14 2 7 Sound Measurements Machines with Wacker Engines 14 3 Operation 15 3 1 Application 15 3 2 Recommended Fuel 15 3 3 Priming Pump 16 3 4 Before Starting 16...

Page 6: ...g 28 4 10 Gear Case 29 4 11 Lubricating Connecting Rod Bearing 30 4 12 Cleaning Pump 30 4 13 Storage 31 4 14 Troubleshooting 32 5 Disassembly Assembly Procedures 33 5 1 Tools 33 5 2 Ordering Parts 33...

Page 7: ...symbol to avoid possible injury or death DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided...

Page 8: ...Damage to equipment and injury to the user may result 1 1 4 NEVER pump volatile flammable or low flash point fluids These fluids could ignite or explode 1 1 5 NEVER pump corrosive chemicals or water...

Page 9: ...necessary 1 3 1 DO NOT attempt to clean or service the machine while it is running Rotating parts can cause severe injury 1 3 2 DO NOT crank a flooded engine with the spark plug removed on gasoline po...

Page 10: ...RE SIN LOS DISPOSITIVOS DE SEGURIDAD LEA Y ENTIENDA PRIMERO LAS INSTRUCCIONES NE PAS OPERER SANS DEFLECTEUR PROTECTIF LIRE ET COMPRENDRE LES INSTRUCTIONS DE SERVICE 117431 WARNING WARNUNG ADVERTENCIA...

Page 11: ...or others WARNING Pinch point Do not operate without safety guards Read and understand the operator s manual CAUTION Grease connecting rod bearing monthly DO NOT OPERATE WITHOUT SAFETY GUARDS READ AN...

Page 12: ...Safety Information PD 2 3 wc_si000176gb fm 8 CAUTION Lifting point Guaranteed sound power level in dB A Label Meaning...

Page 13: ...PD 2 3 Safety Information wc_si000176gb fm 9...

Page 14: ...7629 0009407 Engine Engine Make Honda Engine Model GX 120 K1 QX Rated Power kW Hp 3 0 4 0 Spark Plug type NGK BPR 6ES BOSCH WR 7DC Electrode Gap mm in 0 7 0 8 0 028 0 031 Engine speed rpm 2700 100 Air...

Page 15: ...for the sound pressure level LpA at the operator s location Item Number PDT PDI 2A 0007610 0007611 0007624 0007625 PDT PDI 3A 0007614 0007615 0007616 0007628 0007629 0009407 Pump Weight kg lbs 52 114...

Page 16: ...0 0 1 0 6 2 P D T 2 A 3 A P D I 2 A 3 A P D T 2 A 6 3 5 2 5 P D T 3 A 7 5 0 2 9 5 P D T 2 A 1 0 1 5 4 0 P D T 3 A 1 0 1 5 4 0 P D I 2 A 4 4 5 1 7 5 P D I 3 A 4 4 5 1 7 5 P D I 2 A 1 0 1 5 4 0 P D I 3...

Page 17: ...placement cm3 in3 126 7 7 Engine Speed rpm 2800 Max Operating Power kW Hp 3 2 4 3 Spark Plug type NGK BR6HS Champion RL86C Electrode Gap mm in 0 6 0 7 0 024 0 028 Air Cleaner type Dual element Engine...

Page 18: ...level LWA and ISO 6081 for the sound pressure level LpA at the operator s location Item Number PDI PDT 2 0009489 0009494 PDI PDT 3 0009491 0009492 0009495 Pump Dimensions L x W x H mm in 1010 x 630 x...

Page 19: ...up to 45 mm 1 75 in in diameter Diaphragm pumps are ideal for pumping mud slurries and seepage Typical applications include dewatering of trenches sewers pipelines septic tanks holding tanks farm pond...

Page 20: ...on hose c must not have any air leaks Check that all hose clamps b and couplings a are tight Check that cap on surge chamber f is tight 3 4 4 Check that discharge hose e is not blocked Lay hose out as...

Page 21: ...to left d1 3 5 4 Pull starter rope c Note If the oil level in the engine is low the engine will not start If this happens add oil to engine Some engines are equipped with an oil alert light f that wi...

Page 22: ...3 Open throttle by moving it slightly to left c2 3 7 4 Pull starter rope e Note If the oil level in the engine is low the engine will not start If this happens add oil to engine 3 7 5 Open choke as e...

Page 23: ...not prime check for loose fittings or air leak in suction hose Make sure strainer in water is not blocked DO NOT pump flammable fluids fuels corrosive chemicals or fluids containing toxic substances T...

Page 24: ...ailable from WACKER Contact your nearest dealer for more information Suction Hose to Inlet Coupling Two clamps c are recommended for connection of suction hoses to inlet coupling Note This connection...

Page 25: ...PD 2A 3A Operation wc_tx000592gb fm 21...

Page 26: ...aintenance Daily before starting After first 20 hrs Every 2 weeks or 25 hrs Every 100 hrs Every 300 hrs Check fuel level Check engine oil level Inspect air filter Replace as needed Check and tighten e...

Page 27: ...oil Note In the interests of environmental protection place a plastic sheet and a container under the machine to collect any liquid that drains off Dispose of this liquid in accordance with environme...

Page 28: ...l the drain plug 4 3 5 Fill the engine crankcase through the oil filler opening b to the upper mark on the dipstick c Do not thread in the dipstick to check the level See Technical Data for oil quanti...

Page 29: ...ating temperature 4 6 2 Set the pilot screw a two turns out See Note 4 6 3 With the engine idling turn the pilot screw a in or out to the setting that produces the highest rpm 4 6 4 After the pilot sc...

Page 30: ...er types of low flash point solvents for cleaning the air cleaner A fire or explosion could result To service 4 7 1 Remove air cleaner cover a Remove both elements and inspect them for holes or tears...

Page 31: ...der severe dry and dusty conditions the elements should be maintained daily Replace an element when saturated with dirt that cannot be removed 4 8 1 Remove the air cleaner cover a Remove the filter as...

Page 32: ...he engine Do not touch the muffler while it is hot Note Refer to the Technical Data for the recommended spark plug type and the electrode gap setting 4 9 1 Remove the spark plug and inspect it 4 9 2 R...

Page 33: ...h Check that oil level is even with plug opening If oil level is low add oil through the top fill plug opening g Do not overfill Change oil in gear case once a year or every 300 hours of operation Dr...

Page 34: ...e amounts of dirt and solids clean the pump often If allowed to sit in the pump and dry these materials will harden and could damage the valves or diaphragm inside the pump the next time it is used Wh...

Page 35: ...e housing after pump has cooled 4 13 2 Remove pump cover and clean inside of pump housing Coat inside of pump with a light film of oil to reduce corrosion A spray can of oil works well for this 4 13 3...

Page 36: ...ion hose damaged or collapsed Repair or replace hose Strainer plugged Clean or replace strainer Dirt collecting inside pump and hoses blocking flow Clean inside of pump and flush hoses Engine running...

Page 37: ...procedures contained in this manual do not include part numbers For parts replacement information refer to the Parts Book originally supplied with the machine If the original Parts Book has been lost...

Page 38: ...per valve d 5 4 4 Remove the large and small weights e and f from each side of the flapper valve Installation 5 4 5 Install the weights e and f to the flapper valves d with screws g CAUTION Do not ove...

Page 39: ...PD Repair Disassembly Assembly Procedures wc_tx000590gb fm 35 wc_gr003452 a b c h d d e f f g g e h...

Page 40: ...pump 5 5 7 Remove the screws f or studs and nuts securing the diaphragm g to the connecting rod and remove the diaphragm Installation 5 5 8 Secure the diaphragm g to the connecting rod with screws f o...

Page 41: ...PD Repair Disassembly Assembly Procedures wc_tx000590gb fm 37 wc_gr003453 a c b d e h h f g h A B C D e...

Page 42: ...5 6 5 Remove the screws e that secure the retaining washers c to both sides of the connecting rod f and remove the retaining washers 5 6 6 Support the connecting rod in an Arbor press Press on the thr...

Page 43: ...PD Repair Disassembly Assembly Procedures wc_tx000590gb fm 39 wc_gr003459 a a c e c g e d f b b d...

Page 44: ...from the gearbox until the engine shaft is clear of the pump housing Installation 5 7 7 Position shims g either two C shaped shims or one flat washer per hole on the pump housing 5 7 8 Place the engi...

Page 45: ...PD Repair Disassembly Assembly Procedures wc_tx000590gb fm 41 wc_gr003460 a c f b e d a g g...

Page 46: ...Disassembly Assembly Procedures PD Repair wc_tx000590gb fm 42 5 8 Gearbox Exploded View wc_gr003462 a g c d f e b j n k l m h i...

Page 47: ...x000590gb fm 43 5 9 Gearbox Components Ref Description Ref Description a Screw h Seal b Screw i Needle bearing c Gearbox cover j Woodruff key d Screw k Internal gear e Engine adapter l External gear f...

Page 48: ...to gently pry the gearbox cover to remove it If prying is necessary be careful not to damage the gasket n while prying 5 10 6 Remove the screws d and lockwashers that secure the engine adapter e to th...

Page 49: ...PD Repair Disassembly Assembly Procedures wc_tx000590gb fm 45 wc_gr003461 a c d e b b f h j k l m i n...

Page 50: ...essary to install them 5 11 4 Install the Woodruff key j into the external gear s shaft 5 11 5 Install a new seal h and needle bearing i into the cover of the gearbox 5 11 6 Press the bearing onto the...

Page 51: ...PD Repair Disassembly Assembly Procedures wc_tx000590gb fm 47 wc_gr003463 a c d e b f h k k l m i n...

Page 52: ...e engine and check the operating speed rpm with the tachometer Operating speed should be 2700 100 rpm 5 12 5 Grease the mounting face of the vacuum gauge to ensure a good seal Press the gauge over the...

Page 53: ...PD Repair Disassembly Assembly Procedures wc_tx000590gb fm 49 wc_gr003465 wc_gr003464...

Page 54: ...Disassembly Assembly Procedures PD Repair wc_tx000590gb fm 50...

Page 55: ...5 ml 17380 50 ml Loctite 271 277 Hernon 427 Omnifit 1550 220M Red High strength for all threads up to 25 mm 1 Heat parts before disassembly Temp range 54 to 149 C 65 to 300 F 29312 5 ml 26685 10 ml 7...

Page 56: ...ts follow instructions on container The sealants listed are recommended for use on Wacker equipment TYPE Europe COLOR USAGE PART NO SIZE Loctite 496 Hernon 110 Omnifit Sicomet 7000 Clear Instant adhes...

Page 57: ...5 M4 2 9 26 4 1 36 4 9 43 7 9 32 3 M5 6 0 53 8 5 6 10 7 8 5 16 4 M6 10 7 14 10 17 13 10 5 M8 25 18 35 26 41 30 13 1 2 6 M10 49 36 69 51 83 61 17 11 16 8 M12 86 63 120 88 145 107 19 3 4 10 M14 135 99 1...

Page 58: ...8 2 5 22 3 5 31 4 7 42 9 11 32 9 64 No 10 3 6 32 5 1 45 6 8 60 3 8 5 32 1 4 8 1 6 12 9 16 12 7 16 3 32 5 16 18 13 26 19 33 24 13 1 2 1 4 3 8 31 23 45 33 58 43 9 16 5 16 7 16 50 37 71 52 94 69 16 5 8...

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Page 60: ...02 0 Fax 49 0 89 3 54 02 3 90 Wacker Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Asia Pacific Operations Skyline Tower Suite 2303 2...

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WACKER Group PDT 2, Repair Manual

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