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PD Repair Foreword This manual covers machines with Item Number: 0007610, 0007614, 0007624, 0007625, 0007628, 0007629, 0009407, 0009489, 0009491, 0009492, 0009494, 0009495 Operating / Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or repair it. Basic operating and maintenance procedures are described in the Operator’s Manual supplied with the machine. Keep a copy of the Operator’s Manual with the machine at all times.
Foreword WARNING PD Repair CALIFORNIA Proposition 65 Warning: Engine exhaust, some of its constituents, and certain vehicle components, contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Laws Pertaining to Spark Arresters Notice: State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters be used on internal combustion engines that use hydrocarbon fuels.
PD 2/3 1. Safety Information 1.1 1.2 1.3 1.4 1.5 2. Operating Safety .................................................................................. 4 Operator Safety while using Internal Combustion Engines .................. 5 Service Safety ...................................................................................... 5 Label Locations ................................................................................... 6 Safety Labels ..........................................................
Table of Contents 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 5. PD 2/3 Cleaning Sediment Cup—Machines with Honda Engines ..................25 Carburetor Adjustment—Machines with Honda Engines ....................25 Servicing Air Cleaner—Machines with Honda Engines .......................26 Servicing Air Cleaner—Machines with Wacker Engines .....................27 Spark Plug ...........................................................................................28 Gear Case ..........................
PD 2/3 1. Safety Information 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. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Safety Information 1.1 Operating Safety DANGER wc_si000176gb.fm PD 2/3 Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. Failure to follow the warnings and safety guidelines could result in severe injury or death. 1.1.1 NEVER allow anyone to operate this equipment without proper training.
PD 2/3 1.2 Safety Information Operator Safety while using Internal Combustion Engines Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. WARNING 1.3 1.2.1 DO NOT smoke while operating the machine. 1.2.2 DO NOT smoke when refueling the engine. 1.2.3 DO NOT refuel a hot or running engine. 1.2.4 DO NOT refuel the engine near an open flame. 1.2.
Safety Information Label Locations CAUTION VORSICHT GREASE CONNECTING ROD BEARING MONTHLY PLEUELLAGER JEDEN MONAT SCHMIEREN PRECAUCION PRECAUTION ENGRASE RODAMIENTO DE LA BIELA MENSUALMENTE GRAISSER ROULEMENT DE LA BIELLE TOUS LES MOIS 30744 1.4 PD 2/3 WARNING DO NOT OPERATE WITHOUT SAFETY GUARDS. READ AND UNDERSTAND INSTRUCTION BOOK. WARNUNG NICHT OHNE SCHUTZVORRICHTUNG BETREIBEN. BEDIENUNGSANWEISUNG GENAU DURCHLESEN. ADVERTENCIA AVERTISSEMENT NE PAS OPERER SANS DEFLECTEUR PROTECTIF.
PD 2/3 Safety Information 1.5 Safety Labels Wacker machines use international pictorial labels where needed. These labels are described below: Label Meaning DANGER! Engines emit carbon monoxide; operate only in well-ventilated area. Read the Operator’s Manual. No sparks, flames, or burning objects near the machine. Shut off the engine before refueling. WARNING! Hot surface! CAUTION! Read and understand the supplied Operator’s Manuals before operating this machine.
Safety Information Label PD 2/3 Meaning CAUTION! Lifting point Guaranteed sound power level in dB(A) wc_si000176gb.
PD 2/3 wc_si000176gb.
Technical Data 2. PD Technical Data 2.1 Engine—Machines with Honda Engines Item Number: PDT/PDI 2A 0007610, 0007611 0007624, 0007625 PDT/PDI 3A 0007614, 0007615, 0007616, 0007628, 0007629, 0009407 Engine Engine Make Honda Engine Model GX 120 K1 QX 3.0 (4.0) Rated Power kW (Hp) Spark Plug type Electrode Gap mm (in.) Engine speed rpm 2700 ± 100 Air Cleaner type Dual element Engine Lubrication oil grade SAE10W30 - service class SF, SE, SD, or SC Engine Oil Capacity ml (oz.
PD Technical Data 2.2 Pump—Machines with Honda Engines Item Number: PDT/PDI 2A 0007610, 0007611 0007624, 0007625 PDT/PDI 3A 0007614, 0007615, 0007616, 0007628, 0007629, 0009407 Pump Weight kg (lbs.) 52 (114) 63 (138) *Max. Suction Lift m (ft.) 7.5 (25) Max. Discharge Head m (ft.) 7.5 (25) Max. Total Head m (ft.) 15 (50) Max. Discharge Pressure kg/cm2 (psi) 0.76 (10.8) Max. Discharge Flow m3h (gpm) Gear Case Lubrication 11 (50) 20 (88) oil grade ml (oz.
Technical Data 2.4 PD Dimensions—Machines with Honda Engines mm (in.) P D T 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 T 2 A - 5 7 2 (2 2 .5 ) P D T 3 A - 6 1 0 (2 4 ) P D I 2 A /3 A 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 A - 1 0 1 5 (4 0 ) P D I 2 A - 5 7 2 (2 2 .5 ) P D I 3 A - 6 1 0 (2 4 ) w c _ g r0 0 1 0 6 2 wc_td000178gb.
PD Technical Data 2.5 Engine—Machines with Wacker Engines Item Number: PDI/PDT 2 0009489, 0009494 PDI/PDT 3 0009491, 0009492, 0009495 Engine Engine Make Wacker Engine Model WM 130 Displacement cm3 (in3) Engine Speed rpm Max. Operating Power Spark Plug Electrode Gap Air Cleaner 126 (7.7) 2800 3.2 (4.3) kW (Hp) NGK BR6HS (Champion RL86C) type 0.6–0.7 (0.024–0.028) mm (in.) Dual element type Engine Lubrication oil grade SAE10W30 - SE or higher Engine Oil Capacity ml (oz.
Technical Data 2.6 PD Pump—Machines with Wacker Engines 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 570 (40 x 25 x 22.5) 1010 x 745 x 605 (40 x 29.3 x 24) 52 (114) 61 (133) Operating Weight kg (lbs.) *Max. Suction Lift m (ft.) 7.5 (25) Max. Discharge Head m (ft.) 7.5 (25) Max. Flow Rate l/m (gpm) Gear Case Lubrication oil grade ml (oz.) 189 (50) 333 (88) SAE 80W-90 532 (18) Suction / Discharge Dia.
PD 2A/3A 3. Operation Operation 3.1 Application This pump is intended for removing clean water or water containing a large amount of debris and suspended solids. The model PD 2A can pump water containing solids up to 30 mm (1.25 in.) diameter. The model PD 3A can pump water containing solids up to 45 mm (1.75 in.) in diameter. Diaphragm pumps are ideal for pumping mud, slurries and seepage.
Operation 3.3 PD 2A/3A Priming Pump See Graphic: wc_gr001064 Diaphragm pumps are self priming and seldom need to have water added to them before starting. However, if the pump has not been used for several weeks and the rubber valves inside it are dry, adding water through the surge chamber (f) will help the valves seal and shorten the amount of time required for the pump to prime. f e b a a b c b d 3.4 w c _ g r0 0 1 0 6 4 Before Starting See Graphic: wc_gr001064 3.4.
PD 2A/3A 3.5 Operation To Start—Machines with Honda Engines See Graphic: wc_gr000014 3.5.1 Open fuel valve by moving lever to the right (a1). Note: If engine is cold, move choke lever to close position (b1). If engine is hot, set choke to open position (b2). 3.5.2 Turn engine switch to “ON” (e1). 3.5.3 Open throttle by moving it slightly 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.
Operation 3.7 PD 2A/3A To Start—Machines with Wacker Engines See Graphic: wc_gr000655 3.7.1 Open fuel valve by moving lever down (a1). Note: If engine is cold, move choke lever to close position (d2). If engine is hot, set choke to open position (d1). 3.7.2 Turn engine switch to “ON” (b2). 3.7.3 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.
PD 2A/3A 3.9 Operation Operation Run engine at full speed while operating pump. Pump should begin pumping water within a minute depending on length of suction hose and height of pump above water. Longer hoses will require more time. If pump does not prime, check for loose fittings or air leak in suction hose. Make sure strainer in water is not blocked. WARNING DO NOT pump flammable fluids, fuels, corrosive chemicals or fluids containing toxic substances.
Operation PD 2A/3A 3.11 Hoses and Clamps See Graphic: wc_gr001065 Suction Hose Suction hoses (a) must be rigid enough not to collapse when pump is operating. Discharge Hose Discharge hoses (b) are usually thin-walled collapsible hoses. Rigid hoses similar to those used as suction hoses may also be used as discharge hoses. Note: Suction and discharge hoses are available from WACKER. Contact your nearest dealer for more information.
PD 2A/3A wc_tx000592gb.
Maintenance 4. PD Maintenance 4.1 Periodic Maintenance Schedule The chart below lists basic machine and engine maintenance. Refer to the engine manufacturer’s Operator’s Manual for additional information on engine maintenance. Daily before starting Check fuel level. • Check engine oil level. • Inspect air filter. Replace as needed. • Check and tighten external hardware. • Change engine oil. After first 20 hrs. Every 2 weeks or 25 hrs. • Every 100 hrs. Every 300 hrs.
PD Maintenance 4.2 Changing Engine Oil—Machines with Honda Engines See Graphic: wc_gr000022 4.2.1 Drain the oil while the engine is still warm. 4.2.2 Remove the oil filler plug (a) and the drain plug (b) to drain the 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 environmental protection legislation. wc_tx000593gb.fm 4.2.3 Install the drain plug. 4.2.
Maintenance 4.3 PD Changing Engine Oil—Machines with Wacker Engines See Graphic: wc_gr000087 4.3.1 Drain oil while engine is still warm. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid which drains off. Dispose of this liquid in accordance with environmental protection legislation. 4.3.2 Remove the oil drain plug (a). 4.3.3 Allow the oil to drain. 4.3.4 Install the drain plug. 4.3.
PD Maintenance 4.5 Cleaning Sediment Cup—Machines with Honda Engines See Graphic: wc_gr000029 4.6 4.5.1 Turn the fuel valve off. 4.5.2 Remove the sediment cup (a) and the O-ring (b). 4.5.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 4.5.4 Turn the fuel valve on and check for leaks. Carburetor Adjustment—Machines with Honda Engines See Graphic: wc_gr000032 4.6.1 Start the engine and allow it to warm up to operating temperature. 4.6.
Maintenance 4.7 PD Servicing Air Cleaner—Machines with Honda Engines See Graphic: wc_gr000025 The engine is equipped with a dual element air cleaner. Service air cleaner frequently to prevent carburetor malfunction. CAUTION: NEVER run engine without air cleaner. Severe engine damage will occur. NEVER use gasoline or other types of low flash point solvents for cleaning the air cleaner. A fire or explosion could result. WARNING To service: wc_tx000593gb.fm 4.7.1 Remove air cleaner cover (a).
PD Maintenance 4.8 Servicing Air Cleaner—Machines with Wacker Engines See Graphic: wc_gr000656 NEVER use gasoline or other types of low flash point solvents for cleaning the air cleaner. A fire or explosion could result. WARNING CAUTION: NEVER run engine without air cleaner. Severe engine damage will occur. The engine is equipped with a dual element air cleaner. Under normal operating conditions, elements should be cleaned once every week.
Maintenance 4.9 PD Spark Plug See Graphic: wc_gr000028 Clean or replace the spark plug as needed to ensure proper operation. Refer to the engine owner’s manual. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it is hot. WARNING 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.
PD Maintenance 4.10 Gear Case See Graphic: wc_gr003450 Check the oil level in the gear case once a week or every 25 hours of operation. Remove oil level plug (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. Drain oil through drain plug opening (f) at bottom of gear case. Add oil through fill plug on top of gear case.
Maintenance PD 4.11 Lubricating Connecting Rod Bearing See Graphic: wc_gr003451 Grease connecting rod bearing once a week or every 25 hours of operation. Use a hand operated grease gun. Add grease through grease fitting located behind access hole (j) provided on front cover. k j wc_gr003451 4.12 Cleaning Pump See Graphic: wc_gr003451 When pumping heavy sludges or water containing large amounts of dirt and solids, clean the pump often.
PD Maintenance 4.13 Storage If pump is being stored for more than 30 days: NEVER open priming plug, discharge plug, or cover when pump is hot. WARNING wc_tx000593gb.fm 4.13.1 Remove discharge plug from pump casing and drain out any water left in the 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.
Maintenance PD 4.14 Troubleshooting Problem / Symptom Engine does not start. Reason / Remedy • Engine problem. See engine manufacturer’s service manual for troubleshooting and repair. • Engine oil level too low. Add oil to engine. • Pump housing filled with dirt and debris. Disassemble and clean inside of pump. • Pump gear case damaged. Inspect and repair. Engine starts but pump does not take in water. • Pump is located too high above or too far away from water. Locate pump closer to water.
PD Repair 5. Disassembly/Assembly Procedures Disassembly/Assembly Procedures 5.1 Tools Because all possible problems encountered while repairing the machine cannot be anticipated, it is up to the mechanic to use common sense and good judgement in tool selection. The use of any special tools is recommended only for those operations where the use of conventional tools proves inadequate.
Disassembly/Assembly Procedures 5.4 PD Repair Replacing the Flapper Valve See Graphic: wc_gr003452 There are flapper valves located on both the inlet and the outlet sides of the pump. The procedure for replacing either flapper valve is the same. Removal: 5.4.1 Turn off the engine. 5.4.2 Remove the screws (a) and washers that secure the port (b or c) to the pump water box and remove the port. 5.4.3 Remove the flapper valve (d). 5.4.
PD Repair Disassembly/Assembly Procedures h h b a e f d g c d e f g wc_gr003452 wc_tx000590gb.
Disassembly/Assembly Procedures 5.5 PD Repair Replacing the Diaphragm See Graphic: wc_gr003453 Removal: 5.5.1 Turn off the engine. 5.5.2 Remove the connecting rod cover (a). 5.5.3 With the stop switch in the OFF position, slowly pull the starter rope until the crank arm (b) is in its upper most position. 5.5.4 Loosen the screw (c) that secures the crank arm to the gear shaft. 5.5.5 Remove the screws (h) that secure the pump housing to the water box (d) and remove the water box. 5.5.
PD Repair Disassembly/Assembly Procedures b c a h h e d e h g f A D C B wc_tx000590gb.
Disassembly/Assembly Procedures 5.6 PD Repair Replacing the Connecting Rod and Bearing See Graphic: wc_gr003459 This procedure requires an Arbor or similar type press. Removal: 5.6.1 Turn off the engine. 5.6.2 Remove the connecting rod and diaphragm assembly. See section Replacing the Diaphragm. 5.6.3 Remove the crank arm retaining nut (a). 5.6.4 Loosen the crank arm setscrew (b). 5.6.
PD Repair Disassembly/Assembly Procedures a b d g a e c b d f c e wc_gr003459 wc_tx000590gb.
Disassembly/Assembly Procedures 5.7 PD Repair Replacing the Engine See Graphic: wc_gr003459 Removal: 5.7.1 Turn off the engine. 5.7.2 Remove the drain plug (a) and drain the oil from the gearbox. 5.7.3 Remove the screws (f) and lock washers that secure the engine adapter (b) to the engine. 5.7.4 Remove the screws (c) that secure the bumper bracket (d) and the rear portion of the engine to the pump housing. 5.7.
PD Repair Disassembly/Assembly Procedures b e f g a d c a g wc_gr003460 wc_tx000590gb.
Disassembly/Assembly Procedures 5.8 PD Repair Gearbox Exploded View e d g a c h l n f i j b m k wc_gr003462 wc_tx000590gb.
PD Repair 5.9 Ref. Disassembly/Assembly Procedures Gearbox Components 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 Pinion gear m Seal g Retaining ring n Gasket wc_tx000590gb.
Disassembly/Assembly Procedures PD Repair 5.10 Gearbox Disassembly See Graphic: wc_gr003461 and wc_gr003462 This procedure requires an Arbor or similar type press. Disassembly: 5.10.1 Remove the engine and drain the oil from the gearbox. See section Replacing the Engine. 5.10.2 Remove the connecting rod. See section Replacing the Connecting Rod and Bearing. 5.10.3 The gearbox housing may remain mounted to the pump housing for the rebuilding procedure.
PD Repair Disassembly/Assembly Procedures a n c b b e d f i j h k m l wc_gr003461 wc_tx000590gb.
Disassembly/Assembly Procedures PD Repair 5.11 Gearbox Reassembly See Graphic: wc_gr003462 and wc_gr003463 This procedure requires an Arbor or similar type press. Reassembly: 5.11.1 Lightly coat the seal (m) with grease and place it into the gearbox housing. 5.11.2 Assemble the internal and external gear assemblies by pressing the gears (external and internal) onto their respective shafts. Also press the bearings onto the shafts. 5.11.
PD Repair Disassembly/Assembly Procedures l m k k f i h n a c b e d wc_gr003463 wc_tx000590gb.
Disassembly/Assembly Procedures PD Repair 5.12 Testing See Graphic: wc_gr003464 and wc_gr003465 This procedure requires a vacuum gauge (pn 28755) and a tachometer. wc_tx000590gb.fm 5.12.1 Check that the mounting hardware for the diaphragm and the valves is tight. 5.12.2 If the valves are dry, run the pump for a few minutes while adding water to the pump through the prime plug. Adding water will wet the rubber gaskets in the valves and provide a better seal while testing. 5.12.
PD Repair Disassembly/Assembly Procedures wc_gr003465 wc_gr003464 wc_tx000590gb.
Disassembly/Assembly Procedures wc_tx000590gb.
Threadlockers and Sealants Threadlockers and Sealants 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.
Threadlockers and Sealants Threadlockers and Sealants (continued) 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.
Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) 8.8 10.9 WRENCH SIZE 12.9 Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch M3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 – M4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 – M5 6.0 *53 8.
Torque Values Torque Values (continued) Inch Fasteners (SAE) Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch No.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32 No.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64 No.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.
Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 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, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel.
