Operator’s Manual Diaphragm Pump PDI2A, PDI3A, PDT2A, PDT3A Type PDI2A, PDI3A, PDT2A, PDT3A Document 5000184784 Date 0217 Revision 09 Language EN 5 0 0 0 1 8 4 7 8 4
Copyright notice © Copyright 2017 by Wacker Neuson Production Americas LLC All rights, including copying and distribution rights, are reserved. This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Production Americas LLC. Any type of reproduction or distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights.
PD2A / PD3A Foreword Foreword SAVE THESE INSTRUCTIONS—This manual contains important instructions for the machine models below. These instructions have been written expressly by Wacker Neuson Production Americas LLC and must be followed during installation, operation, and maintenance of the machines.
Foreword Manufacturer’s approval PD2A / PD3A This manual contains references to approved parts, attachments, and modifications. The following definitions apply: ■ Approved parts or attachments are those either manufactured or provided by Wacker Neuson. ■ Approved modifications are those performed by an authorized Wacker Neuson service center according to written instructions published by Wacker Neuson. ■ Unapproved parts, attachments, and modifications are those that do not meet the approved criteria.
EC Declaration of Conformity Manufacturer Wacker Neuson Production Americas LLC, N92W15000 Anthony Avenue, Menomonee Falls, Wisconsin 53051 USA Product Product PDI2A(i) PDI3A(i) Product category Water Pump Units Product function To pump fluid Item number 5000620772 Net installed power 2.
PD2A / PD3A 1 Foreword 3 EC Declaration of Conformity 5 Safety Information 9 1.1 1.2 1.3 1.4 1.5 2 Table of Contents Signal Words Used in this Manual ....................................................... 9 Machine Description and Intended Use ............................................. 10 Operating Safety ................................................................................ 11 Service Safety ....................................................................................
Table of Contents 5.7 5.8 5.9 5.10 5.11 PD2A / PD3A Spark Plug ...........................................................................................38 Changing the Gearbox Oil ...................................................................39 Cleaning the Pump ..............................................................................40 Storage ................................................................................................41 Machine Disposal and Decommissioning ...............
PD2 / PD3 / PD2A / PD3A 1 1.1 Safety Information Safety Information Signal Words Used in this Manual This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words 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 hazards. ► Obey all safety messages that follow this symbol.
Safety Information 1.2 PD2 / PD3 / PD2A / PD3A Machine Description and Intended Use Machine description This machine is a diaphragm pump. The Wacker Neuson Diaphragm Pump consists of a gasoline engine, a fuel tank, a handle, a set of wheels, and a diaphragm pump with ports for fluid suction and discharge. The engine raises and lowers the diaphragm via a connecting rod.
PD2 / PD3 / PD2A / PD3A 1.3 Safety Information Operating Safety Operator training Before operating the machine: ■ Read and understand the operating instructions contained in all manuals delivered with the machine. ■ Familiarize yourself with the location and proper use of all controls and safety devices. ■ Contact Wacker Neuson for additional training if necessary. When operating this machine: ■ Do not allow improperly trained people to operate the machine.
Safety Information Operating guidelines PD2 / PD3 / PD2A / PD3A When operating this machine: ■ Ensure that the machine is on a firm, level surface and that it will not tip, roll, slide, or fall while operating. When operating this machine: ■ Do not pump volatile, flammable, or low-flash-point fluids. ■ Do not change hoses while the engine is running. ■ Do not attempt to move the machine while the engine is running. Personal Protective Equipment (PPE) 1.
PD2 / PD3 / PD2A / PD3A Personal Protective Equipment (PPE) Safety Information Wear the following Personal Protective Equipment (PPE) while servicing or maintaining this machine: ■ Close-fitting work clothes that do not hinder movement ■ Safety glasses with side shields ■ Hearing protection ■ Safety-toed footwear In addition, before servicing or maintaining the machine: ■ Tie back long hair. ■ Remove all jewelry (including rings).
Safety Information 1.5 PD2 / PD3 / PD2A / PD3A Operator Safety while Using Internal Combustion Engines WARNING Internal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety standards could result in severe injury or death. ► Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. DANGER Asphyxiation hazard. Using a pump indoors CAN KILL YOU IN MINUTES. Pump exhaust contains carbon monoxide.
PD2A / PD3A 2 Labels Labels Label Locations K J C A M E F I G L B D wc_gr007188 2.1 wc_si000392gb_FM10.
Labels 2.2 PD2A / PD3A Label Meanings A DANGER Asphyxiation hazard. ■ Engines emit carbon monoxide. ■ Do not run the machine indoors or in an enclosed area. ■ NEVER use inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and vents. ■ Read the Operator’s Manual. ■ No sparks, flames, or burning objects near the machine. ■ Stop the engine before refueling.
PD2A / PD3A Labels D WARNING Pinch point! Do not operate without safety guards. Read and understand the Operator’s Manual. E CAUTION Read and understand the supplied Operator’s Manual before operating this machine. Failure to do so increases the risk of injury to yourself and others. 178714 wc_si000392gb_FM10.
Labels PD2A / PD3A I Notice Do not exceed 60 strokes per minute with the diaphragm pump. Read the Operator’s Manual. J Notice Use noncollapsible hose or pipe on suction side of pump. Read the Operator’s Manual. K WARNING Never pump volatile, flammable, or lowflash-point fluids. These fluids could ignite or explode. Read the Operator’s Manual. 18 wc_si000392gb_FM10.
PD2A / PD3A Labels L Certified Performance Contractors Pump Bureau A Bureau of AEM The manufacturer of this pump certifies that it was manufactured in accordance with the standards of the Contractors Pump Bureau. M WARNING Operation of This Equipment May Create Sparks That Can Start Fires Around Dry Vegetation. A Spark Arrestor May be Required. The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements. Per CAL. PRC.
Labels PD2A / PD3A Notes 20 wc_si000392gb_FM10.
PD2 / PD3 / PD2A / PD3A 3 Lifting and Transporting Lifting and Transporting Requirements ■ Transport vehicle capable of carrying at least 70 kg (150 lbs.) ■ Use lifting equipment capable of lifting at least 70 kg (150 lbs.) WARNING Fire hazard. Spilled fuel can ignite and cause severe burns. ► Lift and transport the machine in an upright position. Guidelines Follow the guidelines below when lifting and transporting this machine. ■ Close the fuel valve. ■ Lift and transport it in an upright position.
Operation 4 4.1 PD2A / PD3A Operation Preparing the Machine for First Use 1. Make sure all loose packaging materials have been removed from the machine. 2. Check the machine and its components for damage. If there is visible damage, do not operate the machine! Contact your Wacker Neuson dealer immediately for assistance. 3. Take inventory of all items included with the machine and verify that all loose components and fasteners are accounted for. 4. Attach component parts not already attached. 5.
PD2A / PD3A 4.3 Operation Recommended Fuel Type This engine/equipment requires regular unleaded gasoline. ■ Use only fresh (no older than three months old), clean gasoline. ■ Use a fuel stabilizer per the fuel stabilizer manufacturer’s instructions. Use of oxygenated fuels Some conventional gasolines are blended with alcohol. These gasolines are collectively referred to as oxygenated fuels. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.
Operation 4.4 PD2A / PD3A Refueling the Machine Requirements ■ ■ ■ ■ Procedure Perform the procedure below to refuel the machine. Machine shut down Engine cool Machine/fuel tank level with the ground Fresh, clean fuel supply WARNING Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause severe burns. ► Keep all sources of ignition away from the machine while refueling. ► Do not refuel if the machine is positioned in a truck fitted with a plastic bed liner.
PD2A / PD3A 4.5 Operation Before Installing the Pump Requirements ■ API GL-5 rated gear oil ■ Machine off Tasks Perform the tasks below before installing the pump. 1. Read the safety instructions at the beginning of this manual. 2. Place the pump on a firm, flat, level surface. 3. Check fuel level. Add fuel as needed. 4. Check engine oil level. Add engine oil as needed. 5. Check condition of air filter. Replace the air filter if needed. 6. Fill the pump’s gearbox with oil. a. Remove the fill plug (a).
Operation 4.6 PD2A / PD3A Installing the Pump Requirements ■ ■ ■ ■ Procedure Perform the procedure below to install the pump. Hoses Hose couplings Suction strainer Clamps NOTICE: Do not use collapsible hoses on the suction side of the pump. 1. Place the pump as near to the water to be pumped as possible. 2. Check that hose couplings/nipples (b) are installed and secure. 3. Make sure the suction strainer (e) is clean and securely attached to the end of the suction hose. 4.
PD2A / PD3A 4.7 Operation Starting Requirements ■ Completed installation procedures ■ Engine owner’s manual read and understood Procedure Perform the procedure below to start the machine. 1. Set the fuel valve lever (a) to the OPEN position (a1). 2. Set the choke lever (b) to the CLOSED position (b1). If the engine is warm, the choke lever may be left in the OPEN position (b2). 3. Set the throttle lever (c) approximately 1/3 of the way to the “MAX.” position. 4.
Operation 4.8 PD2A / PD3A Stopping Procedure Perform the procedure below to stop the machine. Note: To stop the engine in an emergency, move the engine switch to the OFF position. In all other circumstances, use the following procedure. 1. Set the throttle lever (c) to “MIN.” position. 2. Turn the engine switch (d) to the OFF position (d2). 3. Set the fuel valve lever (a) to the CLOSED position (a2). 28 wc_tx001331gb_FM10.
PD2A / PD3A 4.9 Operation Running the Pump Guidelines Follow the guidelines below when running the pump. ■ Run the engine at full speed. NOTICE: Pump speed must not exceed 60 strokes per minute (2800 rpm). ■ The pump should begin pumping water within one minute of being started depending on hose length and height above water. Longer hoses will require more time. ■ If the pump does not prime: a. check for loose fittings, air leaks, and plugged strainer. b.
Operation 4.10 PD2A / PD3A Clearing Jams Overview Large solids or accumulated sand and sediment may become lodged in the pump housing. This debris prevents the plunger arm from making a full stroke, causing the pump to stall or the crank to slip on the output shaft. The debris must be cleared before resuming operation. Prerequisites ■ Engine is stopped ■ Machine is cool to the touch If the pump has stalled Perform the procedure below to clear a jam if the pump has stalled.
PD2A / PD3A 4.11 Operation Emergency Shutdown Procedure Procedure Perform the procedure below if a breakdown/accident occurs while the machine is operating. 1. Stop the engine. 2. Turn off the fuel. 3. Remove the obstruction. 4. Unkink the hoses. 5. Allow the machine to cool. 6. Contact the rental yard or machine owner. wc_tx001331gb_FM10.
Maintenance 5 5.1 PD2A / PD3A Maintenance Maintaining the Emission Control System Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a dealer/service center authorized by the engine manufacturer. See the supplied engine owner’s manual for the applicable emission warranty information. 5.
PD2A / PD3A Maintenance Interval* (hours of service) Task Daily before starting First month Monthly 6 months Yearly --- (20) (40) (100) (300) Check and adjust valve engine clearances Check and adjust idle speed Replace fuel filter * Use whichever comes first, calendar time or service hours. wc_tx001332gb_FM10.
Maintenance 5.3 PD2A / PD3A Servicing the Air Cleaner When Inspect the air cleaner elements daily. Clean the air cleaner elements as needed. Replace the air cleaner elements if they are damaged or cannot be cleaned. Requirements ■ Machine shut down ■ Mild detergent and warm water ■ Clean engine oil WARNING Fire or explosion hazards. Gasoline or low-flash-point solvents are flammable and must not be used to clean the air cleaner or filter element.
PD2A / PD3A Maintenance Continued from the previous page. ■ Foam element a. Wash the foam element in a solution of mild detergent and warm water. b. Rinse the foam element thoroughly in clean water, and allow it to dry completely. c. Soak the foam element in clean engine oil until saturated. Squeeze out excess oil. 6. Re-install the filter elements and air cleaner cover.
Maintenance 5.5 PD2A / PD3A Changing the Engine Oil When Requirements Change the engine oil after the first 20 hours of operation and then after every 100 hours of operation or 6 months, whichever comes first.
PD2A / PD3A 5.6 Maintenance Cleaning the Sediment Cup When Clean the engine sediment cup every 100 hours or 6 months. Requirements ■ Machine shut down ■ Nonflammable solvent Procedure Perform the procedure below to service the sediment cup. 1. Stop the engine. 2. Set the fuel valve to the OFF position. 3. Remove the sediment cup (a) and the O-ring (b). WARNING Fire hazard. Gasoline or low-flash-point solvents are flammable and may ignite if used to clean the machine.
Maintenance 5.7 PD2A / PD3A Spark Plug When Clean the spark plug every 100 hours of operation or every 6 months. Replace the spark plug as needed. Requirements ■ Machine shut down ■ Engine cool Procedure Perform the procedure below to clean the spark plug. WARNING Burn hazard. The engine and muffler become very hot while running. ► Allow the engine to cool before performing this procedure. 1. Stop the engine and allow it to cool. 2. Remove the spark plug. 3. Inspect the spark plug.
PD2A / PD3A 5.8 Maintenance Changing the Gearbox Oil When Change the gearbox oil every 100 hours of operation or every 6 months. Requirements ■ ■ ■ ■ Procedure Perform the procedure below to change the gearbox oil. Machine shut down Engine warm API GL-5 rated gear oil Container for used oil WARNING Burn hazard. The engine and muffler become very while running. ► Stop the engine before performing this procedure. 1. Stop the engine. 2.
Maintenance 5.9 PD2A / PD3A Cleaning the Pump Requirements ■ Machine shut down ■ Machine cool Background When pumping heavy sludges or water containing large amounts of dirt and solids, clean the pump often. Materials left in the pump can dry and harden which may lead to damage of the valves or the diaphragm. Procedure Perform the procedure below to clean the machine. WARNING Fire hazard. Gasoline or low-flash-point solvents are flammable and may ignite if used to clean the machine.
PD2A / PD3A 5.10 Maintenance Storage Introduction Extended storage of equipment requires preventive maintenance. Performing these steps helps to preserve machine components and ensures the machine will be ready for future use. While not all of these steps necessarily apply to this machine, the basic procedures remain the same. When Prepare your machine for extended storage if it will not be operated for 30 days or more.
Maintenance 5.11 PD2A / PD3A Machine Disposal and Decommissioning Introduction This machine must be properly decommissioned at the end of its service life. Responsible disposal of recyclable components, such as plastic and metal, ensures that these materials can be reused—conserving landfill space and valuable natural resources. Responsible disposal also prevents toxic chemicals and materials from harming the environment.
PD2 / PD3 / PD2A / PD3A 6 Troubleshooting Troubleshooting Problem Cause Remedy Engine does not start Engine oil level too low Add oil to engine. Pump housing filled with dirt and debris Clean pump. Air leak in suction line Repair or replace suction line. Defective flapper valve Replace the flapper valves. Clogged strainer Clean or replace the strainer. No liquid in suction line Fill the pump and suction line with water. Pump housing filled with dirt and debris Clean pump.
Troubleshooting PD2 / PD3 / PD2A / PD3A Problem Cause Remedy Water accumulates on top of the diaphragm Diaphragm has crack or hole. Replace the diaphragm. Screw loose holding diaphragm Tighten the screw. Discharge hose height over 25 feet of head Lower the discharge hose. Pump housing filled with dirt and debris Clean the pump. Pump stalls repeatedly or stops for no apparent reason 44 wc_tx001382gb_FM10.
PD2A / PD3A 7 Technical Data Technical Data 7.1 Engine Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Engine PDI2 / PDT2 PDI3 / PDT3 Type — Air-cooled Manufacturer — Honda Model — GX120UT2QX2 Maximum rated power at rated speed Operating speed Displacement Number of cylinders Oil capacity kW/rpm (hp/rpm) 2.6/3600 (3.5/3600) rpm 2800 cm3 (in.3) 118 (7.2) — ml (oz.
Technical Data 7.2 PD2A / PD3A Pump Machine PDI2 / PDT2 PDI3 / PDT3 50 (2) 75 (3) kg (lb) 59 (131) 63 (140) Maximum discharge head m (ft) 7.6 (38) 7.6 (38) Maximum flow rate L/min (gpm) 189 (50) 333 (88) Maximum suction lift m (ft) 6.1 (20) 6.1 (20) mm (in.) 38 (1.5) 41 (1.625) Suction and discharge hose diameter Operating weight Maximum solid size diameter 7.3 mm (in.) Sound Measurements Products are tested for sound pressure level in accordance with EN ISO 11201:2010.
PD2A / PD3A 7.4 Technical Data Dimensions PD2 590 (23) PD3 590 (23) PD2 1000 (40) PD3 1070 (42) PD2 580 (23) PD3 680 (27) PD2 590 (23) PD3 590 (23) PD2 460 (18) PD3 460 (18) PD2 1000 (40) PD3 1070 (42) wc_gr007189 wc_td000379gb_FM10.
Emission Control Systems Information and Warranty 8 Emission Control Systems Information and Warranty The Emission Control Warranty and associated information is valid only for the U.S.A., its territories, and Canada. 8.1 Emission Control Systems Warranty Statement See the supplied engine owner’s manual for the applicable exhaust and evaporative emission warranty statement. 48 wc_tx001753gb_FM10.
Important: For spare parts information, please see your Wacker Neuson Dealer, or visit the Wacker Neuson website at http://www.wackerneuson.com/. Wichtig! Informationen über Ersatzteile erhalten Sie von Ihrem Wacker Neuson Händler oder besuchen Sie die Wacker Neuson Website unter http://www.wackerneuson.com/. Important : Pour des informations sur les pièces détachées, merci de consulter votre distributeur Wacker Neuson, ou de visiter le site Internet de Wacker Neuson sur http://www.wackerneuson.com/.
