Operator’s Manual Pump PG2A Type PG2A Document 5000184844 Date 0818 Revision 13 Language EN 5 0 0 0 1 8 4 8 4 4
Copyright notice © Copyright 2018 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.
CALIFORNIA Proposition 65 Warning CALIFORNIA Proposition 65 Warning WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. WARNING Cancer and Reproductive Harm www.P65Warnings.ca.gov.
CALIFORNIA Proposition 65 Warning Notes 4 wc_tx004643en.
PG 2A 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 PG 2A 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 USA Product Product PG2A Product category Water Pump Units Product function To pump fluid Item number 5000009054 Net installed power 2.
PG 2A 1 CALIFORNIA Proposition 65 Warning 3 Foreword 5 EC Declaration of Conformity 7 Safety Information 1.1 1.2 1.3 1.4 1.5 2 Table of Contents 11 Signal Words Used in this Manual ..................................................... 11 Machine Description and Intended Use ............................................. 12 Safety Guidelines for Operating the Machine ..................................... 14 Operator Safety while Using Internal Combustion Engines ............... 15 Service Safety .
Table of Contents 5.9 5.10 5.11 5.12 PG 2A Cleaning the Sediment Cup ................................................................34 Adjusting the Carburetor .....................................................................35 Adjusting the Idle Speed .....................................................................35 Long-Term Storage .............................................................................36 6 Troubleshooting 37 7 Technical Data 38 7.1 7.2 7.3 7.
PG 2A 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 PG 2A Machine Description and Intended Use This machine is a centrifugal dewatering pump. The Wacker Neuson Dewatering Pump consists of a tubular steel frame surrounding a gasoline engine, a fuel tank, and an impeller pump with ports for water suction and discharge. The engine rotates the impeller during operation. Waste water is drawn into the pump through the suction port and expelled through the discharge port.
PG 2A Safety Information • Fuel and its fumes • Personal injury from improper lifting techniques • Projectile hazard from discharge • Crushing hazards from a tipping or falling pump To protect yourself and others, make sure you thoroughly read and understand the safety information presented in this manual before operating the machine. wc_si000415gb.
Safety Information 1.3 PG 2A Safety Guidelines for Operating the Machine WARNING Familiarity and proper training are required for the safe operation of the machine. Machines operated improperly or by untrained personnel can be hazardous. Read the operating instructions contained in this manual and the engine manual, and familiarize yourself with the location and proper use of all controls.
PG 2A 1.4 Safety Information • Do not open pump housing cover while pump is operating, or start pump with the cover off. The rotating impeller inside the pump can cut or sever objects caught in it. • Do not block or restrict flow from inlet line or discharge line. Remove kinks from discharge line before starting pump. Operation with a blocked inlet line or discharge line can cause water inside pump to overheat.
Safety Information PG 2A When operating the pump: • Do not smoke while operating the machine. • Do not run the machine if fuel leaks are present or the fuel lines are loose. • Do not run the engine near sparks or open flames. • Do not touch the engine or muffler while the engine is running or immediately after it has been turned off. • Do not operate a machine when its fuel cap is loose or missing. • Do not start the engine if fuel has spilled or a fuel odor is present.
PG 2A wc_si000415gb.fm Safety Information • Tie back long hair. • Remove all jewelry (including rings). • Do not attempt to clean or service the machine while it is running. Rotating parts can cause severe injury. • Do not crank a flooded engine with the spark plug removed on gasoline-powered engines. Fuel trapped in the cylinder will squirt out the spark plug opening. • Do not test for spark on gasoline-powered engines if the engine is flooded or the smell of gasoline is present.
Labels 2 2.1 PG 2A Labels Label Locations A B F C G D E H wc_gr000833 18 wc_si000416gb.
PG 2A 2.2 Labels Label Meanings A wc_gr014566 STOP 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.
Labels PG 2A F Guaranteed sound power level in db(A) G A nameplate listing the model number, item number, revision number, and serial number is attached to each unit. Please record the information found on this nameplate so it will be available should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model number, item number, revision number, and serial number of the unit.
PG 2A / 3A 3 Lifting and Transporting Lifting and Transporting Lifting the machine This pump is heavy enough to cause injury if proper lifting techniques are not used. Observe the following guidelines when lifting the pump. Do not attempt to lift the pump unassisted. Use appropriate lifting equipment such as slings, chains, hooks, ramps, or jacks. Make sure lifting equipment is attached securely and has enough weightbearing capacity to lift or hold the pump safely.
Operation 4 4.1 PG 2A / 3A 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.
PG 2A / 3A 4.3 Operation Before Starting 1. Read safety instructions at the beginning of this Operator’s Manual. 2. Place pump as near to water as possible, on a firm, flat, level surface. 3. To prime pump, remove prime plug (a) and fill pump housing with water. If the pump housing is not filled with water before starting, it will not begin pumping. WARNING Do not open priming plug, discharge plug, or loosen hose fittings if pump is hot! Water or vapor inside pump may be under pressure. WARNING 4.
Operation 4.4 PG 2A / 3A Starting 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). 2. Turn engine switch to “ON” (e1). 3. Open throttle by moving it slightly to left (d1). 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.
PG 2A / 3A 4.6 Operation Operation 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. WARNINGIf pump does not prime, check for loose fittings or air leak in suction hose. Make sure strainer in water is not blocked. WARNING Run engine at full speed while operating pump. 4.7 Hoses and Clamps Suction hoses (a) must be rigid enough not to collapse when pump is operating.
Operation 4.8 PG 2A / 3A Emergency Shutdown Procedure If a breakdown/accident occurs while the machine is operating, follow the procedure below. 1. Stop the engine. 2. Turn off the fuel supply. 3. Remove any obstructions. 4. Unkink the hoses. 5. Allow the machine to cool. 6. Contact the rental yard or machine owner. 26 wc_tx000177gb.
PG 2A / 3A 5 5.1 Maintenance 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. 5.2 Periodic Maintenance Schedule The table below lists basic machine maintenance.
Maintenance 5.3 PG 2A / 3A Cleaning the Pump After pumping water containing a large amount of dirt or debris, clean out inside of pump housing. 1. Remove drain plug (b) from pump housing and drain any water left in pump. 2. Loosen the four knobs holding the pump cover (a) and remove cover. 3. Clean out dirt and debris. Inspect impeller and volute insert for wear. The impeller may develop sharp edges. Use care when cleaning around impeller to avoid getting cut.
PG 2A / 3A 5.4 Maintenance Adjusting the Impeller Clearance If it is necessary to replace impeller or volute, be sure clearance between impeller and volute is adjusted correctly. The impeller (a) should be as close to the volute (b) as possible without rubbing against it. Clearance is adjusted by adding or removing shims (c) from behind impeller. To adjust the clearance do the following: 1. Remove pump housing but do not remove impeller. 2. Measure the distance (d) of volute. 3.
Maintenance 5.5 PG 2A / 3A Replacing the Mechanical Seal To service the mechanical seal do the following: 1. Remove the impeller (a) from the engine shaft by turning it countercockwise. Note: If the impeller is hard to remove, tap it with a plastic mallet. Do not lose any adjusting shims (b). 2. Remove mechanical seal spring (c) and carbon face (d) from crankshaft. 3. Remove mechanical seal ceramic face (e) and L-ring (f). 4. Clean engine shaft, remove any rust.
PG 2A / 3A 5.6 Maintenance Spark Plug Clean or replace spark plug as needed to ensure proper operation. Refer to the engine owner’s manual. Recommended Plug: (NGK) BPR 6ES 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 1. Remove spark plug and inspect it. 2. Replace plug if the insulator is cracked or chipped. 3. Clean spark plug electrodes with a wire brush. 4. Set gap (a) to 0.7-0.8 mm (0.028–0.
Maintenance 5.7 PG 2A / 3A Servicing the Air Cleaner Service air cleaner frequently to prevent carburetor malfunction. NOTICE: 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: 1. Remove air cleaner cover (a). Inspect element (b) for holes or tears. Replace element if damaged. 2. Wash element in solution of mild detergent and warm water.
PG 2A / 3A 5.8 Maintenance Changing the Engine Oil Procedure 1. Drain the oil while the engine is still warm. 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. 3. Install the drain plug. 4.
Maintenance 5.9 PG 2A / 3A Cleaning the Sediment Cup 1. Turn the fuel valve off. 2. Remove the sediment cup (a) and the O-ring (b). 3. Wash the sediment cup in a nonflammable solvent. 4. Dry and install the sediment cup. b 5. Replace the O-ring with a new one. 6. Turn the fuel valve on and check for leaks. a wc_gr000029 b a wc_gr000029 34 wc_tx000178gb.
PG 2A / 3A 5.10 Maintenance Adjusting the Carburetor 1. Start the engine and allow it to warm up to operating temperature. 2. Set the pilot screw (a) two turns out. See Note. 3. With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm. 4. After the pilot screw is adjusted, turn the throttle stop screw (b) to obtain the standard idle speed. See Technical Data.
Maintenance 5.12 PG 2A / 3A Long-Term Storage If pump is being stored for more than 30 days: Do not open priming plug, discharge plug, or cover when pump is hot. WARNING 1. After pump has cooled, remove discharge plug from pump housing and drain out any water left in the housing. 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. 3.
PG 2A / 3A 6 Troubleshooting Troubleshooting Problem / Symptom Reason / Remedy Pump does not take in water. Pump takes in water, little or no discharge. Suction hose leaks at inlet. Discharge hose does not stay on coupling. Impeller does not turn; pump is hard to start. wc_tx001575gb.fm Not enough priming water in housing. Engine speed too low. Adjust speed. Strainer plugged. Clean strainer. Suction hose damaged. Replace or repair hose.
Technical Data 7 PG 2A 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. Item Number: PG 2A 0009054 Rev. 102 and lower; 0007658 PG 2A 0009054 Rev. 103 and higher Engine Engine Make Honda Engine Model Max. Rated Power @ Rated Speed GX120K1WKT2 kW (Hp) GX120K1WKT4 2.6 (3.5) @ 3600 rpm Operating Speed rpm 3600 ± 100 Spark Plug type NGK BPR 6ES Electrode Gap mm (in.
PG 2A 7.2 Technical Data Machine Pump Weight kg (lbs.) 24 (53) *Max. Suction Lift m (ft.) 7.5 (25) Max. Total Head m (ft.) 30 (98) Suction / Discharge Dia. mm (in.) 50 (2) Maximum Solid Size mm (in.) 6.5 (0.25) l/min (gpm) 600 (159) Max. Discharge * Based on pump operating at sea level. Maximum suction lift will be less at higher altitudes. 7.3 Sound Measurements The required sound specification, Paragraph 1.7.4.
Emission Control Systems Information and Warranty—Gasoline 8 BV50A-H Emission Control Systems Information and Warranty—Gasoline 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. 40 wc_tx001753gb.
PORTABLE PUMPS Table of Contents Acknowledgment....................................................................2 Foreword .................................................................................3 Safety Alerts ............................................................................4 A Word to the User/Operator ................................................5 Follow a Safety Program........................................................6 Prepare for Safe Operation.........................
Foreword This safety manual is intended to point out some common safety situations that may be encountered during the normal operation and maintenance of your pump and to instruct you in safety practices for dealing with these conditions. This manual is NOT a substitute for the manufacturer’s operating manual(s). Additional precautions may be necessary, or some instructions may not apply, depending on equipment, attachments and conditions at the job site or in the service area.
A Word to the User/Operator It is YOUR responsibility to read and understand this safety manual and the manufacturer’s manual(s) before operating this equipment. This safety manual takes you step by step through the working day. Graphics have been provided to help you understand the text. Hazard recognition and accident prevention depend upon you being alert, careful, and properly trained in the inspection, operation, transport, maintenance, and storage of this equipment.
Follow a Safety Program Be Careful! Human error is the result of many factors: carelessness, fatigue, sensory overload, preoccupation, unfamiliarity with the machine or attachments, or drugs and alcohol, to name a few. You can avoid death or serious injury caused by these and other unsafe work practices. Be careful; never assume accidents cannot happen to you. For your safety and the safety of others, act safely and encourage your fellow workers to act safely as well.
Follow a Safety Program • Never allow children to play near, ride on or operate the equipment • Keep bystanders well clear of the operation • Know the work area before you use the equipment.
Prepare for Safe Operation Use Caution When Fueling WARNING! Avoid injury from fire or explosion. Never fill the fuel tank with the engine running, while smoking or when near an open flame. Never overfill the tank or spill fuel. If fuel is spilled, clean it up immediately. Be sure to use the correct type and grade of fuel. Ground the fuel funnel or nozzle against the filler neck to prevent sparks that could ignite fuel vapors. Be sure to replace the fuel fill cap (if equipped) when you are done.
Prepare for Safe Operation Loading & Transporting Pumps WARNING! Before loading or unloading any type of pump, make sure to wear all necessary PPE such as steel toed boots, gloves, safety glasses and hard hat. Wear necessary PPE when loading and unloading Loading Hauling Pumps Before unloading and loading hauling pumps, always refer to the manufacturer’s operating manual for specific instructions.
Start Safely Starting Aids If you have trouble starting the engine and need to use jumper cables, follow the instructions in manufacturer’s operating manual(s). Jump-starting is a two-person operation. The operator must be in the operator’s seat when jump-starting so the machine will be under control when the engine starts. WARNING! Improper jump-starting procedures may cause serious injury or death from a battery explosion or a run-away machine. Always use proper jump-starting procedure.
Operate Safely Pumps in General Keep hands and feet clear of moving parts. DO NOT stick fingers into a pump when in operation. Check suction strainer and hose regularly for proper submergence and to be sure it is free of obstructions. Safe Working Procedures USE COMMON SENSE! Most accidents can be avoided by using common sense and concentrating on the job to be done. NEVER operate a self-priming pump unless the volute is filled with liquid. The pump will not prime when dry.
Operate Safely Before Starting Check the pump thoroughly at delivery for any shipping damage. Locate the pump in an accessible location, as close to the liquid as possible. Secure the pump after it is placed in its intended operating position so it does not tip, roll, slide or fall. Immediately On Starting the Pump Observe gauges, instruments and warning lights to ensure that they are functioning and their readings are within the normal operating range.
Operate Safely Electric Motor Driven Pumps Allow only qualified personnel to INSTALL, WIRE and OPERATE electric motor driven pumps. Whenever electricity is present there is the possibility of electrocution. NEVER use a pump/motor in an explosive atmosphere if it is not exclusively designed for the application. Always ground electrical units. Make certain to connect pump motor to the right phase and voltage. Do not run pump if voltage is not within limits.
Shut Down Safely WARNING! Avoid death or serious injury. Never leave a machine unattended with the engine running. Safe Shutdown The detailed shutdown procedure is given in your manufacturer’s manual(s).
Perform Maintenance Safely WARNING! Avoid death or serious injury from entanglement. Do not wear loose clothing or accessories. Stay away from all rotating components when the engine is running. Contact, wrapping or entanglement with rotating or moving parts could result in death or serious injury. Avoid rotating parts Wear a rubber apron and rubber gloves when working with corrosives. Wear gloves and safety shoes when handling wooden blocks or sharp-edged metal.
Perform Maintenance Safely Attach a “DO NOT OPERATE” warning tag to the control levers. Lock out the unit according to the manufacturer’s operating manual. If there is a key, remove it and take it with you. Install approved support device(s) when working under or near raised equipment. Remove only guards or covers that provide access to the area being serviced. Replace all guards and covers when work is complete. WARNING! Avoid injury or death.
Perform Maintenance Safely Ultra-Low Sulfur Diesel (ULSD) Hazard Hydraulic System Hazards WARNING! Ultra-Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier diesel formulations with higher sulfur content. Avoid death or serious injury from fire or explosion; consult with your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.
Perform Maintenance Safely Battery Hazards The liquid in batteries contains acid, which is a POISON and could cause SEVERE CHEMICAL BURNS. Avoid injury: • Wear a face shield to prevent contact with your eyes • Wear chemical-resistant gloves and clothing to keep electrolyte off your skin and regular clothing Wear hand protection WARNING! Electrolyte will damage eyes or skin on contact. Always wear a face shield to avoid electrolyte in eyes.
Perform Maintenance Safely Complete Service and Repairs Before Machine is Released Tighten all bolts, fittings, and connections to torques specified by the manufacturer. Recheck all fluid levels before releasing the equipment for operation. Are there any missing cotter pins, washers, locknuts, etc.? Are there any parts left over? All parts should be inspected during repair and replaced if worn, cracked or damaged. Excessively worn or damaged parts could fail and cause injury or death.
Final Word to the User You have just finished reading the AEM Portable Pumps Safety Manual. It is impossible for this manual to cover every safety situation that you may encounter on a daily basis. Your knowledge of these safety precautions and your application to the basic rules of safety will help to build good judgment in all situations. Our objective is to help you develop, establish, and maintain good safety habits to make operating a portable pump easier and safer for you.
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/.
