WACKER Group PDT 2 Repair Manual
  1. Manuals
  2. Brands
  3. WACKER Group Manuals
  4. Water Pump
  5. PDT 2
  6. Repair manual
WACKER Group PDT 2 Repair Manual

WACKER Group PDT 2 Repair Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PDT 2 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for WACKER Group PDT 2

Summary of Contents for WACKER Group PDT 2

  • Page 1 0163153en 0606 Pump PDT 2 PDI 2 PDT 3 PDI 3 REPAIR MANUAL...
  • Page 3 This manual provides information and procedures to safely repair and maintain the above Wacker model(s). For your own safety and protection from injury, carefully read, understand, and observe all instructions...
  • Page 4 Wacker Corporation. Any type of reproduction or distribution not authorized by Wacker Corporation represents an infringement of valid copyrights, and violators will be prosecuted. We expressly reserve the right to make technical modifications, even without due notice, which aim at improving our machines or their safety standards.

  • Page 5: Table Of Contents

    Accessories ..................19 3.11 Hoses and Clamps ................20 Maintenance Periodic Maintenance Schedule ............22 Changing Engine Oil—Machines with Honda Engines ...... 23 Changing Engine Oil—Machines with Wacker Engines ..... 24 Cleaning Fuel Strainer—Machines with Wacker Engines ....24 wc_br0163153001enTOC.fm...

  • Page 6: Table Of Contents Pd

    Table of Contents 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 4.10 Gear Case ...................29 4.11 Lubricating Connecting Rod Bearing ...........30...

  • Page 7: Safety Information

    PD 2/3 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.

  • Page 8: Operating Safety

    1.1.3 NEVER use accessories or attachments that are not recommended by Wacker. 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.

  • Page 9: Operator Safety While Using Internal Combustion Engines

    A hot muffler could ignite the debris and start a fire. 1.3.7 ALWAYS replace worn or damaged components with spare parts designed and recommended by Wacker Corporation. 1.3.8 ALWAYS disconnect the spark plug on machines equipped with gasoline engines, before servicing, to avoid accidental start-up.

  • Page 10: Label Locations

    Safety Information PD 2/3 Label Locations CAUTION VORSICHT GREASE CONNECTING PLEUELLAGER JEDEN ROD BEARING MONTHLY MONAT SCHMIEREN PRECAUCION PRECAUTION ENGRASE RODAMIENTO GRAISSER ROULEMENT DE LA BIELA DE LA BIELLE TOUS MENSUALMENTE LES MOIS WARNING DO NOT OPERATE WITHOUT SAFETY GUARDS. READ AND UNDERSTAND INSTRUCTION BOOK.

  • Page 11: Safety Labels

    PD 2/3 Safety Information 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.
  • Page 12 Safety Information PD 2/3 Label Meaning CAUTION! Lifting point Guaranteed sound power level in dB(A) wc_si000176gb.fm...
  • Page 13 PD 2/3 Safety Information wc_si000176gb.fm...

  • Page 14: Technical Data

    Technical Data Technical Data Engine—Machines with Honda Engines Item Number: PDT/PDI 2A PDT/PDI 3A 0007610, 0007611 0007614, 0007615, 0007624, 0007625 0007616, 0007628, 0007629, 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...

  • Page 15: Pump-Machines With Honda Engines

    Technical Data Pump—Machines with Honda Engines Item Number: PDT/PDI 2A PDT/PDI 3A 0007610, 0007611 0007614, 0007615, 0007624, 0007625 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.

  • Page 16: Dimensions-Machines With Honda Engines

    Technical Data 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 2 A - 1 0 1 5 ( 4 0 ) P D T 3 A - 7 5 0 ( 2 9 .

  • Page 17: Engine-Machines With Wacker Engines

    Technical Data Engine—Machines with Wacker Engines Item Number: PDI/PDT 2 PDI/PDT 3 0009489, 0009494 0009491, 0009492, 0009495 Engine Engine Make Wacker Engine Model WM 130 Displacement 126 (7.7) Engine Speed 2800 Max. Operating Power kW (Hp) 3.2 (4.3) Spark Plug...

  • Page 18: Pump-Machines With Wacker Engines

    ) = 96 dB(A). • the sound pressure level at operator’s location (L PDT 2 = 78.8, PDT 3 = 82. These sound values were determined according to ISO 3744 for the sound power level (L ) and ISO 6081 for the sound pressure level ) at the operator’s location.

  • Page 19: Operation

    PD 2A/3A Operation Operation 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.

  • Page 20: Priming Pump

    Operation 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.

  • Page 21: To Start-Machines With Honda Engines

    PD 2A/3A 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”...

  • Page 22: To Start-Machines With Wacker Engines

    Operation 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).

  • Page 23: Operation

    These fluids can create potentially dangerous health and environmental hazards. Contact local WARNING authorities for assistance. 3.10 Accessories WACKER offers a complete line of fittings, hoses, and clamps to properly connect the pump to match various job conditions. wc_tx000592gb.fm...

  • Page 24: Hoses And Clamps

    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. Suction Hose to Inlet Coupling Two clamps (c) are recommended for connection of suction hoses to inlet coupling.
  • Page 25 PD 2A/3A Operation wc_tx000592gb.fm...

  • Page 26: Maintenance

    Maintenance Maintenance Periodic Maintenance Schedule The chart below lists basic machine and engine maintenance. Refer to engine manufacturer’s Operator’s Manual for additional information on engine maintenance. Daily After Every 2 Every Every before first weeks starting 20 hrs. or 25 hrs.

  • Page 27: Changing Engine Oil-Machines With Honda Engines

    Maintenance 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.

  • Page 28: Changing Engine Oil-Machines With Wacker Engines

    Maintenance 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.

  • Page 29: Cleaning Sediment Cup-Machines With Honda Engines

    Maintenance Cleaning Sediment Cup—Machines with Honda Engines See Graphic: wc_gr000029 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...

  • Page 30: Servicing Air Cleaner-Machines With Honda Engines

    Maintenance 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.

  • Page 31: Servicing Air Cleaner-Machines With Wacker Engines

    Maintenance 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.

  • Page 32: Spark Plug

    Maintenance 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.

  • Page 33: Gear Case

    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.

  • Page 34: Lubricating Connecting Rod Bearing

    Maintenance 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. wc_gr003451 4.12 Cleaning Pump See Graphic: wc_gr003451...

  • Page 35: Storage

    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 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.

  • Page 36: Troubleshooting

    Maintenance 4.14 Troubleshooting Problem / Symptom Reason / Remedy Engine does not start. • 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. Disassem- ble and clean inside of pump.

  • Page 37: Disassembly/Assembly Procedures

    Wacker Corporation. When ordering a replacement Parts Book, please list the model number, item number, revision level, and serial number of the machine. Parts Books are also available on the Wacker Corporation Web site. See www.wackergroup.com. Enter the site as a visitor.

  • Page 38: Replacing The Flapper Valve

    Disassembly/Assembly Procedures 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.
  • Page 39 PD Repair Disassembly/Assembly Procedures wc_gr003452 wc_tx000590gb.fm...

  • Page 40: Replacing The Diaphragm

    Disassembly/Assembly Procedures 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.
  • Page 41 PD Repair Disassembly/Assembly Procedures wc_gr003453 wc_tx000590gb.fm...

  • Page 42: Replacing The Connecting Rod And Bearing

    Disassembly/Assembly Procedures 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).
  • Page 43 PD Repair Disassembly/Assembly Procedures wc_gr003459 wc_tx000590gb.fm...

  • Page 44: Replacing The Engine

    Disassembly/Assembly Procedures 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.
  • Page 45 PD Repair Disassembly/Assembly Procedures wc_gr003460 wc_tx000590gb.fm...

  • Page 46: Gearbox Exploded View

    Disassembly/Assembly Procedures PD Repair Gearbox Exploded View wc_gr003462 wc_tx000590gb.fm...

  • Page 47: Gearbox Components

    PD Repair Disassembly/Assembly Procedures Gearbox Components Ref. Description Ref. Description Screw Seal Screw Needle bearing Gearbox cover Woodruff key Screw Internal gear Engine adapter External gear Pinion gear Seal Retaining ring Gasket wc_tx000590gb.fm...

  • Page 48: Gearbox Disassembly

    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.
  • Page 49 PD Repair Disassembly/Assembly Procedures wc_gr003461 wc_tx000590gb.fm...

  • Page 50: Gearbox Reassembly

    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.
  • Page 51 PD Repair Disassembly/Assembly Procedures wc_gr003463 wc_tx000590gb.fm...

  • Page 52: Testing

    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. 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.
  • Page 53 PD Repair Disassembly/Assembly Procedures wc_gr003465 wc_gr003464 wc_tx000590gb.fm...
  • Page 54 Disassembly/Assembly Procedures PD Repair wc_tx000590gb.fm...
  • Page 55 175°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. TYPE PART NO. –...
  • Page 56 175°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. TYPE PART NO. –...
  • Page 57 Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE 10.9 12.9 Size ft.lb. ft.lb. ft.lb. Metric Inch Metric Inch 7/32 – 9/32 – 5/16 – – – – 11/16 – – – 15/16 –...
  • Page 58 Torque Values Torque Values (continued) Inch Fasteners (SAE) Size ft.lb. ft.lb. ft.lb. Metric Inch Metric Inch No.4 – 3/32 No.6 5/16 – 7/64 No.8 11/32 – 9/64 No.10 – – 5/32 – 7/16 – 3/32 5/16 – – 9/16 – 5/16 7/16 –...
  • Page 60 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. +852 2406 60 32 · Fax: +852 2406 60 21...

This manual is also suitable for:

Pdi 2Pdi 3Pdt 3

Table of Contents