WACKER Group PDT 2, PDI 3, PDI 2, PDT 3 Repair Manual
www.wackergroup.com
Pump
PDT 2
PDI 2
PDT 3
PDI 3
REPAIR MANUAL
0163153en 001
0606
0163153EN
PD Repair Foreword
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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. Use the separ ate Parts Book supp lied with the mach ine to order
replacement parts. If you are missing either of the documents, please
contact Wacker Corporation to order a replacement.
Damage caused by misuse or neg lect of the unit should be brough t to
the attention of the operator to prevent similar occurrences from
happening in the future.
This manual provides information and procedures to safe ly repair and
maintain the above Wacker model(s). For your own safety and
protection from injury, carefully read, understand, and observe all
instructions described in this manual. THE INFORMATION
CONTAINED IN THIS MANUAL IS BASED ON MACHINES
MANUFACTURED UP TO THE TIME OF PUBLIC ATION. WACKER
CORPORATION RESERVES THE RIGHT TO CHANGE ANY
PORTION OF THIS INFORMATION WITHOUT NOTICE.
This manual covers machines with Item Number:
0007610, 0007614, 0007624, 0007625, 0007628, 0007629, 0009407,
0009489, 0009491, 0009492, 0009494, 0009495
Foreword PD Repair
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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. A spark arrester is a
device designed to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are 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 Administrator.
All rights, especially copying and distribution ri ghts, are reserved.
Copyright 2006 by Wacker Corporation
No part of this pu blication may be rep roduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from 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.
WARNING
PD 2/3 Table of Contents
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1. Safety Information 3
1.1 Operating Safety .................................................................................. 4
1.2 Operator Safety while using Internal Combustion Engines .................. 5
1.3 Service Safety ...................................................................................... 5
1.4 Label Locations ................................................................................... 6
1.5 Safety Labels ........................................................................................ 7
2. Technical Data 10
2.1 Engine—Machines with Honda Engines ............................................10
2.2 Pump—Machines with Honda Engines .............................................. 11
2.3 Sound Measurements—Machines with Honda Engines .................... 11
2.4 Dimensions—Machines with Honda Engines ..................................... 12
2.5 Engine—Machines with Wacker Engines .................................. ......... 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
3.5 To Start—Machines with Honda Engines ............................. ..... .... .....17
3.6 To Stop—Machines with Honda Engines .................................. .... .....17
3.7 To Start—Machines with Wacker Engines ......................................... 18
3.8 To Stop—Machines with Wacker Engines .........................................18
3.9 Operation ............................................................................................ 19
3.10 Accessories ........................................................................................ 19
3.11 Hoses and Clamps ............................................................................. 20
4. Maintenance 22
4.1 Periodic Maintenance Schedule ......................................................... 22
4.2 Changing Engine Oil—Machines with Honda Engines ...................... 23
4.3 Changing Engine Oil—Machine s with Wacker Engines ..................... 24
4.4 Cleaning Fuel Strainer—Machines with Wacker Engines .................. 24
Table of Contents PD 2/3
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4.5 Cleaning Sediment Cup—Machines with Honda Engines ..................25
4.6 Carburetor Adjustment—Machines with Honda Engines ....................25
4.7 Servicing Air Cleaner—Machines with Honda Engines .......................26
4.8 Servicing Air Cleaner—Machines with Wacker Engines .....................27
4.9 Spark Plug ...........................................................................................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
5.3 Reference Numbers ( ) ................................................. .... ..... ..... .........33
5.4 Replacing the Flapper Valve ...............................................................34
5.5 Replacing the Diaphragm ................................................. ..... ..............36
5.6 Replacing the Connecting Rod and Bearing .......................................38
5.7 Replacing the Engine ........................... ..... ..... .... ............................ .....40
5.8 Gearbox Exploded View ............................ ..........................................42
5.9 Gearbox Components ............................... ..........................................43
5.10 Gearbox Disassembly .................................... .... .................................44
5.11 Gearbox Reassembly ................................................... .... ..... ..............46
5.12 Testing .................................................................................................48
PD 2/3 Safety Information
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1. Safety Information
This manual contains DANGER, WARNING, CAUTION, and NOTE
callouts which must be followed to reduce the po ssibility 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 pos sible injury or death.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous si tuation w hich, if no t avoided, co uld
result in death or serious injury.
CAUTION indicat es a hazardous situation which, i f n ot a voi de d, co ul d
result in minor or moderate inj ury.
CAUTION: Used without the safety alert symbol, CAUTION indicates
a potentially hazardous situation which, if not avoided, may result in
property damage.
Note: Contains additional information important to a procedure.
DANGER
WARNING
CAUTION
Safety Information PD 2/3
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1.1 Operating Safety
Internal combustion eng ine s present sp ecial ha zard s during op eratio n
and fueling. Read and follow the warning instructions in the engine
owner’s manual and t he saf ety gu ideli nes belo w. Failu re to follow the
warnings and saf ety guidelines could result in severe injury or death.
1.1.1 NEVER allow anyone to operate this equipment without proper
training. People operating this equipment must be familiar with the
risks and hazards associated with it.
1.1.2 NEVER touch the engine or muffler while the engine is on or
immediately after i t has been turned off. The se areas get hot and may
cause burns.
1.1.3 NEVER use accessories or attachm ents that are not recom mended by
Wacker. Damage to equipment and injury to the user m ay result.
1.1.4 NEVER pump vola tile, flam mable or l ow flash poi nt fluids. The se fluids
could ignite or explode.
1.1.5 NEVER pump corrosive chemicals or water containing toxic
substances. These fluids could create serious health and
environmental hazards. Contact local authorities for assistance.
1.1.6 ALWAYS read, understand, and follow procedures in the Operator’s
Manual before attempting to operate the equipment.
1.1.7 ALWAYS be sure operator is familiar with proper safety precau tions
and operation techniques before using machine.
1.1.8 ALWAYS be sure the machine is on a firm, level surface and will not
tip, roll, slide, or fall while operating.
1.1.9 ALWAYS close fuel valve on engines equipped with one when
machine is not being oper ate d.
1.1.10 ALWAYS store the equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the reach of
children.
DANGER
PD 2/3 Safety Information
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1.2 Operator Safety while using Internal Combustion En gines
Poorly maintained equipment can become a safety hazard! In order
for the equipment to operate safely and prop erly over a long period of
time, periodic maintenance and occasional repairs are necessary.
1.2.1 DO NOT smoke while operating the machine.
1.2.2 DO NOT smoke when refueling t he engine.
1.2.3 DO NOT refuel a hot or running engine.
1.2.4 DO NOT refuel the engine near an open flame.
1.2.5 DO NOT spill fuel when refueling the engine.
1.2.6 DO NOT run the engine near open flames.
1.2.7 ALWAYS refill the fuel tank in a well-ventilated area.
1.2.8 ALWAYS replace the fuel tank cap after refueling.
1.3 Service Safety
Poorly maintained equipment can become a safety hazard! In order
for the equipment to operate safely and prop erly over a long period of
time, periodic maintenance and occasional repairs are 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-powered en gines. Fuel trappe d in the cylinder will sq uirt out
the spark plug opening.
1.3.3 DO NOT test for spark on gasoline-powered engines if the engine is
flooded or the smell of gasoline is present. A stray spark could ignite
the fumes.
1.3.4 DO NOT use gasoline or othe r typ es of fuel s or fl am mab le solv en ts to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
1.3.5 ALWAY S operate the machine with all safe ty devices and guards in
place and in workin g or der.
1.3.6 ALWAYS keep the area around the muffler free of debris such as
leaves, paper, cartons, etc. A ho t muffler could igni te the d ebris 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.
WARNING
WARNING
Safety Information PD 2/3
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1.4 Label Locations
DO NOT OPERATE WITHOUT SAFETY GUARDS.
READ AND UNDERSTAND INSTRUCTION BOOK.
NICHT OHNE SCHUTZVORRICHTUNG
BETREIBEN. BEDIENUNGSANWEISUNG
GENAU DURCHLESEN.
NO OPERE 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
AVERTISSEMENT
GREASE CONNECTING
ROD BEARING MONTHL
Y
30744
CAUTION
PRECAUTIONPRECAUCION
ENGRASE RODAMIENTO
DE LA BIELA
MENSUALMENTE
GRAISSER ROULEMENT
DE LA BIELLE TOUS
LES MOIS
VORSICHT
PLEUELLAGER JEDEN
MONAT SCHMIEREN
PD 2/3 Safety Information
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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 ob ject s ne ar the
machine. Shut off the engine before refueling.
WARNING!
Hot surface!
CAUTION!
Read and understand the supplied Operator’s
Manuals before operating this machine. Failure to do so increases the risk of injury to yourself 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 AND UNDERSTAND INSTRUCTION BOOK.
NICHT OHNE SCHUTZVORRICHTUNG
BETREIBEN. BEDIENUNGSANWEISUNG
GENAU DURCHLESEN.
NO OPERE 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
AVERTISSEMENT
GREASE CONNECTING
ROD BEARING MONTHL
Y
30744
CAUTION
PRECAUTIONPRECAUCION
ENGRASE RODAMIENTO
DE LA BIELA
MENSUALMENTE
GRAISSER ROULEMENT
DE LA BIELLE TOUS
LES MOIS
VORSICHT
PLEUELLAGER JEDEN
MONAT SCHMIEREN
Safety Information PD 2/3
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CAUTION!
Lifting point
Guaranteed sound power level in dB(A)
Label Meaning
PD 2/3 Safety Information
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Technical Data PD
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2. 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
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 Cleaner
type
Dual element
Engine Lubrication
oil grade
SAE10W30 - service class SF, SE, SD, or SC
Engine Oil Capacity
ml (oz.)
600 (20)
Fuel
type
Regular unleaded gasoline
Fuel Tank Capacity
l (qts.)
2.5 (2.6)
PD Technical Data
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2.2 Pump—Machines with Honda Engines
2.3 Sound Measurements—Machines with Honda En gines
The required sound specification, Paragraph 1.7.4.f of 89/392/EEC
Machinery Directive, is:
• the guaranteed sound power level (LWA) = 96 dB(A).
• the sound pressure level at operator’s location (L
pA
) = 82 dB(A).
These sound values were determined according to ISO 3744 for the
sound power level (LWA) and ISO 6081 for the sound pressure level
(L
pA
) 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) 63 (138)
*Max. Suction Li ft
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)
11 (50) 20 (88)
Gear Case Lubric ation
oil grade
ml (oz.)
SAE 80W-90
532 (18)
SAE 80W-90
532 (18)
Suction / Discharge Dia.
mm (in.)
50 (2) 75 (3)
Maximum Solid Size
mm (in.)
30 (1.25) 45 (1.75)
* Based on pump operating at sea level. Maximum suction lift will be less at higher altitudes.
Technical Data PD
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2.4 Dimensions—Machines with Honda Engines
mm (in.)
w c _ g r 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 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
- 5 7 2 ( 2 2 . 5 )
P D I 3 A
- 6 1 0 ( 2 4 )
PD Technical Data
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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)
126 (7.7)
Engine Spee d
rpm
2800
Max. Operating Power
kW (Hp)
3.2 (4.3)
Spark Plug
type
NGK BR6HS (Champion RL8 6C)
Electrode Gap
mm (in.)
0.6–0.7 (0.024–0.0 28 )
Air Cleaner
type
Dual element
Engine Lubrication
oil grade
SAE10W30 - SE or higher
Engine Oil Capacity
ml (oz.)
600 (20)
Fuel
type
Regular unleaded gasoline
Fuel Tank Capacity
l (qts.)
2.7 (2.9)
Fuel Consumption
l (qts.)/hr.
1.1 (1.2)
Running Time
hr.
2.5
Technical Data PD
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2.6 Pump—Machines with Wacker Engines
2.7 Sound Measurements—Machines with Wacker Engines
The required sound specification, Paragraph 1.7.4.f of 89/392/EEC
Machinery Directive, is:
• the guaranteed sound power level (LWA) = 96 dB(A).
• the sound pres sure level at oper ator’s location (LpA):
PDT 2 = 78.8, PDT 3 = 82.
These sound values were determined according to ISO 3744 for the
sound power level (LWA) and ISO 608 1 for the sound pre ssure 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 570
(40 x 25 x 22.5)
1010 x 745 x 605
(40 x 29.3 x 24)
Operating Weight
kg (lbs.)
52 (114) 61 (133)
*Max. Suction Lift
m (ft.)
7.5 (25)
Max. Discharge Head
m (ft.)
7.5 (25)
Max. Flow Rate
l/m (gpm)
189 (50) 333 (88)
Gear Case Lubrication
oil grade
ml (oz.)
SAE 80W-90
532 (18)
Suction / Discharge Dia.
mm (in.)
50 (2) 75 (3)
Maximum Solid Size
mm (in.)
32 (1.25) 45 (1.75)
* Based on pump operating at sea level. Maximum suction lift will be less at higher altitudes.
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