WACKER NEUSON PT4A Repairs Manual

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PT Series Trash Pump

Service Manual

Type: PT2, PT3, PT4 Document: 5100048604 Date: 0121 Revision: 0.2 Language: EN-US

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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 America Corporation.

Any type of reproduction or distribution not authorized by Wacker Neuson America Corporation represents an infringement of valid copyrights. Violators will be prosecuted.

Trademarks

Manufacturer

Original instructions

All trademarks referenced in this manual are the property of their respective owners.

Wacker Neuson America Corporation N92W15000 Anthony Avenue Menomonee Falls, WI 53051 U.S.A. Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957 www.wackerneuson.com

This Manual presents the original instructions. The original language of this Manual is American English.

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Foreword

General

This manual provides detailed information and procedures to safely repair and maintain the following: Wacker Neuson PT Series Trash Pump.

This manual is intended to introduce and guide the user through the latest factory-approved troubleshooting and repair techniques and practices.

Before you attempt to troubleshoot or make repairs, you must be familiar with the operation of this machine. Refer to the operator's manual for specific information on these topics.

THE INFORMATION CONTAINED IN THIS MANUAL IS BASED ON MACHINES MANUFACTURED UP TO THE TIME OF PUBLICATION. WACKER NEUSON RESERVES THE RIGHT TO CHANGE ANY OF THIS INFORMATION WITHOUT NOTICE.

California Proposition 65 Warning

WARNING

Certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Trademark Acknowledgment

Wacker Neuson acknowledges the following trademarks for company names or products mentioned within this publication: Lubriplate® is a trademark of Fiske Brothers Refining Co. Loctite® and Permatex® are trademarks of Henkel Corporation.

How to Use This Manual

This manual is designed to provide multiple ways to locate and access repair information. Read each section in its entirety before beginning a procedure. Proper understanding of machine operation and components is the key to successful diagnostics and repair.

Make use of special information features within this manual in order to be better prepared to perform repairs. Always follow manual procedures and safety guidelines. Never take shortcuts.

Table of Contents

Major machine components or topics of interest are separated into specific chapters. Each manual lists these chapters in a main Table of Contents.

Chapter Table of Contents

Each chapter begins with a detailed Table of Contents related to the specific machine component or system. Use the Chapter Table of Contents to find specific component procedural information.

Index

An alphabetical Index is located at the back of the manual. Use the Index to find specific components and related procedures.

Required Tools and Materials

Some procedures will require the use of specific tools and/or materials. These tools and/or materials will be listed for reference prior to beginning a procedure.

Specifications

Near the beginning of each chapter is a specifications list. This listing contains any specifications contained within the chapter.

Warnings and Cautions

Warning and Caution indicators are located throughout the manual at specific points of interest. These notices are given to prevent personal injury, death, and/or equipment damage. Always heed these notices, and practice common sense when performing any maintenance or repair procedure.

Notes

Special notes are given in order to draw attention to detailed instructions. These notes are intended to give further important information regarding the machine and/or a step in a procedure.

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FOREWORD

Safety

Introduction

Safety is the most important element of any repair procedure. Knowledge of the procedure to be performed and safe work habits are essential to preventing death, personal injury, or property damage. Use the following statements as a common-sense guide to proper work and tool-use habits.

Preparing for the Job

Preparation is essential to complete a procedure in a safe and efficient manner.

Service Training

• Read and understand the instructions contained in all manuals delivered with the pump.

•

Familiarize yourself with the location and proper use of all controls and safety devices.

• Only trained personnel shall troubleshoot or repair problems occurring with the pump. Contact Wacker Neuson for additional training if necessary.

• Visit http://www.wackerneuson.us/en/support-usa/ technical-training.html for more information.

Repair Person Qualifications

Work on the electric system, equipment on the undercarriage, and the steering and brake systems may be performed only by skilled individuals who have been specially trained for such work.

Personal Protective Equipment (PPE)

PPE while servicing or maintaining this pump:

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 pump:

• Tie back long hair.

• Remove all jewelry (including rings).

Personal Safety Measures

• Follow the specific safety instructions in this manual.

Apply special care when working on the fuel

• system due to increased risk of fire.

• Engine block and muffler system become very hot during operation and require cool-down time after pump is shut off. Avoid contact with hot parts.

•

Retainer pins can fly out or splinter when struck with force. Use a brass hammer or a suitable material between the hammer and pin.

• To reduce the risk of explosions, do not use starting fluid (for example, ether), especially in those cases in which a heater or glow plug (intake air pre-heating) is used at the same time.

Precautions

• Read and understand the service procedures before performing any service on the pump.

• Remain aware of the pump’s moving parts. Keep hands, feet, and loose clothing away from the pump’s moving parts.

• Reinstall the safety devices and guards after repair and maintenance procedures are complete.

Cleaning

• Ensure the pump is clean and free of debris such as leaves, paper, cartons, etc.

• Ensure all labels are legible.

• Do not clean the pump while it is running.

• Never use gasoline or other types of fuels or flammable solvents to clean the pump. Fumes from fuels and solvents can become explosive.

Preparing Pump for Maintenance

• Prior to performing assembly work on the pump, make sure no movable parts will roll away or start moving.

Position on firm and level ground.

•

• Secure pump against unintentional movement.

• Stop engine unless maintenance or repair is required with engine running.

• Attach warning tag (Do Not Operate) to pump unless maintenance or repair is required with engine running.

• Prior to performing assembly work on the pump, stabilize the area under repair and use proper lifting and support devices.

General Maintenance Notes

• Make sure all tools and service center equipment are capable of performing the tasks prescribed. Do not use malfunctioning or broken tools. Use certified measuring devices that are routinely calibrated for accuracy (for example torque wrench, pressure gauge, or multimeter).

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FOREWORD

• Recycle scrapped parts and drained fluids according to environmental and hazardous material requirements. To avoid fire and health hazards, dispose of soiled shop towels by approved methods.

Always retighten any screws, electrical

• connections, or hose connections that may have been loosened during maintenance and repair.

• Any safety devices removed for setup, maintenance, or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work.

Pump Modifications

• Do not defeat safety devices.

• Do not modify the pump without the express written approval of Wacker Neuson.

• Do not make any modifications, additions, or conversions to the pump and its superstructures or the pump's attachments without the approval of Wacker Neuson. Such modifications may affect safety and/or pump performance. This also applies to the installation and adjustment of safety devices. Use only accessories/attachments that are approved by Wacker Neuson.

Safety Symbols Found in This Manual

Throughout this manual, the following key safety words will be used to alert the reader of potential hazards. Become familiar with these words and their meanings. Take all precautions to avoid the hazards described.

DANGER

NOTICE

Indicates a potentially hazardous situation which, if not avoided, MAY result in property damage. It may also be use to alert against unsafe practices.

Safety Label Inspection

Safety labels are critical to the safe operation of the pump. Inspect the pump for any damaged, missing, or unreadable labels. Replace labels as needed before placing the pump back in service.

Keep Work Area Clean

A clean, organized, well-lit work area is important to promote safe working conditions.

•

Keep floor clean of debris and clear of parts and tools.

• Clean up any spilled fuel, oil, and/or chemicals immediately.

• Store all air hoses and electrical cords properly when not in use.

Keep Work Area Well-Ventilated

WARNING

Never operate the engine without proper ventilation. Exhaust fumes can be fatal if inhaled.

Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

WARNING

Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury and property damage. It may also be used to alert against unsafe practices.

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Certain test and adjustment procedures require the engine to be running. Be sure work area is well ventilated. Never run the engine in an enclosed area.

Use Proper Eye and Face Protection

WARNING

Always use approved personal protection equipment. Avoid workplace hazards by wearing properly maintained, approved eye and face protection. Failure to use appropriate protection equipment may result in serious injury or death.

Always wear eye protection while in a shop environment.

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FOREWORD

• Safety Glasses: Safety glasses offer a minimum level of protection from flying debris.

• Face Shields: Face shields are often used along with safety glasses to offer a higher level of protection when sparks and flying debris are present.

• Vented Goggles: Goggles offer side protection not offered by safety glasses alone.

• Unvented Goggles: Unvented goggles offer protection from chemical splashes and vapors.

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Support Pump Securely

1. Place the pump on a solid, level surface.

2. Secure the pump against unintentional movement.

3. Stop engine, unless maintenance or repair is required with engine running.

4. Attach Do Not Operate warning tag to pump.

5. Do not use wood or concrete blocks to support the pump. Failure to properly support the pump may result in death or serious injury.

Use Lifting Equipment Safely

WARNING

Always check the lifting capacity and condition of hoists, slings, cables, or chains before use. Using underrated or worn lifting components can result in death or serious injury.

FOREWORD

• Never point air nozzles directly at skin.

• Compressed air is a useful tool when used in a safe manner.

• Always use eye and ear protection while using compressed air and air tools.

• When using air tools, do not exceed the air pressure rating for the tool.

• When using an impact wrench, always use approved impact sockets. Never use standard sockets on an impact wrench.

• Disconnect the air supply before changing air tool attachments.

• Always properly maintain air tools.

• Always use a lifting device with a lifting capacity greater than the weight of the item being lifted.

• Secure the load to the lifting device using cables, chains, or slings rated to handle the load being lifted. Fasteners being used to connect lifting devices must be strong enough to handle the load. Be sure the mounting point of load is strong enough to handle the load.

• When using a lifting device, always connect the load so it is balanced.

• Always use a lifting device on a hard, level surface.

• Lower the lifting device to the lowest point before moving. Move the load slowly.

• Always support the load as soon as possible. Never leave a load suspended in mid-air.

Use Compressed Air and Air Tools Safely

WARNING

Always wear approved eye and ear protection while using compressed air. Misuse of compressed air could result in death or serious injury.

• When using air nozzles, air pressure should not exceed 30 psi (206.8 kPa).

• Never direct air nozzles or tools at a person.

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FOREWORD

Handle Fuel Safely

WARNING

• Never remove the fuel cap from the fuel tank or add fuel when the engine is running or while the engine is hot.

• Do not smoke when handling fuel. Never fill or drain the fuel tank indoors.

• Do not spill fuel. Clean spilled fuel immediately.

• Never handle or store fuel containers near an open flame or any device that may create sparks and ignite the fuel or fuel vapors.

• Be sure to reinstall and tighten fuel cap securely.

• Use an approved container; the spout must fit inside the fuel filler neck. Avoid using cans and funnels to transfer fuel.

Routine service often requires the use of various chemical products, including lubricants and cleaning solutions. Many of these chemicals are flammable and can pose health risks if not handled properly.

• Never mix chemicals. Mixing chemicals can produce toxic or explosive results.

• Follow the manufacturer’s recommendations for safe usage and handling of the product.

• Various materials may pose a health hazard if used incorrectly. An MSDS contains important information regarding proper handling and health hazards, as well as emergency response procedures. Contact the chemical manufacturer to obtain an MSDS for the chemical product.

• Store fuel according to local, state, or federal ordinances and recommendations from your fuel supplier.

• Never overfill or allow the tank to become empty.

• Use clean, fresh fuel.

• Do not fill above the fuel filler neck.

Store Volatile and Hazardous Materials Safely

Store volatile materials (for example, gasoline, diesel fuel, oil, etc.) in approved containers that are clearly marked. Containers should be stored in an approved safety cabinet away from possible sources of ignition. Storage areas and cabinets should be well-ventilated to prevent the possible build-up of fumes.

Handle Chemical Products Safely

WARNING

Exposure to chemical products could result in serious injury. Handle chemical products with care.

Refer to the chemical manufacturer’s Material Safety Data Sheet (MSDS) for information regarding health hazards, safe handling, and emergency response procedures.

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Service Electrical Components Safely

WARNING

FOREWORD

environment. Collect fluids in well-marked, approved storage containers. Some waste fluids can react with certain types of plastics. Make sure the fluid to be stored is compatible with the storage container. Never use food or beverage containers to store waste fluids.

Always disconnect the negative terminal first and positive terminal last. Connect positive terminal first and negative terminal last. Use care when testing live circuits to prevent arcing. Arcing could result in death or serious injury.

• Make sure circuit breakers are open (off).

• Disconnect the battery negative (–) cable before removing or installing electrical components. Always connect the battery negative (–) cable last.

• Certain test and adjustment procedures must be performed with the battery connected. Use care to prevent arcing when working on live circuits or components. Arcing can cause component damage and could ignite flammable materials.

Dispose of Waste Materials Safely

Routine service can produce waste products such as used oil, coolant, grease, and batteries. If not handled properly, these materials can pose a threat to the

NOTICE

• Dispose of waste fluids properly at approved local recycling centers. If recycling facilities are not available, contact your local community for the correct disposal procedure for waste fluids.

• Dispose of old batteries properly. Battery electrolyte contains sulfuric acid and other hazardous materials. Never place an old battery in the trash. Batteries must be disposed of in a manner consistent with EPA and/or local regulations.

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Table of Contents

Specification and General Information

Maintenance

Troubleshooting

2 3

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Chapter 1

Specification and General Information

Standard Torque Values ................................................................. 1-2

Torque Values ....................................................................1-2

General Specifications ...................................................................1-6

General Specifications ..............................................................1-6

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62363

62365

SPECIFICATION AND GENERAL INFORMATION

Standard Torque Values

Torque Values

1. Always use torque values listed in Table 1-1, Torque Limits - SAE Standard Fasteners and Table 1-2, Torque Values for Lubricated or Plated Metric Thread Fasteners when a maintenance procedure does not provide a specific torque value.

2. Unless otherwise indicated, standard torque tolerance shall be ±10 percent.

3. Torque values listed are based on clean, dry threads.

a. Reduce torque by 25 percent when engine oil is

used as a lubricant.

b. Reduce torque by 25 percent if new plated cap

screws are used.

4. If the maintenance procedures do not specify a tightening order, use the following guidelines:

a. Lubricate threads of fasteners as specified in work

procedure or Table 2.

b. Tighten fasteners above 30 lb-ft (41 N•m) using

torque pattern and tighten to 70 percent of final value.

c. Multiply final value by 0.7 and torque to

specifications.

f. Tighten straight patterns using Figure 1-2, Straight

Torque Pattern.

Figure 1-2: Straight Torque Pattern

SAE Standard Fasteners Torque Limits

CAUTION

If replacement cap screws are of a higher grade than originally supplied, use torque specifications for original cap screw. Failure to comply may result in damage to equipment.

d. Use torque pattern to torque to final value. e. Tighten circular patterns using Figure 1-1, Circular

Torque Pattern.

Figure 1-1: Circular Torque Pattern

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Table 1-1. Torque Limits - SAE Standard Fasteners

SPECIFICATION AND GENERAL INFORMATION

Cap Screw Head Markings

(Manufacturer’s Marks May Vary)

SIZE

DIA. INCHES

1/4 1/4

5/16 5/16

3/8 3/8

7/16 7/16

1/2 1/2

9/16 9/16

5/8 5/8

3/4 3/4

7/8 7/8

1 1

1-1/8 1-1/8

1-1/4 1-1/4

1-3/8 1-3/8

1-1/2 1-1/2

THREADS PER

INCH

20 28

18 24

16 24

14 20

13 20

12 18

11 18

10 16

TORQUE

SAE GRADE

NO. 1 or 2 and

General Hardware

lb-ft (N•m) lb-ft (N•m) lb-ft (N•m) lb-ft (N•m)

5 (7) 6 (8)

11 (15) 12 (16)

20 (27) 23 (31)

30 (41) 35 (47)

50 (68) 55 (75)

65 (88)

75 (102) 90 (122)

100 (136) 160 (217)

180 (244) 140 (190)

155 (210) 220 (298)

240 (325) 300 (407)

340 (461) 420 (569)

460 (624) 560 (759)

640 (868)

740 (1003) 840 (1139)

SAE GRADE NO.5SAE GRADE NO.

6 or 7

8 (11)

10 (14) 17 (23)

19 (26) 30 (41)

35 (47) 50 (68)

55 (75)

75 (102) 90 (122)

110 (149) 120 (163)

150 (203) 180 (244)

260 (353) 300 (407)

400 (542) 440 (597)

580 (786) 640 (868)

800 (1085) 880 (1193)

1120 (1519) 1240 (1681)

1460 (1980) 1680 (2278)

1940 (2630) 2200 (2983)

10 (14) 12 (16)

21 (28) 24 (33)

40 (54) 45 (61)

60 (81) 70 (95)

95 (129)

100 (136) 135 (183)

150 (203) 190 (258)

210 (285) 320 (434)

360 (488) 520 (705)

580 (786)

800 (1085) 860 (1166)

1120 (1519) 1260 (1708)

1580 (2142) 1760 (2386)

2080 (2820) 2380 (3227)

2780 (3769) 3100 (4203)

SAE GRADE NO.

900 (1220)

1000 (1356) 1280 (1735)

1440 (1952) 1820 (2468)

2000 (2712) 2380 (3227)

2720 (3688) 3160 (4285)

3560 (4827)

12 (16) 14 (19)

25 (34) 45 (61)

50 (68) 70 (95)

80 (108)

110 (149) 120 (163)

150 (203) 170 (230)

220 (298) 240 (325)

380 (515) 420 (569)

600 (813) 660 (895)

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SPECIFICATION AND GENERAL INFORMATION

Metric Fasteners Torque Limits

Table 1-2. Torque Limits - Torque Values for Lubricated or Plated Metric Thread Fasteners

Cap Screw Head Markings

(Manufacturer’s Marks

May Vary)

Thread Diameter-Pitch Torque: lb-ft (N•m)

DIA. INCHES lb-ft (N•m) lb-ft (N•m) lb-ft (N•m)

M6M8

M8 X 1.25

M10

M10 X 1.25

M12

M12 X 1.5

M14

M14 X 1.5

M16

M16 X 1.5

M18

M18 X 1.5

M20

M20 X 1.5

M22

M22 X 1.5

M24

M24 X 2

M27

M27 X 2

M30

M30 X 2

M33 1300 (1763) 1850 (2508) 2150 (2915) M36 2100 (2847) 3000 (4067) 3500 (4745)

*Coat plated and unplated fasteners with oil before installation. +Use if bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed).

Class 8.8* or 9.8+ Class 10.9* Class 12.9

5 (7) 12 (16) 13 (18)

24 (33) 27 (37)

42 (57) 43 (58)

66 (89) 72 (98)

103 (140) 110 (149)

147 (199) 165 (224)

208 (282) 213 (289)

283 (384) 315 (427)

360 (488) 392 (531)

527 (715) 569 (771)

715 (969)

792 (1074)

7 (9) 17 (23) 18 (24)

34 (46) 38 (52)

60 (81) 62 (84)

95 (129)

103 (140) 148 (201)

157 (213) 203 (275)

320 (434) 288 (390)

320 (434) 392 (531)

431 (584) 498 (675)

542 (735) 729 (988)

788 (1068) 990 (1342)

1096 (1486)

12 (16) 30 (41) 29 (39)

70 (95) 60 (81)

120 (163)

190 (258)

300 (407)

410 (556)

580 (786)

800 (1085)

1000 (1356)

1475 (2000)

2000 (2712)

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62364

Using a Torque Wrench Extension

Occasionally an extension, crowfoot, or other adapter is necessary to use with a torque wrench to torque a bolt or line fitting. Adding adapters or extensions will alter the torque on the fastener from what the torque wrench reads. Use the following formula to calculate the correct torque wrench setting to achieve a specific torque value.

Figure 1-3: Torque Wrench and Extension

SPECIFICATION AND GENERAL INFORMATION

F - Force applied by technician L - Total length through which force is applied to fastener TW - Torque applied at end of torque wrench

TS = TE (LW / (LW + LE))

TS - Torque wrench setting TE - Torque specified at fastener LW - Length of torque wrench LE - Length of extension

Example: A component requires a specified torque value of 65 lb-ft and a 6 inch extension is required to reach it. What should the torque wrench setting (TS) be to compensate for the extension?

Torque specified at fastener (TE) = 65 lb-ft Length of torque wrench (LW) = 12 in. Length of extension (LE) = 6 in.

TS = TE (LW / (LW + LE)) TS = 65 lb-ft (12 in. / (12 in. + 6 in.) TS = 65 lb-ft (12 in. / (18 in.) TS = 65 lb-ft (0.666) TS = 43.33 lb-ft

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SPECIFICATION AND GENERAL INFORMATION

General Specifications

Engine

Engine Model GX 160 GX 270 GX 390

Engine Make Honda

Engine Type 4-stroke, 2-cylinder, air-cooled

Displacement 9.95 in³ (163 cm³) 16.48 in³ (270 cm³) 23.74 in³ (389 cm³)

Fuel Type Regular unleaded gasoline

Fuel Tank Capacity 0.8 gal (3.1 L) 1.4 gal (5.3 L) 1.6 gal (6.1 L)

Starting System Recoil Starter

Pump

Model PT2 PT3 PT4

Connection Diameter 2 in. (50 mm) 3 in. (80 mm) 4 in. (100 mm)

Connection Thread Parallel Pipe Thread or NPT

Total Head 98 ft (30 m) 89 ft (27 m) 98 ft (30 m)

Discharge Volume 185 gal/min (700 L/min) 383 gal/min (1450 L/min) 542 gal/min (2050 L/min)

Complete Pump Assembly

Model PT2 PT3 PT4

(1) strainer

Standard Accessory

(1) multi-tool for pump cover and plugs

Net Weight 104 lb (47 kg) 146 lb (66 kg) 181 lb (82 kg)

Guaranteed Sound Power LWA 105 dB LWA 105 dB LWA 106 dB

(1) barbed fitting

(2) wire hose clamps

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SPECIFICATION AND GENERAL INFORMATION

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SPECIFICATION AND GENERAL INFORMATION

Page Intentionally Blank

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Chapter 2

Maintenance

Maintinance and Testing .................................................................2-2

Engine Oil Drain/Fill Procedure .......................................................2-2

Pump Priming and Operation ........................................................2-3

After Use ........................................................................ 2-4

Front Cover ......................................................................2-5

Suction Test ......................................................................2-6

Suction and Discharge Flange .......................................................2-7

Spark Plug Inspection ..............................................................2-7

Mechanical Seal ...................................................................2-8

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MAINTENANCE

Maintinance and Testing

Engine Oil Drain/Fill Procedure

Drain/Fill

NOTE

The oil drain/fill procedure is the same on all pumps. PT4 is shown.

See Figure 2-1.

WARNING

Prolonged contact with lubricating oil may cause skin rash. Remove saturated clothing immediately and thoroughly wash skin that comes in contact with lubricating oil. Failure to comply may result in injury or death to personnel.

CAUTION

1. Support pump securely. (See "Support Pump Securely" on page 7.)

Figure 2-1: Engine Oil Tank Drain/Fill Procedure

Wipe clean area around all fluid connections prior to removal. Cap and plug all hoses, lines, fittings, and ports during removal to prevent contamination of system components. System must be kept clean from contaminants. Failure to comply may result in damage to equipment.

CAUTION

Ensure oil proper engine oil level prior to each startup. The engine manufacturer will not warranty damages caused due to low oil situations. Failure to comply may result in damage to equipment.

NOTES

• Oil should be changed every 8 hours of use for the first 20 hours of operation.

• Oil should be changed every 50 hours after the first 20 hours of operation.

• SAE#30 should be used during spring and summer months.

• SAE#20 should be used in during autumn and winter months.

• SAE10W-30 should be used in any conditions 50° F (10° C) and below.

2. Position suitable drain pan under the engine (1).

3. Remove the filler cap (2) from engine (1)

4. Remove drain plug (3) and sealing washer from engine (1). Allow engine oil to completely drain into drain pan.

Installation Notes

• Install drain plug and sealing washer.

• Ensure pump is on a level surface.

• Fill engine oil to the upper fill limit.

• Install filler cap.

• Start engine. Check for leaks. Repair as necessary.

• Check engine oil and add if necessary.

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MAINTENANCE

Pump Priming and Operation

Priming Pump

NOTE

All pumps are primed in a similar fashion. PT4 is shown.

See Figure 2-2.

WARNING

When priming the pump, only use water. Failure to comply may result in injury or death to personnel.

WARNING

Do not prime pump for more than 5 minutes. If pump priming is taking longer than 5 minutes, turn off engine and allow pump to cool. Failure to comply may result in injury or death to personnel.

CAUTION

inspect hoses to ensure they are the correct diameter and free of damage. If the hose diameter is to small or the hose is damaged, it will cause the pump to cavitate. Failure to comply may result in damage to equipment.

NOTE

To avoid air leaks and slow priming, ensure the suction hose is connected properly.

WARNING

High temperatures and/or pressures may be caused during priming or operation. If high temperatures and/or pressure conditions exist, do not open any plugs or hoses. Failure to comply may result in injury or death to personnel.

WARNING

Ensure discharge hose is secure before operating the pump. A loose discharge hose may cause the hose to slip or become detached. Failure to comply may result in injury or death to personnel.

CAUTION

Inspect pump and associated accessories before each use. Failure to comply may result in damage to equipment.

Figure 2-2: Pump Priming

1. Install suction hose on pump (2).

CAUTION

Do not run pump before filling with water. Failure to comply may result in damage to equipment.

2. Remove fill cap (1) from pump (2).

3. Completely fill pump (2) with water.

4. Install fill cap (1) on pump (2).

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MAINTENANCE

Pump Operation

WARNING

Ensure discharge hose is secure before operating the pump. A loose discharge hose may cause the hose to slip or become detached. Failure to comply may result in injury or death to personnel.

CAUTION

inspect pump and associated accessories before each use. Failure to comply may result in damage to equipment.

WARNING

Do not dead head or restrict water flow either at suction or discharge side of the pump. This will cause high air pressure and/or high temperature conditions. Failure to comply may result in injury or death to personnel.

4. Ensure discharge and suction hoses are free of any kinks, blockages, or obstructions.

CAUTION

Do not allow any vehicle to run over the delivery hose or close the delivery valve abruptly. This may cause waterhammering. Failure to comply may result in damage to equipment.

5. Start pump.

After Use

Draining Pump

CAUTION

Inspect hoses to ensure they are the correct diameter and free of damage. If the hose diameter is too small or the hose is damaged, it will cause the pump to cavitate. Failure to comply may result in damage to equipment.

1. Install suction hose on pump.

CAUTION

Do not operate pump before filling with water. Failure to comply may result in damage to equipment.

2. Prime pump. (See "Priming Pump" on page 2-3.)

3. Submerge strainer at the end of the suction hose in water. Ensure the strainer is suspended above any dirt or debris that may be at the bottom of the water being pumped.

NOTE

All pumps are drained in a similar fashion. PT4 is shown.

See Figure 2-3.

CAUTION

Ensure all water is drained from pump after use. Water left in pump may freeze and expand, damaging components. Failure to comply may result in damage to equipment.

1. Support pump securely. (See "Support Pump Securely" on page 7.)

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See Figure 2-4.

MAINTENANCE

WARNING

1. Support pump securely. (See "Support Pump Securely" on page 7.)

Figure 2-3: Draining Pump

NOTE

The number of drain plugs and drain plug locations vary depending on model.

2. Remove the water drain plug(s) (2) from bottom of pump (1), allowing water to drain.

3. Tilt pump (1) so remaining water and sediment will drain from pump (1). Ensure all sediment is drained.

4. Tilt pump (1) so remaining water and sediment will drain from suction and discharge ports. Ensure all sediment is drained.

NOTE

If the pump is used to transfer muddy water, sand and dirt will accumulate in the pump casing. This will make it difficult to remove the front cover.

5. If pump was used to transfer muddy water, remove front cover and clean the inside of pump prior to storage. (See "Removal and Installation" on page 2-5.)

Front Cover

Removal and Installation

NOTE

Figure 2-4: Front Cover Removal and Installation

2. Loosen knobs (2) securing front cover (3) to pump (1) using tool supplied with pump.

3. Pull front cover (3) away from pump (1) evenly, ensuring O-ring is does not become damaged.

4. Remove front cover (3) from pump (1).

Installation Notes

• Install front cover by reversing the order of removal.

• Ensure front cover seal is undamaged prior to installation.

• Tighten front cover fasteners evenly.

All front covers are removed the same way. PT4 is shown.

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MAINTENANCE

Suction Test

NOTE

The suction test is perfomed the same way on all pumps. PT4 is shown.

See Figure 2-5.

1. Support pump securely. (See "Support Pump Securely" on page 7.)

2. Remove suction hose.

3. Prime pump. (See "Inspection" on page 2-7.)

4. Start engine.

7. Inspect suction hose for holes, crushing, or any other damage.

Is suction hose free of holes, crushing, or damage?

YES Proceed to Step 8. NO Hose is damaged. Replace suction hose.

8. Remove front cover. (See " Front Cover" on page 2-5.)

9. Inspect the impeller for debris or blockage.

Is the impeller free of any blockage or debris?

YES Proceed to Step 10. NO Impeller is blocked. Remove any

blockage or debris.

10. Inspect impeller for damage.

Is the impeller free of any damage?

YES Pump suction is good. Inspect hoses and

strainer for damage or clogging.

Figure 2-5: Suction Port

5. Place palm of hand over the suction port (1) for 30 seconds.

Is suction present?

YES Pump suction is good. Inspect hoses and

strainer for damage or clogging

NO Impeller is damaged. Replace impeller.

NO Proceed to Step 6.

6. Inspect the suction hose for packing.

Is the packing present and undamaged?

YES Proceed to Step 7. NO Missing or damaged packing. Replace

packing.

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MAINTENANCE

Suction and Discharge Flange

Removal and Installation

NOTE

All suction and discharge flanges are removed the same way. PT4 is shown.

See Figure 2-6.

WARNING

NOTE

Both discharge and suction flanges are removed the same way. The discharge flange is shown.

1. Support pump securely. (See "Support Pump Securely" on page 7.)

Installation Notes

• Install discharge flange by reversing the order of removal.

• Ensure discharge flange seal is undamaged prior to installation.

• Torque discharge flange mounting screws to 7.4 lb-ft (10 N•m).

Spark Plug Inspection

Inspection

WARNING

1. Support pump securely. (See "Support Pump Securely" on page 7.)

2. Remove spark plug.

3. Using a clean cloth, remove any fuel and dirt from spark plug.

Figure 2-6: Discharge Flange Removal and

Installation

2. Remove screws (2) securing discharge flange (1) to pump (3). Remove discharge flange (1) from pump (3).

4. Using apropriate tool, adjust spark plug gap to

0.024 - 0.028 in. (0.6 - 0.7 mm) gap.

5. Install spark plug.

6. Attempt to start pump.

7. If pump does not start, replace spark plug.

5100048604 (12-18) 2-7

Page 28

MAINTENANCE

Mechanical Seal

Inspection

NOTE

All mechanical seals are inspected the same way. PT4 is shown.

See Figure 2-7.

See Figures 2-8 through 2-11.

WARNING

1. Support pump securely. (See "Support Pump Securely" on page 7.)

2. Remove front cover. (See " Front Cover" on page 2-5.)

Figure 2-7: Mechanical Seal Inspection

1. Inspect area between pump casing and engine (1) for water leaks.

2. If water is leaking between pump casing and engine, replace the mechanical seal. (See "Removal and Installation" on page 2-8.)

Removal and Installation

NOTE

All mechanical seals are removed in a similar fashion. PT4 is shown.

Figure 2-8: Impeller Plug

3. Remove impeller plug (1) from pump (2).

NOTE

If available, an impact wrench can be used to loosen the impeller on PT3 and PT4 models.

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6. Remove the mechanical seal (4) from impeller (3).

MAINTENANCE

Figure 2-9: Impeller Removal and Installation

4. Using appropriate punch or drift and hammer, loosen the impeller (3) by hammering impeller counterclockwise.

5. Remove the impeller (3) from pump (2).

Figure 2-11: Pump Mechanical Seal Removal and

Installation

7. Use two suitable tools to evenly pry the machine seal (5) away from the pump (2).

Installation Notes

• Install mechanical seal by reversing the order of removal.

• Ensure all sealing surfaces are clean prior to installation.

• Ensure seals are fully set.

• Replace impeller adjusting washer.

• Use a mallet or soft hammer to tighten the impeller.

Figure 2-10: Impeller Mechanical Seal Removal and

Installation

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MAINTENANCE

Page Intentionally Blank

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Chapter 3

Troubleshooting

Troubleshooting ........................................................................3-2

Starting Engine ................................................................... 3-2

Pump Functions ...................................................................3-3

Oil Leak .........................................................................3-4

5100048604 (12-18) 3-1

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TROUBLESHOOTING

Troubleshooting

Starting Engine

Symptom: Can Not Pull or Hard to Pull Recoil Starter.

Probable Cause Remedy

Old Fuel Replace fuel.

A separate engine manual, prepared by the engine

Rusted Internal Engine Components

Engine Failure

Blockage at Impeller Inlet Clean Impeller. (See " Front Cover" on page 2-5.) Debris Jamming Impeller Clean Impeller. (See " Front Cover" on page 2-5.)

manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for all engine-related service.

A separate engine manual, prepared by the engine manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for all engine-related service.

Symptom: Engine Does Not Start.

Probable Cause Remedy

Old Fuel Replace fuel. Faulty or Wet Spark Plug

Engine Oil Level is Too High or Too Low

Dirty or Plugged Air Cleaner

Engine Failure

Replace or clean spark plug as needed. (See " Spark Plug Inspection" on page 2-7.)

Adjust engine oil level as needed. (A separate engine manual, prepared by the engine manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for all engine-related service.)

Replace or clean air cleaner as needed. (A separate engine manual, prepared by the engine manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for all engine-related service.)

A separate engine manual, prepared by the engine manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for all engine-related service.

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TROUBLESHOOTING

Pump Functions

Symptom: Pump Has Low Delivery Volume.

Probable Cause Remedy

Air Leak at Suction Hose Repair or replace suction hose as needed. Water Leaking at Delivery Hose Repair or replace delivery hose as needed.

A separate engine manual, prepared by the engine

Engine Failure

Pump Placement Too High Suction Hose Too Long Replace or shorten suction hose as needed.

Suction Hose Diameter Too Small Replace suction hose. Blockage at Impeller Inlet Clean impeller. (See " Front Cover" on page 2-5.) Debris Jamming Impeller Clean impeller. (See " Front Cover" on page 2-5. ) Broken or Damaged Impeller Replace impeller. (See "Mechanical Seal" on page 2-8. )

manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for all engine-related service.

Move pump lower, so that it is closer to the fluid being pumped.

Symptom: Pump Does Not Prime.

Probable Cause Remedy

Air Leak At Suction Hose Repair or replace suction hose as needed. Insufficient Water Inside Pump Fill pump with water. (See "Inspection" on page 2-7.)

A separate engine manual, prepared by the engine

Engine Failure

Pump Placement Too High Lower pump closer to the fluid being pumped. Suction Hose Too Long Replace or shorten suction hose as needed. Suction Hose Diameter Too Small Replace suction hose. Blockage at Impeller Inlet Clean impeller. (See " Front Cover" on page 2-5.) Debris Jamming Impeller Clean impeller. (See " Front Cover" on page 2-5.) Broken or Damaged Impeller Replace impeller. (See "Mechanical Seal" on page 2-8.)

manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for all engine-related service.

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TROUBLESHOOTING

Oil Leak

Symptom: Oil Leaks From Muffler or Air Cleaner.

Probable Cause Remedy

Clean or replace the following:

• air cleaner

• carburetor

• muffler

Engine Has Been Tipped Over

• spark plug

(A separate engine manual, prepared by the engine manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for all engine-related service.)

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INDEX

Numerics

After Use

Draining Pump .................................. 2-4

Engine Oil Drain/Fill Procedure

Drain/Fill ........................................ 2-2

Front Cover

Removal and Installation ........................ 2-5

Pump Priming and Operation

Priming Pump ................................... 2-3

Pump Operation ................................ 2-4

Spark Plug Inspection

Inspection ....................................... 2-7

Suction and Discharge Flange

Removal and Installation ........................ 2-7

Foreward ............................................ 3

Starting Engine

Symptom: Can Not Pull or Hard to Pull Recoil

Starter. ...................................... 3-2

Symptom: Engine Does Not Start. .............. 3-2

Suction Test ....................................... 2-6

Torque Values

Metric Fasteners Torque Limits ................. 1-4

SAE Standard Fasteners Torque Limits ......... 1-2

Using a Torque Wrench Extension .............. 1-5

Troubleshooting

Troubleshooting ................................. 3-2

General Specifications

Complete Pump Assembly ...................... 1-6

Engine .......................................... 1-6

Pump ........................................... 1-6

Maintenance

Maintinance and Testing ........................ 2-2

Mechanical Seal

Inspection ....................................... 2-8

Removal and Installation ........................ 2-8

Oil Leak

Symptom: Oil Leaks From Muffler or Air

Cleaner. ..................................... 3-4

Pump Functions

Symptom: Pump Does Not Prime. .............. 3-3

Symptom: Pump Has Low Delivery Volume. .... 3-3

Specification and General Information

General Specifications .......................... 1-6

Standard Torque Values ........................ 1-2

5100048604 (12-18) IX-1

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Page 37

Notes

Page 38

Wacker Neuson America Corporation N92W15000 Anthony Avenue Menomonee Falls, WI 53051 U.S.A. Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957