WACKER Group PDI 2, Repair Manual

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

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Page 3: ...Damage caused by misuse or neglect of the unit should be brought to the attention of the operator to prevent similar occurrences from happening in the future 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 described in this manual THE INFORMAT...

Page 4: ... 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 rights are reserved Copyright 2006 by Wacker Corporation No part of this publication may be reproduced in any form or by any means electronic ...

Page 5: ...s 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 ...

Page 6: ...ug 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...

Page 7: ... symbol to avoid possible injury or death DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury CAUTION Used without the safety alert symbol CAUTION ind...

Page 8: ...r 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 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 Opera...

Page 9: ... 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 engines Fuel trapped in the cylinder will squirt 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 ...

Page 10: ...ERE 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 MONTHLY 30744 CAUTION PRECAUTION PRECAUCION ENGRASE RODAMIENTO DE LA BIELA MENSUALMENTE GRAISSER ROULEMENT DE LA BIELLE TOUS LES MOIS VORSICHT PLEUELLAGER ...

Page 11: ...f 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 OP...

Page 12: ...Safety Information PD 2 3 wc_si000176gb fm 8 CAUTION Lifting point Guaranteed sound power level in dB A Label Meaning ...

Page 13: ...PD 2 3 Safety Information wc_si000176gb fm 9 ...

Page 14: ...07629 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 ...

Page 15: ... for the sound pressure level LpA 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 Lift 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 Lubrication o...

Page 16: ... 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 ...

Page 17: ...splacement cm3 in3 126 7 7 Engine Speed rpm 2800 Max Operating Power kW Hp 3 2 4 3 Spark Plug type NGK BR6HS Champion RL86C Electrode Gap mm in 0 6 0 7 0 024 0 028 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...

Page 18: ... level LWA and ISO 6081 for the sound pressure 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 Lubr...

Page 19: ... up to 45 mm 1 75 in in diameter Diaphragm pumps are ideal for pumping mud slurries and seepage Typical applications include dewatering of trenches sewers pipelines septic tanks holding tanks farm ponds fields and excavations where a large amount of solids may be present in the water 3 2 Recommended Fuel The engine requires regular grade unleaded gasoline Use only fresh clean gasoline Gasoline con...

Page 20: ...ion hose c must not have any air leaks Check that all hose clamps b and couplings a are tight Check that cap on surge chamber f is tight 3 4 4 Check that discharge hose e is not blocked Lay hose out as straight as possible Remove any twists or sharp bends from hose which may block the flow of water Note Operating the pump with any part of the discharge line positioned higher than 7 5 m 25 ft above...

Page 21: ...y to left d1 3 5 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 Some engines are equipped with an oil alert light f that will come on while pulling the starter rope 3 5 5 Open choke as engine warms b2 3 5 6 Open throttle fully to operate 3 6 To Stop Machines with Honda Engines See Graphic wc_gr000014 3 6 1 Reduce engine ...

Page 22: ...7 3 Open throttle by moving it slightly to left c2 3 7 4 Pull starter rope e Note If the oil level in the engine is low the engine will not start If this happens add oil to engine 3 7 5 Open choke as engine warms d1 3 7 6 Open throttle fully to operate c1 3 8 To Stop Machines with Wacker Engines See Graphic wc_gr000655 3 8 1 Reduce engine RPM to idle by moving throttle completely to right c3 3 8 2...

Page 23: ... not prime check for loose fittings or air leak in suction hose Make sure strainer in water is not blocked DO NOT pump flammable fluids fuels corrosive chemicals or fluids containing toxic substances These fluids can create potentially dangerous health and environmental hazards Contact local authorities for assistance 3 10 Accessories WACKER offers a complete line of fittings hoses and clamps to p...

Page 24: ...vailable 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 Note This connection is important Even a small air leak on the suction side of pump will prevent the pump from priming Other Hose Connections For other hose connections one T bolt or worm gear type clamp is usually suffi...

Page 25: ...PD 2A 3A Operation wc_tx000592gb fm 21 ...

Page 26: ...maintenance Daily before starting After first 20 hrs Every 2 weeks or 25 hrs Every 100 hrs Every 300 hrs Check fuel level Check engine oil level Inspect air filter Replace as needed Check and tighten external hardware Change engine oil Check oil level in pump gear case Grease pump connecting rod bearing Clean sediment cup on engine fuel system Check and clean spark plug Check and adjust valve clea...

Page 27: ...e 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 4 2 3 Install the drain plug 4 2 4 Fill the engine crankcase with the recommended oil up to the level of the plug opening c See Technical Data for oil quantity and type 4 ...

Page 28: ...ll the drain plug 4 3 5 Fill the engine crankcase through the oil filler opening b to the upper mark on the dipstick c Do not thread in the dipstick to check the level See Technical Data for oil quantity and type 4 3 6 When the crankcase is full reinstall the dipstick 4 4 Cleaning Fuel Strainer Machines with Wacker Engines See Graphic wc_gr001093 4 4 1 To remove water and dirt close the fuel lever...

Page 29: ...rating temperature 4 6 2 Set the pilot screw a two turns out See Note 4 6 3 With the engine idling turn the pilot screw a in or out to the setting that produces the highest rpm 4 6 4 After the pilot screw is adjusted turn the throttle stop screw b to obtain the standard idle speed See Technical Data Note On some engines the pilot screw is fitted with a limiter cap c to prevent excessive enrichment...

Page 30: ...her types of low flash point solvents for cleaning the air cleaner A fire or explosion could result To service 4 7 1 Remove air cleaner cover a Remove both elements and inspect them for holes or tears Replace damaged elements 4 7 2 Wash foam element b in solution of mild detergent and warm water Rinse thoroughly in clean water Allow element to dry thoroughly Soak element in clean engine oil and sq...

Page 31: ...nder severe dry and dusty conditions the elements should be maintained daily Replace an element when saturated with dirt that cannot be removed 4 8 1 Remove the air cleaner cover a Remove the filter assembly by pulling it straight up Inspect both elements for holes or tears Replace damaged elements 4 8 2 Wash the foam element b in a solution of mild detergent and warm water Rinse it thoroughly in ...

Page 32: ...the engine Do not touch the muffler while it is hot Note Refer to the Technical Data for the recommended spark plug type and the electrode gap setting 4 9 1 Remove the spark plug and inspect it 4 9 2 Replace the spark plug if the insulator is cracked or chipped 4 9 3 Clean the spark plug electrodes with a wire brush 4 9 4 Set the electrode gap a 4 9 5 Tighten the spark plug securely CAUTION A loos...

Page 33: ...g 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 Change oil in gear case once a year or every 300 hours of operation Drain oil through drain plug opening f at bottom of gear case Add oil through fill plug on top of gear case See Technical Data for oil quantity and type g g f f h h wc_gr003450 ...

Page 34: ...ge amounts of dirt and solids clean the pump often If allowed to sit in the pump and dry these materials will harden and could damage the valves or diaphragm inside the pump the next time it is used When cleaning pump 4 12 1 Pump clean water through pump for a few minutes after each use to flush dirt from inside pump and hoses 4 12 2 Remove dirt from between engine cooling fins to prevent them fro...

Page 35: ...he housing after pump has cooled 4 13 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 4 13 3 Tape up suction and discharge ports to prevent anything from falling into pump 4 13 4 Change engine oil and follow procedures described in engine manual for engine storage 4 13 5 Cover pump and engi...

Page 36: ...tion hose damaged or collapsed Repair or replace hose Strainer plugged Clean or replace strainer Dirt collecting inside pump and hoses blocking flow Clean inside of pump and flush hoses Engine running slow Check engine speed and adjust See chapter Technical Data for engine speed Pump valves damaged or not seating properly Check for stones and gravel imbedded in valves Replace valves Diaphragm loos...

Page 37: ... procedures contained in this manual do not include part numbers For parts replacement information refer to the Parts Book originally supplied with the machine If the original Parts Book has been lost a replacement may be ordered from 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 al...

Page 38: ...pper valve d 5 4 4 Remove the large and small weights e and f from each side of the flapper valve Installation 5 4 5 Install the weights e and f to the flapper valves d with screws g CAUTION Do not over tighten the screws Over tightening will crush the rubber flapper and may prevent it from sealing properly Tighten the screws just so the rubber begins to compress 5 4 6 Using the dowel pins h as a ...

Page 39: ...PD Repair Disassembly Assembly Procedures wc_tx000590gb fm 35 wc_gr003452 a b c h d d e f f g g e h ...

Page 40: ... pump 5 5 7 Remove the screws f or studs and nuts securing the diaphragm g to the connecting rod and remove the diaphragm Installation 5 5 8 Secure the diaphragm g to the connecting rod with screws f or studs and nuts Torque the screws to 75 81 Nm 55 60 ft lbs 5 5 9 Secure the crank arm to the gear shaft with the screw c 5 5 10 Carefully position the connecting rod diaphragm assembly e between the...

Page 41: ...PD Repair Disassembly Assembly Procedures wc_tx000590gb fm 37 wc_gr003453 a c b d e h h f g h A B C D e ...

Page 42: ... 5 6 5 Remove the screws e that secure the retaining washers c to both sides of the connecting rod f and remove the retaining washers 5 6 6 Support the connecting rod in an Arbor press Press on the threaded end of the bearing d to remove it from the crank arm g and the connecting rod Installation 5 6 7 Using an Arbor press press the bearing d into the connecting rod 5 6 8 Install the retaining was...

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Page 44: ...y from the gearbox until the engine shaft is clear of the pump housing Installation 5 7 7 Position shims g either two C shaped shims or one flat washer per hole on the pump housing 5 7 8 Place the engine onto the shims pump housing Turn the engine s drive shaft as necessary to align its key with the keyway in the engine adapter b 5 7 9 Slide the engine through the engine adapter and into the gearb...

Page 45: ...PD Repair Disassembly Assembly Procedures wc_tx000590gb fm 41 wc_gr003460 a c f b e d a g g ...

Page 46: ...Disassembly Assembly Procedures PD Repair wc_tx000590gb fm 42 5 8 Gearbox Exploded View wc_gr003462 a g c d f e b j n k l m h i ...

Page 47: ...tx000590gb fm 43 5 9 Gearbox Components Ref Description Ref Description a Screw h Seal b Screw i Needle bearing c Gearbox cover j Woodruff key d Screw k Internal gear e Engine adapter l External gear f Pinion gear m Seal g Retaining ring n Gasket ...

Page 48: ... to gently pry the gearbox cover to remove it If prying is necessary be careful not to damage the gasket n while prying 5 10 6 Remove the screws d and lockwashers that secure the engine adapter e to the gearbox cover and remove the engine adapter 5 10 7 Pull the pinion gear f with the bearing attached from the gearbox cover 5 10 8 Remove the retaining ring g from the pinion gear and press the bear...

Page 49: ...PD Repair Disassembly Assembly Procedures wc_tx000590gb fm 45 wc_gr003461 a c d e b b f h j k l m i n ...

Page 50: ...cessary to install them 5 11 4 Install the Woodruff key j into the external gear s shaft 5 11 5 Install a new seal h and needle bearing i into the cover of the gearbox 5 11 6 Press the bearing onto the pinion gear f and secure it with the retaining ring g 5 11 7 Install the pinion gear f into the gearbox cover c 5 11 8 Secure the engine adapter e to the gearbox cover with the screws d 5 11 9 Place...

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Page 52: ...he engine and check the operating speed rpm with the tachometer Operating speed should be 2700 100 rpm 5 12 5 Grease the mounting face of the vacuum gauge to ensure a good seal Press the gauge over the inlet port Note It is not necessary to keep water in the pump while testing Diaphragm pumps do not use a mechanical seal which requires water in the pump to keep the mechanical seal cool 5 12 6 Obse...

Page 53: ...PD Repair Disassembly Assembly Procedures wc_tx000590gb fm 49 wc_gr003465 wc_gr003464 ...

Page 54: ...Disassembly Assembly Procedures PD Repair wc_tx000590gb fm 50 ...

Page 55: ...1 5 ml 17380 50 ml Loctite 271 277 Hernon 427 Omnifit 1550 220M Red High strength for all threads up to 25 mm 1 Heat parts before disassembly Temp range 54 to 149 C 65 to 300 F 29312 5 ml 26685 10 ml 73285 50 ml Loctite 290 Hernon 431 Omnifit 1710 230LL Green Medium to high strength for locking preassembled threads and for sealing weld porosity wicking Gaps up to 0 13 mm 0 005 Temp range 54 to 149...

Page 56: ...nts follow instructions on container The sealants listed are recommended for use on Wacker equipment TYPE Europe COLOR USAGE PART NO SIZE Loctite 496 Hernon 110 Omnifit Sicomet 7000 Clear Instant adhesive for bonding rubber metal and plastics general purpose For gaps up to 0 15 mm 0 006 Read caution instructions before using Temp range 54 to 82 C 65 to 180 F 52676 1oz Loctite Primer T Hernon Prime...

Page 57: ... 5 M4 2 9 26 4 1 36 4 9 43 7 9 32 3 M5 6 0 53 8 5 6 10 7 8 5 16 4 M6 10 7 14 10 17 13 10 5 M8 25 18 35 26 41 30 13 1 2 6 M10 49 36 69 51 83 61 17 11 16 8 M12 86 63 120 88 145 107 19 3 4 10 M14 135 99 190 140 230 169 22 7 8 12 M16 210 155 295 217 355 262 24 15 16 14 M18 290 214 405 298 485 357 27 1 1 16 14 M20 410 302 580 427 690 508 30 1 1 4 17 1 ft lb 1 357 Nm in lb 1 inch 25 4 mm 8 8 10 9 12 9 ...

Page 58: ...o 8 2 5 22 3 5 31 4 7 42 9 11 32 9 64 No 10 3 6 32 5 1 45 6 8 60 3 8 5 32 1 4 8 1 6 12 9 16 12 7 16 3 32 5 16 18 13 26 19 33 24 13 1 2 1 4 3 8 31 23 45 33 58 43 9 16 5 16 7 16 50 37 71 52 94 69 16 5 8 3 8 1 2 77 57 109 80 142 105 19 3 4 3 8 9 16 111 82 156 115 214 158 13 16 5 8 152 112 216 159 265 195 24 15 16 1 2 3 4 271 200 383 282 479 353 1 1 8 5 8 1 ft lb 1 357 Nm in lb 1 inch 25 4 mm ...

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Page 60: ... 02 0 Fax 49 0 89 3 54 02 3 90 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 ...