WACKER Group PT 6LT, Operator'S Manual

Page 1: ...Pump PT 6 OPERATOR S MANUAL 0154629en 006 0107 0 1 5 4 6 2 9 E N ...

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Page 3: ...afety Labels 10 3 Technical Data 13 3 1 Engine 13 3 2 Pump 14 3 3 Lubrication 14 3 4 Trailer 14 3 5 Dimensions 15 4 Operation 16 4 1 Operation and Service Locations 16 4 2 Application 18 4 3 Recommended Fuel 18 4 4 Before Starting the Engine 18 4 5 Before Starting the Pump 18 4 6 To Start 20 4 7 To Stop 20 4 8 Automatic Shutdown System 21 4 9 Important Operation Note 21 4 10 Hoses 22 4 11 Hose Cou...

Page 4: ...Mounting Bolts 35 5 12 Mechanical Seal Lubrication 36 5 13 Bearing Housing Lubrication 37 5 14 Impeller Clearance 38 5 15 Cleaning the Engine Cooling Fins 40 5 16 Battery 40 5 17 Lifting the Machine 41 5 18 Tires 42 5 19 Wheels and Lug Nuts 42 5 20 Tongue Jack 42 5 21 Safety Chains 43 5 22 Lights 44 5 23 Wiring Diagram Trailer 45 5 24 Wiring Diagram 0007174 Rev 119 0007175 Rev 122 46 5 25 Wiring D...

Page 5: ...d serviced Follow operating instructions carefully If you have questions about operating or servicing this equipment please contact Wacker Corporation The information contained in this manual was based on machines in production at the time of publication Wacker Corporation reserves the right to change any portion of this information without notice All rights especially copying and distribution rig...

Page 6: ... indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Used without the safety alert symbol NOTICE indicates a hazardous situation which if not avoided could result in property damage Note Contains additional information important to a procedure 2 1 State Regulations Concerning Trailers Trailer laws covering such things as brakes lights safety chains ...

Page 7: ...p is hot Never loosen or remove inlet or discharge hose fittings when the pump is hot Hot water inside could be pressurized much like the radiator on an automobile Allow the pump to cool to the touch before loosening the plug and before loosening or removing the inlet or discharge hose fittings 2 2 7 NEVER position the pump on a loose uneven or unstable surface where it can tip roll slide or fall ...

Page 8: ...n open flame 2 3 6 ALWAYS refill the fuel tank in a well ventilated area 2 3 7 ALWAYS replace the fuel tank cap after refueling 2 3 8 ALWAYS check the fuel lines and the fuel tank for leaks and cracks before starting the engine Do not run the machine if fuel leaks are present or the fuel lines are loose 2 3 9 ALWAYS keep the area around a hot exhaust pipe free of debris to reduce the chance of an ...

Page 9: ...nt 2 5 1 ALWAYS check that the hitch and coupling on the vehicle are rated equal to or greater than the trailer s gross vehicle weight rating GVWR 2 5 2 ALWAYS inspect the hitch and coupling for wear or damage DO NOT tow the trailer using defective parts 2 5 3 ALWAYS make sure the coupling is securely fastened to the vehicle 2 5 4 ALWAYS check the tires on the trailer for tread wear inflation and ...

Page 10: ...n investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Wacker Corporation To contact NHTSA you may either contact the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0129 in Washington DC area www nhtsa com or write to NHTSA U S Departm...

Page 11: ...PT 6 Safety Information wc_si000098gb fm 9 2 7 Label Locations wc_gr001145 1 3 7 6 3 8 10 9 5 6 4 12 11 2 ...

Page 12: ...t off the engine before refueling 2 CAUTION Use only clean filtered diesel fuel 3 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 4 CAUTION Lifting point 5 WARNING Hot surface 6 WARNING Pressurized contents Do not open when hot 7 WARNING Never pump volatile flammable or low flash point flu...

Page 13: ...UAL 2 USE HITCH RATED FRO TRAILER S GROSS VEHICLE WEIGHT RATING 3 SECURELY ATTACH TRAILER TO TOW VEHICLE 4 ATTACH SAFETY CHAINS USING CROSS PATTERN 5 ATTACH BREAKDOWN CHAIN TO VEHICLE 6 CHECK TRAILER LIGHTS 1 BETRIEBSVORSCHRIFT LESEN 2 ANHANGEVORRICHTUNG VERWENDEN DIE DER GESAMTBETRIEBSGEWICHTSKLASSE ENTSPRICHT 3 ANHANGER SICHER AM ZUGFAHRZEUG BEFESTIGEN 4 SICHERHEITSKETTEN KREUZWEISE ANBRINGEN 5 ...

Page 14: ...Safety Information PT 6 wc_si000098gb fm 12 12 CAUTION Engine overheat Check fan belt This machine may be covered by one or more patents Ref Label Meaning ...

Page 15: ...esel engine Engine make Lombardini Engine model 11LD625 3 Rated power kW Hp 22 30 Alternator Amp 14 Engine speed full load rpm 2500 100 Engine speed idle rpm 1500 100 Valve clearance cold intake exhaust mm in 0 15 0 006 0 20 0 007 Air cleaner type Oil Bath Do not use oil lighter than 20W Battery V size 12V 31 Fuel type No 2 Diesel Fuel tank capacity l gal 98 26 ...

Page 16: ...discharge dia mm in 150 6 Max solid size mm in 50 2 Item No PT 6LT 0007175 PT 6LS 0007174 Lubrication Engine type qty SAE 15W40 CD Rated 5 0 L 5 qts Pump seal housing type qty SAE 15W40 800ml 27oz Pump bearing housing type qty SAE 15W40 470ml 16oz Item No PT 6LT 0007175 Trailer Power take off type Direct Drive with Flex Coupling Trailer tounge weight kg lbs 75 165 Gross vehicle weight Rating kg lb...

Page 17: ...PT 6 Technical Data wc_td000099gb fm 15 3 5 Dimensions wc_gr001154 ...

Page 18: ...nual fuel pump lever 16 Trailer hitch 4 Engine oil drain plug 17 Jack stand 5 Engine throttle solenoid 18 Rear stabilizers 6 Control panel 19 Drain cover 7 Ignition switch 20 Front impeller cover 8 Hour meter 21 Suction port 9 Bearing Seal housing 22 Priming cover 10 Lifting point 23 Discharge port 11 Engine oil fill cap 24 Fuel fill cap 12 Inspection cover 25 License plate holder 13 Air cleaner 2...

Page 19: ...PT 6 Operation wc_tx000261gb fm 17 wc_gr003183 18 17 15 16 7 8 9 6 26 23 22 21 20 19 25 12 11 13 10 14 24 1 2 4 5 3 ...

Page 20: ...eck The oil level in the engine The fuel level The condition of the air cleaner The tightness of the external fasteners The condition of the fuel lines NOTICE DO NOT run the engine without oil in the oil bath air cleaner or severe engine damage will result 4 5 Before Starting the Pump See Graphic wc_gr001165 4 5 1 Check the bearing seal housing f for proper oil level Also check the oil for water c...

Page 21: ...ps and coupling to make sure the hoses are securely fastened A loose connection can create a serious safety hazard should it break loose while the pump is running 4 5 7 Attach the suction strainer to the suction hose to prevent large debris from being pulled into the pump 4 5 8 Prime the pump To do so open the cover c at the top of the pump and fill the pump housing with water The pump will not pr...

Page 22: ...t prime shut off the engine and refer to the section on troubleshooting NOTICE DO NOT crank the starter for more than 15 20 seconds at a time the starter motor can overheat and be damaged NOTICE DO NOT run the pump dry for long periods of time or run the pump without oil in the bearing seal housing The mechanical seal could overheat and be damaged Adjusting Pump Flow Pump flow can be set by adjust...

Page 23: ...zed the engine stops If the engine stops unexpectedly and the circuit breaker trips it is a sign of a problem with the fan belt Check the fan belt and replace it if necessary Reset the circuit breaker before resuming use of the pump If the engine stops unexpectedly without the circuit breaker tripping check the amount of oil in the engine crankcase Fill the engine crankcase with oil as needed 4 9 ...

Page 24: ... suction and discharge hoses are available through Wacker Corporation 4 11 Hose Couplings A variety of couplings are available to attach the hoses to the suction and discharge ports as well as to connect two hose lengths together 4 12 Hose Clamps Suction Hose to Inlet Port Coupling At least two T bolt clamps are recommended for connection of the suction hose to the pump inlet Index clamps at 90 in...

Page 25: ...ilure to follow the above directives may cause pump damage 4 14 Discharge Port See Graphic wc_gr001184 The discharge port a can be rotated 360 to direct water flow in any direction To rotate the elbow 4 14 1 Remove the locknuts b which hold the port to the pump housing 4 14 2 Lift the port off the studs and position it as desired Always check the gasket and replace it if it is damaged 4 14 3 Tight...

Page 26: ...nspect the pump interior To remove the impeller cover and elbow 4 15 1 Turn the inner star wheel d in until it is seated tightly against the impeller cover 4 15 2 Turn the outer star wheel e in until the cover is pulled out of the housing 4 15 3 When the impeller cover is free of the housing rotate the clamp f counterclockwise and pull the impeller cover from the housing To install the impeller 4 ...

Page 27: ...PT 6 Operation wc_tx000261gb fm 25 wc_gr003210 3 1 2 e g 3 1 2 d a b c f ...

Page 28: ...s on the tongue are secure To hitch the trailer 4 16 1 Back your vehicle as close as possible to the trailer It is easier and safer to back the tow vehicle under the trailer than to pull the trailer to the vehicle 4 16 2 Check that the coupler locking device h is released 4 16 3 Raise the trailer coupler using the tongue jack d to a height just above the ball on the hitch Carefully position the ve...

Page 29: ...ce turning stopping and backing up in an area away from traffic DO NOT exceed 55 mph when towing the trailer In most states large trailers must be registered and licensed by the State Department of Transportation Before towing be sure to check licensing requirements Always refer to the applicable Department of Transportation regulations before towing CAUTION WARNING wc_gr003185 h d c f g k e ...

Page 30: ...lt water be sure to use fresh water when flushing it 5 2 2 Change the engine oil 5 2 3 Drain and clean the fuel tank Replace the fuel filter 5 2 4 Thoroughly clean the exterior of the pump and engine Visually inspect the machine for signs of damage or loose bolts 5 2 5 Remove the covers and clean the pump interior Wipe or spray all interior surfaces with a rust inhibiting oil 5 2 6 Change the oil ...

Page 31: ...ondition and tension on fan belt Change oil in engine crankcase Change engine oil filter Change fuel filter Clean engine cooling fins Check valve clearance Tighten fittings and clean injectors Replace fan belt Machine Daily before starting Every 100 hrs Every 250 hrs Every 500 hrs Check external hardware Open pump housing cover and remove any debris from inside of pump housing Check oil level in s...

Page 32: ...NOTICE NEVER run the engine without oil in the air cleaner Severe engine damage will result To clean the air cleaner 5 4 1 Release the snap clips b and remove the oil bowl c 5 4 2 Remove the filter element d from the oil bowl Be careful not to damage the rubber seal ring e on the element 5 4 3 Rinse the filter element with diesel fuel or kerosene DO NOT use gasoline Allow the filter element to air...

Page 33: ...y it will be necessary to prime the fuel system To prime fuel system 5 6 1 Remove the small plug from the top of the water separator and prefill the element with clean diesel fuel 5 6 2 Loosen the bleed screw a on the fuel filter and pump the manual lever on the fuel pump b until fuel flows freely from the screw hole Tighten the bleed screw 5 6 3 Loosen the bleed screw c starting with the injector...

Page 34: ...hat the oil level is at the top mark Add oil through the oil filler cap a on top of engine checking occasionally with dipstick DO NOT overfill Suggested oil grades Use only diesel engine oil API service rating CD or equivalent ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE Ambient Temperature Multi grade 25ºC 13ºF 15ºC 5ºF 20ºC 4ºF 15ºC 59ºF 30ºC 86ºF 0ºC 32ºF SAE 10W 30 SAE 15W 40 20W 40 SAE 5W 2...

Page 35: ...f this liquid properly 5 8 2 Install the drain plug 5 8 3 Remove the oil filler cap a and fill the engine crankcase with the recommended oil Oil Capacity 5 liters 5 qts SAE15W40 CD rated 5 8 4 Install the oil filler cap 5 9 Valve Clearances See Graphic wc_gr000476 Check and adjust the valve clearance every 500 hours Set the clearance when the engine is cold 5 9 1 Remove the rocker arm cover and ch...

Page 36: ...d a and check the fan belt b for cracks or splitting 5 10 2 To tighten the fan belt add or remove spacers c located between the fan pulley halves d Spacers are 0 5 1 0 2 0 mm 0 017 0 034 0 068 in thick 5 10 3 To check fan belt tension press the fan belt halfway between belt pulleys with a 10 kg 22 lb load or strong thumb pressure The fan belt should deflect 1 cm 3 8 in wc_gr001190 a b d c ...

Page 37: ...using Mounting Bolts See Graphic wc_gr003178 Tighten the mounting bolts a on the pump housing after the first 50 hours of operation Inspect the bolts periodically thereafter and tighten when required Torque the bolts to 330 Nm 243 ft lbs wc_gr003178 a ...

Page 38: ...nical seal however if water contamination is heavy and oil feels watered down inspect the mechanical seal for signs of wear or damage To check the oil level 5 12 1 Remove the plastic fill plug a from the top of the bearing housing The oil level should touch the base of the plug opening Add oil as required To change the oil 5 12 2 Remove the drain plug c from the bottom of the bearing housing 5 12 ...

Page 39: ...3 1 Remove plastic fill plug b from top of bearing housing Oil level should be near center of drive shaft Add oil as required To change oil 5 13 1 Remove plug d from bottom of bearing housing 5 13 2 Replace drain plug and add 470 ml 16 oz of 15W40 oil through port b on top of bearing housing DO NOT overfill housing Inspect drained oil If oil is dirty or feels watered down inspect pump and bearing ...

Page 40: ...ore working on it 5 14 5 Reach inside the pump through the suction port and use a feeler gauge c to check the gap between the impeller and the insert e The pump will operate most efficiently when the gap is maintained between 0 15 0 75 mm 0 005 025 in Larger gaps are allowable but may reduce pump output slightly 5 14 6 If necessary add shims f between the insert and the impeller cover g to decreas...

Page 41: ...PT 6 Maintenance wc_tx000567gb fm 39 wc_gr003206 a b g c d d e e f g g e f g 0 15 0 75 mm 0 005 0 025 in ...

Page 42: ... air Replace the inspection cover before starting the engine 5 16 Battery See Graphic wc_gr003177 The battery a supplied on this machine is a heavy duty lead acid battery rated at 12V 160 Ah BCI group 31 Check the level of the electrolyte in the battery periodically and add distilled water as required to keep the electrolyte at the correct level Keep the battery terminals clean and tighten them as...

Page 43: ... of at least 1090 Kg 2400 lbs Only use steel ropes or chains for hoisting The rope or chain must have the suitable specified lifting capacity of 1090 Kg 2400 lbs Do not use improvised ropes or chains Never use any other part of the PT6 Pump to lift the machine as severe damage may occur Do not stand under or get onto the machine while it is being hoisted or moved WARNING CAUTION WARNING wc_gr00318...

Page 44: ... tire 5 19 Wheels and Lug Nuts Loose or missing lug nuts can cause you to lose a wheel Keep all lug nuts tight Before each trip check for loose or missing lug nuts When replacing lug nuts make sure the replacement nut matches the original nut exactly While the threads of the nut may match the nut may be a size that does not hold the wheel securely against the hub even when fully tightened Torque n...

Page 45: ... trip Chains should be attached in a crossing pattern under the trailer tongue The chains will prevent the trailer tongue from dropping to the ground if the trailer separates from the hitch Rig the chains as tight as possible with just enough slack to permit tight turns If a chain must be replaced do not substitute a lighter weight chain This trailer must be equipped with two chains each with a mi...

Page 46: ...working before towing the trailer State and federal regulations require that all types of trailers be equipped with tail stop and turn lights e and side marker lights f A special wiring harness g for connecting the trailer lights to the lighting system of the tow vehicle is supplied with the trailer WARNING wc_gr003182 e f g ...

Page 47: ...aintenance wc_tx000567gb fm 45 5 23 Wiring Diagram Trailer Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue ...

Page 48: ... wc_gr003163 R R B RWB L W Br W Br L Br B B R L B W Br Y R Br L Gr W B Y G B B Y W B R Y Br L L Br P G W G L R Or R R G W R V B W R G Or V W W Y Y Y Y Y R B B R L L Y Y P B B L V B G Y B P B P B 50 30 15 54 86 85 30 87 1 3 4 5 6 7 8 25 26 9 10 11 12 13 22 21 14 23 23 15 16 17 18 24 19 20 2 ...

Page 49: ...5 Throttle solenoid 18 Voltage regulator 6 Hour meter 19 Low oil pressure switch N O 7 Control panel 20 Low oil pressure switch N C 8 Keyswitch 21 Diagnostic port 9 Glow plug relay 22 Cam RPM sensor 10 15A Fuse 23 Control solenoids 11 20A Circuit breaker 24 Engine alternator 12 Pump sensor 25 80A Fuse 13 Engine RPM sensor 26 Control panel harness Wire Colors B Black R Red Y Yellow Or Orange G Gree...

Page 50: ...PT 6 wc_tx000567gb fm 48 5 26 Wiring Diagram 0007174 Rev 120 0007175 Rev 123 wc_gr003173 W Or Br G B L Y G B B Y W R Y L Br G V W W Y Y Y Y Y R B B R L L L G Y B 50 30 15 54 1 3 5 6 7 8 4 10 11 13 14 9 12 6 15 2 R ...

Page 51: ...ine harness 10 15A Fuse 3 Extension harness 11 20A Circuit breaker 4 Control panel harness 12 Engine alternator 5 Throttle solenoid 13 Battery 6 Hour meter 14 Starter solenoid 7 Control panel 15 Oil pressure failure sensor 8 Keyswitch Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue ...

Page 52: ...e faulty Engine is hard to start Dirt or debris inside pump housing blocking move ment of impeller Battery charge low Engine faulty Engine starts but pump does not take in water Pump housing not filled with water Strainer on suction hose plugged Suction hose damaged Air leak above water line Air leak at suction port Pump too high above water line Engine speed too low Debris collecting in pump hous...

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Page 66: ... 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 ...