WACKER Group PG 2, Repair Manual

Page 1: ...www wackergroup com Pump PG 2 PG 2A PG 3 PG 3A REPAIR MANUAL 0163172en 001 0806 0 1 6 3 1 7 2 E N...

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Page 3: ...to order a replacement 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 provide...

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 Admi...

Page 5: ...ions PG 3 Machines with Honda Engines 13 2 6 Dimensions PG 3 Machines with Honda Engines 13 2 7 Technical Data Machines with Wacker Engines 14 2 8 Pump Machines with Wacker Engines 15 2 9 Sound Specif...

Page 6: ...Strainer Machines with Wacker Engines 29 4 12 Carburetor Adjustment Machines with Honda Engines 30 4 13 Adjusting Idle Speed Machines with Honda Engines 30 4 14 Storage 31 4 15 Troubleshooting 32 5 D...

Page 7: ...llow this 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 n...

Page 8: ...als or water containing toxic substances These fluids could create serious health and environmental hazards Contact local authorities for assistance 1 1 6 NEVER open the priming plug when the pump is...

Page 9: ...l combustion engines present special hazards during operation and fueling Read and follow the warning instructions in the engine owner s manual and the safety guidelines below Failure to follow the wa...

Page 10: ...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 other ty...

Page 11: ...PG Pumps Safety Information wc_si000180gb fm 7 1 4 Label Locations w c _ g r 0 0 0 8 3 3...

Page 12: ...in well ventilated area Read the Operator s Manual No sparks flames or burning objects near the machine Shut off the engine before refueling WARNING Hot surface CAUTION Read and understand the suppli...

Page 13: ...nit Please record the information found on this plate so it will be available should the nameplate become lost or damaged When ordering parts or requesting service information you will always be asked...

Page 14: ...0 8 0 028 0 031 Air Cleaner type Single element Engine Lubrication oil grade class SAE 10W30 SG or SF Engine Oil Capacity ml oz 600 20 Fuel type Regular unleaded gasoline Fuel Tank Capacity l qts 2 5...

Page 15: ...89 392 EEC Machinery Directive is the sound pressure level at operator s location LpA 84 dB A the guaranteed sound power level LWA 103 dB A These sound values were determined according to ISO 3744 fo...

Page 16: ...8 0 031 Air Cleaner type Single element Engine Lubrication oil grade class SAE 10W30 SG or SF Engine Oil Capacity ml oz 600 20 Fuel type Regular unleaded gasoline Fuel Tank Capacity l qts 3 6 3 8 Valv...

Page 17: ...re level at operator s location LpA 87 dB A the sound power level LWA 108 dB A These sound values were determined according to ISO 3744 for the sound power level LWA and ISO 6081 for the sound pressur...

Page 18: ...Operating Power kW Hp 3 2 4 3 4 2 5 7 Rated Power kW Hp 2 2 3 0 3 0 4 0 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 Lubricati...

Page 19: ...es were determined according to ISO 3744 for the sound power level LWA and ISO 6081 for the sound pressure level LpA at the operator s location Item Number PG 2 0009496 0009497 PG 3 0009498 0009499 Pu...

Page 20: ...and water containing some debris and solids Refer to Technical Data for maximum solid size 3 2 Recommended Fuel The engine requires regular grade unleaded gasoline Use only fresh clean gasoline Gasoli...

Page 21: ...ed Continued operation may cause water damage to engine 3 3 5 Check that hoses are securely attached to pump Suction hose b must not have any air leaks Tighten hose clamps c and couplings d Check that...

Page 22: ...to left d1 3 4 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 wi...

Page 23: ...3 Open throttle by moving it slightly to left c2 3 6 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 6 5 Open choke as e...

Page 24: ...ction hoses a must be rigid enough not to collapse when pump is operating Discharge hoses b are usually thin walled collapsible hoses Rigid hoses similar to those used as suction hoses may also be use...

Page 25: ...very 100 hrs Every 300 hrs Check fuel level Check engine oil level Inspect air filter Replace as needed Check external hardware Inspect hoses and housing for leaks Clean air cleaner element Change eng...

Page 26: ...f pump housing 4 2 1 Remove drain plug b from pump housing and drain any water left in pump 4 2 2 Loosen the four knobs holding the pump cover a and remove cover 4 2 3 Clean out dirt and debris Inspec...

Page 27: ...pump housing but do not remove impeller 4 3 2 Measure the distance d of volute 4 3 3 Measure the distance e of impeller 4 3 4 Subtract the distance e from d d e f clearance 4 3 5 The clearance between...

Page 28: ...hims b 4 4 2 Remove mechanical seal spring c and carbon face d from crankshaft 4 4 3 Remove mechanical seal ceramic face e and L ring f 4 4 4 Clean engine shaft remove any rust Also clean contact surf...

Page 29: ...gine 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 5 1 Remove spark plug and inspect it 4 5 2 Replace pl...

Page 30: ...types of low flash point solvents for cleaning the air cleaner A fire or explosion could result To service 4 6 1 Remove air cleaner cover a Inspect element b for holes or tears Replace element if dama...

Page 31: ...severe dry and dusty conditions the elements should be maintained daily Replace an element when saturated with dirt that cannot be removed 4 7 1 Remove the air cleaner cover a Remove the filter assem...

Page 32: ...s off Dispose of this liquid in accordance with environmental protection legislation 4 8 3 Install the drain plug 4 8 4 Fill the engine crankcase with the recommended oil up to the level of the plug o...

Page 33: ...nstall the drain plug 4 10 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...

Page 34: ...standard idle speed See Technical Data Note On some engines the pilot screw is fitted with a limiter cap c to prevent excessive enrichment of the air fuel mixture in order to comply with emission regu...

Page 35: ...the housing after pump has cooled 4 14 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 1...

Page 36: ...gine speed too low Adjust speed Suction strainer partially plugged Clean strainer Impeller worn Adjust clearance by adding shims or replace impeller Volute insert worn or damaged Adjust clearance or r...

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...

Page 38: ...ler Vanes on the impeller move the liquid into the volute where it is gathered and directed to the discharge port 5 Clearance between the impeller and the volute is maintained by the addition of shim...

Page 39: ...PG Repair Disassembly Assembly Procedures wc_tx000608gb fm 35 4 9 10 2 3 1 6 5 7 wc_gr003495 8...

Page 40: ...nnot be used Check that the strainer hose lines are not blocked or restricted Remove any dirt debris or vegetation which might interfere with the fluid flow If possible flush the hoses with clear wate...

Page 41: ...pump housing O ring and rear pump flange Replace the O ring if it is torn or crushed Make sure the cover is tightened evenly Check that the rear plate is not warped Check for water leaks between the...

Page 42: ...Disassembly Assembly Procedures PG Repair wc_tx000608gb fm 38 5 6 Pump Exploded View wc_gr003496 1 6 7 9 10 12 13 14 17 16 18 5 4 2 1 3 19 15 11 8 2...

Page 43: ...nts Ref Description Ref Description 1 Plug 11 Ring 2 O ring 12 Volute 3 Screw 13 Impeller 4 Discharge port 14 O ring 5 Discharge gasket 15 Mounting flange 6 Screw 16 Washer 7 Suction port 17 Mechanica...

Page 44: ...Remove the three screws 3 that secure the suction inlet port 2 to the pump 5 8 2 Remove the inlet port and flapper valve assembly 1 Installation 5 8 3 Install the new flapper valve assembly 1 with the...

Page 45: ...oval 5 9 1 Remove the four screws 1 and nuts 2 the secure the pump engine 3 to the frame 4 Installation 5 9 2 Secure the pump engine 3 to the frame 4 using screws 1 and nuts 2 Apply Loctite 243 or an...

Page 46: ...any debris from the pump housing 7 volute 9 and flange 8 5 10 5 Remove the volute 9 and the clean O ring 10 and the intake port Installation 5 10 6 Check the clearance between the impeller 11 and the...

Page 47: ...PG Repair Disassembly Assembly Procedures wc_tx000608gb fm 43 8 11 12 9 7 10 6 5 wc_gr003499...

Page 48: ...impeller is hard to remove tap it with a plastic mallet Do not lose any adjusting shims when removing the impeller 5 11 4 Remove the four screws 5 and washers 6 securing the rear pump flange 2 to the...

Page 49: ...PG Repair Disassembly Assembly Procedures wc_tx000608gb fm 45 wc_gr003500 PE 50 E 50 1 7 8 9 10 11 4 2 3 6 5 3...

Page 50: ...shaft 5 12 3 Remove the mechanical seal ceramic face 10 and L ring 11 from the rear pump flange Installation 5 12 4 Clean the engine shaft and remove any rust Clean the contact surface of the mechanic...

Page 51: ...PG Repair Disassembly Assembly Procedures wc_tx000608gb fm 47 wc_gr003500 PE 50 E 50 1 7 8 9 10 11 4 2 3 6 5 3...

Page 52: ...engine and prime the pump It may be necessary to tilt the pump or partially cover the discharge port to prevent the water in the pump housing from being lost while still allowing air to be vented 5 1...

Page 53: ...PG Repair Disassembly Assembly Procedures wc_tx000608gb fm 49 1 wc_gr003501...

Page 54: ...Disassembly Assembly Procedures PG Repair wc_tx000608gb fm 50...

Page 55: ...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 7...

Page 56: ...ts 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 adhes...

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 1...

Page 58: ...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...

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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 2...