Wacker 0009098 Instructions / Assembly
Contents
1. or elsewhere When you see this symbol be alert i oe as DISABLE to the possibility of personal injury or death Follow ccidents the instructions in the safety message e Accidents CAN BE AVOIDED NOTICE OF COPYRIGHT PROTECTION AEM Safety Manuals are protected as a copyrighted work with creation of derivative works based on an AEM Safety Manual ownership duly registered with the Copyright Office without the prior written approval of AEM is expressly Washington D C Any reproduction translation decompiling or prohibited Copyright infringement can result in civil and criminal other use of an AEM Safety Manual or portion thereof or the sanctions damages and other penalties being imposed Copyright 2004 Association of Equipment Manufacturers REFERENCES The following is a partial list of referenced material SAE Society of Automotive Engineers Inc on safe operating practices 400 Commonwealth Drive Warrendale PA 15096 U S Department of Labor publishes safety and a e health regulations and standards under the Publishes a list Operator Precautions SAE J153 authority of the Occupational Safety and Health Act Mai for the general construction and mining industries AEM Association of Equipment Manufacturers U S Department of Labor 111 East Wisconsin Avenue Washington DC 20210 Milwaukee WI 53202 NFPA National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 91012. Keep hands and feet clear of moving parts DO NOT stick fingers into a pump when in operation Check suction strainer and hose regularly for proper submergence and to be sure it is free of obstructions NEVER operate a self priming pump unless the volute is filled with liquid The pump will not prime when dry PUMP only liquids for which the pump has been designed to handle DO NOT pump flammable corrosive or caustic materials unless the pump and piping are explicitly designed for that purpose NOTE the direction of rotation operation of a pump in the wrong direction can cause the impeller to unscrew and damage the volute case A pump should not be operated against a closed valve or other no flow conditions Refer to the pump manufacturer s recommended practice for start up operation and shut down procedures DO NOT close down or restrict a discharge hose Be careful of discharge hose whipping under pressure 12 MAKE CERTAIN that whatever is to be connected to he pump is not subjected to pressures greater than those given in the manufacturer s instructions MAKE CERTAIN all connections are securely made and hoses under pressure are secured with appropriate safety devices to prevent whipping BE AWARE OF LIGHTNING Stay clear of the pumping equipment during electrical storms It can attract lightning FIG 10 OVERHEATING PRECAUTIONS Overheated pumps can cause severe damage to the equipment and can caus
3. 5000185222 or Ka Copyright notice Trademarks Manufacturer Original instructions Copyright 2011 by Wacker Neuson Production Americas LLC All 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 Production Americas LLC Any type of reproduction or distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights Violators will be prosecuted All trademarks referenced in this manual are the property of their respective owners Wacker Neuson Production Americas LLC 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 Operator s Manual presents the original instructions The original language of this Operator s Manual is American English PT 3 PT3A PT 3H Foreword Foreword SAVE THESE INSTRUCTIONS This manual contains important instructions for the machine models below These instructions have been written expressly by Wacker Neuson Production Americas LLC and must be followed during installation operation and maintenance of the machines Machine Item Number PT 3 1 0620726 0009321 0009322 0009323 PT 3A 0009098 0009101 0009
4. PT 2 3 Safety Information 44 Operator Safety while Using Internal Combustion Engines WARNING Internal combustion engines present special hazards during operation and fueling Failure to follow the warnings and safety standards could result in severe injury or death gt Read and follow the warning instructions in the engine owner s manual and the safety guidelines below DANGER Asphyxiation hazard Using a pump indoors CAN KILL YOU IN MINUTES Pump exhaust contains carbon monoxide This is a poison you cannot see or smell gt NEVER use this pump inside a home or garage EVEN IF doors and windows are open Only use OUTSIDE and far away from windows doors and vents gt NEVER use a pump inside an enclosed area such as a tunnel or a trench unless adequate ventilation is provided through such items as exhaust fans or hoses Operating safety When operating the pump e Keep the area around exhaust pipe free of flammable materials e Check the fuel lines and the fuel tank for leaks and cracks before starting the engine When operating the pump e Do not smoke while operating the machine e Do not run the machine if fuel leaks are present or the fuel lines are loose e Do not run the engine near sparks or open flames e Do not touch the engine or muffler while the engine is running or immediately after it has been turned off e Do not operate a machine when its fuel cap is loose or missing e Do not star
5. Permanent damage to the machine which will not be covered under warranty Contact your Wacker Neuson dealer immediately if you have questions about approved or unapproved parts attachments or modifications NEUSON 4 wc_tx001780gb fm WACKER NEUSON EC Declaration of Conformity Manufacturer Wacker Neuson Production Americas LLC N92W15000 Anthony Avenue Menomonee Falls Wisconsin USA Product Product PT 3 PT 3A PT 3H Product category Centrifugal Trash Pump Product function To pump fluid Item number 0009101 0009240 0009103 0620726 0620800 Net installed power PT 3 6 6 kW PT 3A 5 9 kW PT 3H 5 0 kW Measured sound power level PT 3 103 dB A PT 3A 101 db A PT 3H 107 dB A Guaranteed sound power level PT 3 104 dB A PT 3A 102 db A PT 3H 108 dB A Conformity Assessment Procedure According to ANNEX V Guidelines and Standards We hereby declare that this product meets and complies with the relevant regulations and requirements of the following guidelines and standards 2006 42 EC 2000 14 EC 2002 88 EC 89 336 EEC 98 37 EEC Authorized Person for Technical Documents Axel H ret Wacker Neuson SE PreukenstraBe 41 80809 Munchen Menomonee Falls WI USA 17 5 11 ASA Sore EE mano E 5 E William Lahner Dan Domanski Q Vice President of Engineering Manager Product Engineering Original Declaration of Conformity PT 3 PT 3A PT 3H Table of Contents Foreword 3 Safety Information 9
6. FOREWORD FOLLOW A SAFETY PROGRAM PERFORM MAINTENANCE SAFELY PREPARE FOR SAFE OPERATION WORK SAFELY Pumps In General WORK SAFELY Engine Driven Pumps WORK SAFELY Electric Motor Driven Pumps WORK SAFELY Submersibles TESTYOUR KNOWLEDGE FINAL WORD TO THE USER FOREWORD This safety manual is intended to point out some of the basic situations which may be encountered during the normal operation and maintenance of your equipment and to suggest possible ways of dealing with these conditions Additional precautions may be necessary depending on application pump type configuration and attachments used conditions at the work site or in the maintenance area The manufacturer has no direct control over pump application operation inspection lubrication or maintenance Therefore it is your responsibility to use good safe practices in these areas The information provided in this manual supplements the specific information about your pump that is contained in the manufacturer s manual s Other information which may affect the safe operation of your pump may be contained on safety signs decals markings insurance requirements employer s safety programs safety codes local state provincial and federal laws rules and regulations contracts agreements and warranties CONTENTS Page It is your responsibility to read and understand this safety manual and the manufacturers manual s before operating your pump
7. Technical Data 49 6 1 PP a 49 6 2 A o a e A o lo E IA 50 6 3 Sound Measurements occoocccncccncncncnnncnncncncnnnnncnonnnonanonanonannnnanenanenaninos 51 6 4 DIMENSIONS wo iR Aa A iban AAAA CE W Ao 51 Emission Control Systems Information and Warranty 52 7 1 Emission Control Systems Warranty Statement useeeeeeeeeeeeeeeee 52 AEM Safety Manual 53 WACKER wc_bo5000185222_11TOC fm NEUSON 8 PT 2 3 Safety Information 1 Safety Information 1 1 Signal Words Used in this Manual This manual contains DANGER WARNING CAUTION NOTICE and NOTE signal words which must be followed to reduce the possibility of personal injury damage to the equipment or improper service This is the safety alert symbol It is used to alert you to potential personal hazards gt Obey all safety messages that follow this symbol DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury gt To avoid death or serious injury from this type of hazard obey all safety mes sages that follow this signal word WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury gt To avoid possible death or serious injury from this type of hazard obey all safety messages that follow this signal word CAUTION CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury gt To avoid possible minor or mo
8. This safety manual takes you step by step through your working day If you do not understand any of this information or if errors or contradictions seem to exist consult with your supervisor before operating your pump IMPORTANT If you do not have the manufacturer s manual s for your particular pump get a replacement manual from your employer equipment dealer or manufacturer of your pump Keep this safety manual and the manufacturer s manual s with your pump Unauthorized modifications of pumps create hazards Pumps must not be modified or altered unless prior approval is obtained from the manufacturer DO NOT PUMP VOLATILE FLAMMABLE OR CAUSTIC CORROSIVE LIQUIDS REFER TO THE OWNER S MANUAL OR CONSULT WITH THE MANUFACTURER FOR THE PROPER PUMP MATERIALS IF YOU ARE TO PUMP HAZARDOUS CAUSTIC CORROSIVE LIQUIDS Section O u N KNOW THE RULES Every employer is concerned about safety Safe operation and proper maintenance of your pump can prevent accidents KNOW the rules LIVE by them FIG 1 When starting work at a new site check with the designated safety coordinator for specific safety instructions DON T LEARN SAFETY THE HARD WAY Know the meaning of all hand signals signal flags signs and markings Know the traffic rules used at the work site Know who the signal man is watch and obey his signals Know where the fire extinguishers and first aid kits are kept and how to use t
9. 4 4 7 WACKER NEUSON Read safety instructions at the beginning of this Operator s Manual Place pump as near to water as possible on a firm flat level surface To prime pump remove prime plug a and fill pump housing with water If the pump housing is not filled with water before starting it will not begin pumping Do not open priming plug discharge plug or loosen hose fittings if pump is hot Water or vapor inside pump may be under pressure Check for leaks between pump and engine If water is leaking the seal inside pump is worn or damaged Continued operation may cause water damage to engine 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 discharge hose e is not restricted Lay hose out as straight as possible Remove any twists or sharp bends from hose which may block the flow of water Make sure suction strainer f is clean and securely attached to end of hose The strainer is designed to protect the pump by preventing large objects from being pulled into the pump NOTICE Strainer should be positioned so it will remain completely under water Running the pump with the strainer above water for long periods can damage the pump Check fuel level engine oil level and condition of air cleaner 24 wc_tx001779gb fm Operation PT3 PT3A PT3H wc gr000013 w WACKER NEUSON wc
10. Measurements The required sound specification per paragraph 1 7 4 f of 89 392 EEC Machinery Directive is Guaranteed sound power level Lwa PT 3A 102 dB A PT 3H 108 a dB A PT 3 104 dB A The sound pressure level at operator s location Lpa PT 3A 90 4 dB A PT 3H 99 dB A PT 3 92 dB A These sound values were determined according to ISO 3744 for the sound power level Lwa and ISO 6081 for the sound pressure level Lpa at the operators location 6 4 Dimensions 505 S p 675 7 20 26 l gt al b s S T m 23 Em Ly y R a wc_gr000012 E WACKER c_td000440gb f 51 NEUSON Emission Control Systems Information and Warranty 7 Emission Control Systems Information and Warranty The Emission Control Warranty and associated information is valid only for the U S A its territories and Canada 7 1 Emission Control Systems Warranty Statement See the supplied engine owner s manual for the applicable exhaust and evaporative emission warranty statement NEUSON 52 we_tx001753gb fm CIATION OF PORTABLE PUMPS www aem org A SAFETY MANUAL FOR OPERATING AND MAINTENANCE PERSONNEL SAFETY ALERT SYMBOL A e ld Why is SAFETY important to YOU The Safety Alert Symbol identifies important safety 3 BIG REASONS messages on machines safety signs in manuals
11. Power Rating Net power rating per SAE J1349 and ISO 3046 Actual power output may vary due to conditions of specific use AA TA AA ii Engine Type 4 stroke overhead valve 4 stroke air single cylinder cooled diesel engine Engine Model NM WM270 GX240 UT2PA2 1B 30 Max rated power at W Hp 6 6 9 5 9 7 9 5 0 6 8 rated speed pan rom Aa rem rpm Displacement 265 16 17 270 16 5 347 21 2 Spark Plug NGK BR 6HS NGK BPR 6ES dee RL86C DENSO W20EPR U Electrode Gap in 0 6 0 7 0 7 0 8 0 024 0 028 0 028 0 031 Operating speed 3500 Engine Speed idle 1600 100 Valve Clearance cold Intake and in 0 10 0 004 Air Cleaner type Dual element Dry pleated paper element Engine Lubrication oil SAE 10W30 CD CE CF CG grade Service Class SJ Rated Engine Oil Capacity 1 1 37 1 1 37 Regular Unleaded Gasoline No 2 Diesel Fuel Tank Capacity qt 6 0 6 4 5 3 5 6 5 0 5 2 WACKER wc_td000440gb fm 49 NEUSON Technical Data PT 3 PT 3A PT 3H 6 2 Pump PT 3 I PT 3 PT 3A PT 3H 0620726 0009321 0009098 0009100 0009322 0009101 0009103 0009323 0009240 0009242 0620800 Dimensions mm in 675 x 505 x 570 26 x 20 x 23 Weight 68 148 Max suction lift E 7 5 25 Max discharge I min 1515 gpm 400 Based on pump operating at sea level Maximum suction lift will be less at higher altitudes NEUSON 90 wc_td000440gb fm PT 3 PT 3A PT 3H Technical Data 6 3 Sound
12. frequently to prevent carburetor malfunction NOTICE NEVER run engine without air cleaner Severe engine damage will occur NEVER use gasoline or other types of low flash point solvents for cleaning the air cleaner A fire or explosion could result WARNING To service 5 6 1 Remove air cleaner cover a Remove both elements and inspect them for holes or tears Replace damaged elements 5 6 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 squeeze out excess oil 5 6 3 Tap paper element c lightly to remove excess dirt Replace paper element if it appears heavily soiled CR wc_gr000025 WACKER i NEUSON 38 wc_tx001776gb f PT 3 PT 3A PT 3H Maintenance 5 7 Air Cleaner Hatz See Graphic wc_gr000027 5 7 1 9 7 2 ES wc_tx001776gb fm The filter cartridge should always be replaced after 500 operating hours at the latest Remove the air cleaner cover a Unscrew and remove knurled nut b and take off air cleaner element c Clean the filter compartment and the cover Dirt and other foreign debris must not be allowed to enter the engine s air inlet points The filter cartridge should either be replaced or depending upon the degree of contamination cleaned or checked as follows Dry Contamination Use compressed air to blow through the filter cartridge from the inside outward
13. hydraulic fluid leaks worn and damaged hoses lines or power cables Refueling When refueling the following precautions must be followed e Add fuel of proper type and grade only when the pump is not running and engine is cool Fuel in well ventilated area Turn off all electrical switches Keep lighted smoking materials flames or spark producing devices at a safe distance while refueling Keep fuel nozzle in contact with tank being filled or provide a ground to prevent static sparks from igniting fuel Do not spill fuel on hot surfaces Clean up spillage immediately Do not start engine until fuel cap is secured to the fuel tank e Always make sure that fuel is being put in the fuel tank motor oil in the proper location and hydraulic oil into hydraulic oil reservoirs WORK SAFELY Engine Driven Pumps Maintenance and Repair All installations operations and maintenance should be in accordance with pump and engine manufacturer s recommended operation and maintenance program These manuals should be kept available with the equipment Maintenance work can be hazardous if not done in a careful manner All personnel should realize the hazards and strictly follow safe practices NEVER perform any work on the equipment unless authorized to do so BEFORE ANY maintenance work is to be done a LOCKOUT TAGOUT standard device and procedure should be implemented Prior to removal of LOCKOUT TAGOUT the equipme
14. 1 1 Signal Words Used in this Manual occcocccccnccocccccncconcccncnaninanonanoss 9 1 2 Machine Description and Intended Use occocccccccccccnoccconconconncancncnos 10 1 3 Operan Eois a AO A 11 1 4 Operator Safety while Using Internal Combustion Engines 13 1 5 SOMICODAIE zac oi ON Eo nace ais 15 Labels 16 2 1 Label Locations PT 2A PT 3A PT 2 PT3 eeeneeeeernerrereerreerne 16 2 2 Label Locations PT 2H PT 3H occoccccncnnncnnncnnnononanonococnnnnnononanonanonos 17 2 3 Label Meanings muesca ciclo iadeseddacerdnanesderteraieceasieredeasutes 18 Lifting and Transporting 21 Operation 22 4 1 Preparing the Machine for First Use c occcccnccccncocncocncccncconccononanonos 22 4 2 Recommended Fuel occcoccocccoccconcncncncccononancnnnnononanonnonononanenanennnnnns 23 4 3 Recommended Fuel Hatz cooocccocccocccccncncnnconocococanonncnncanonanonos 23 4 4 BEOS LATUNO ares a A RY O RCA R AAAA WAS A R 24 4 5 To Start Wacker Neuson eeaaee aaa aaa aaa aaa aaa zawie zaaaaaaaaaazazaza wia 26 4 6 To Stop Wacker Neuson eeuae aaa aaa aaa aaa cece eeseeeseeeseaeeseeeaeees 26 4 7 TO Stat COMO CE 2 4 8 TEGO SUP TIONG m wwwvwvvwwwwvvwvwvwvwwwvwvvvv 2 4 9 TO SS is ro eee eee ee eee eee eee 28 4 10 Cold Weather Starting Hatz ooccocccconcononoccniconocanononnnnanonanenanonos 29 4 11 o AP 29 4 12 ODOTAUO immmmmmmmmmmmmmmmmmmmmmmmmmmmmmm
15. 240 0620800 PT 3H 0009100 0009103 0009242 Machine m From this point forward in this documentation Wacker Neuson Production documentation Americas LLC will be referred to as Wacker Neuson u Keep a copy of the Operator s Manual with the machine at all times Use the separate Parts Book supplied with the machine to order replacement parts u Refer to the separate Repair Manual for detailed instructions on servicing and repairing the machine a If you are missing any of these documents please contact Wacker Neuson to order a replacement or visit www wackerneuson com m When ordering parts or requesting service information be prepared to provide the machine model number item number revision number and serial number Expectations This manual provides information and procedures to safely operate and main for a tain the above Wacker Neuson model s For your own safety and to reduce the information in risk of injury carefully read understand and observe all instructions described this manual A in this manual m Wacker Neuson expressly reserves the right to make technical modifications even without notice which improve the performance or safety standards of its machines m The information contained in this manual is based on machines manufactured up until the time of publication Wacker Neuson reserves the right to change any portion of this information without notice CALIFORNIA Engine exhaust some of its constitue
16. FELY Submersibles Pump Maintenance and Repair MAKE SURE the pump is disconnected from the power source or the appropriate circuits are dead and OSHA Lockout Tagout is applied before doing any maintenance or repair work on the unit Maintenance work can be hazardous if not done in a careful manner All personnel should realize the hazards and strictly follow safe practices NEVER perform any work on the equipment unless authorized to do so Before performing any maintenance or repair work consult the manufacturer s instruction manual for recommended procedures BEFORE ANY maintenance work is to be done a LOCKOUT TAGOUT standard device and procedure should be implemented Prior to removal of LOCKOUT TAGOUT the equipment must be fully operational and all personnel accounted for Except in cases of emergency the removal of the LOCKOUT TAGOUT should be done ONLY by the initiating person prior to the return to start up Check oil level ONLY when pump is cool USE ONLY recommended oil per manufacturer s recommendation WORK SAFELY Submersibles NEVER position the pump directly on a soft loose bottom To attain maximum capacity and prevent excessive wear position the pump so it will not burrow itself into sand or clay Stand the pump on a plank a bed of coarse gravel within a perforated container on a suitable floatation device or retain it hanging freely by a lifting cable FIG 13 FIG 13 17
17. INSPECT ELECTRICAL WIRING for worn or damaged insulation INSTALL new wiring if wires are damaged After repairs are made clean the equipment before putting the pump back into position 20 Do you understand this AEM SAFETY MANUAL AND ITEMS SUCH AS Your safety program Your pump manufacturers manual s Proper clothing and personal safety equipment Your pump s controls warning signs and devices and safety equipment How to properly inspect mount and start your pump How to check your pump for proper operation Your work area and any special hazards that may exist FINAL WORD TO THE USER Remember that YOU are the key to safety Good safety practices not only protect you but protect the people around you You have read this safety manual and the manufacturer s manual s for your specific pump Make them a working part of your safety program Keep in mind that this safety manual is written for only this type of equipment Practice all other usual and customary safe working precautions and above all REMEMBER SAFETY IS UP TO YOU YOU CAN PREVENT SERIOUS INJURY OR DEATH TEST YOUR KNOWLEDGE e Proper operating procedures e Proper shutdown procedures e Proper maintenance procedures e Proper loading and unloading procedures for transporting e Under what conditions you should not operate your pump If you do not understand any of these items consult with your supervisor BEFORE opera
18. SON Maintenance 5 17 Basic Troubleshooting PT 3 PT3A PT 3H Problem Symptom Reason Remedy Pump does not take in water Pump takes in water little or no discharge Suction hose leaks at inlet Discharge hose does not stay on coupling Impeller does not turn pump is hard to start WACKER NEUSON Not enough priming water in housing Engine speed too low Adjust speed Strainer plugged Clean strainer Suction hose damaged Replace or repair hose Air leak at suction port Check that fittings are tight and housing cover O rings are sealing properly Pump too high above water Debris collecting in pump housing Clean pump housing Too much clearance between impeller and insert Engine 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 replace insert Clamps are not sealing properly Tighten replace or add clamp Hose diameter is too large Hose is damaged Pressure may be too high for clamps being used Add another clamp Hose kinked or end blocked Check hose Impeller jammed or blocked Open pump cover and clean dirt and debris from inside of pump housing Impeller and insert binding Adjust clearance by removing shim from behind insert 48 wc_tx001776gb fm PT 3 PT3A PT 3H Technical Data 6 Technical Data 6 1 Engine Engine
19. T 3H Maintenance 5 3 13 Run the engine for a short interval then check the drain plug b for any leaks Tighten the drain plug if necessary wc gr008241 WARNING Most used oil contains small amounts of materials that can cause cancer and other health problems if inhaled ingested or left in contact with skin for prolonged peri ods of time Take steps to avoid inhaling or ingesting used engine oil gt Wash skin thoroughly after exposure to used engine oil wc_tx001776gb fm 35 WACKER NEUSON Maintenance PT3 PT3A PT 3H 5 4 Engine Oil Wacker Neuson Honda See Graphic wc_gr000022 5 4 1 Drain the oil while the engine is still warm 5 4 2 Remove the oil filler plug a and the drain plug b to drain the oil Note n 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 5 4 3 Install the drain plug 5 4 4 Fill the engine crankcase with the recommended oil up to the level of the plug opening c See section Technical Data for oil quantity and type 5 45 Install the oil filler plug wc gr000022 WARNING Most used oil contains small amounts of materials that can cause cancer and other health problems if inhaled ingested or left in contact with skin for prolonged peri ods of time Take steps to avoid inhaling or ingesting
20. _tx001779gb fm Operation PT3 PT3A PT3H 45 To Start Wacker Neuson See Graphic wc_gr000655 4 5 1 4 5 2 4 5 3 4 5 4 4 5 5 4 5 6 Open fuel valve by moving lever down a1 Note f engine is cold move choke lever to close position d2 If engine is hot set choke to open position d1 Turn engine switch to ON b2 Open throttle by moving it slightly to left c2 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 Open choke as engine warms d1 Open throttle fully to operate c1 wc_gr000655 46 To Stop Wacker Neuson See Graphic wc_gr000655 4 6 1 4 6 2 4 6 3 WACKER NEUSON Reduce engine RPM to idle by moving throttle completely to right c3 Turn engine switch to OFF b1 Close fuel valve a2 2 6 wc_tx001779gb fm PT 3 PT 3A PT 3H Operation 4 7 To Start Honda See Graphic wc_gr000014 4 7 1 4 7 2 4 7 3 4 7 4 4 7 5 4 7 6 Open fuel valve by moving lever to the right a1 Note f engine is cold move choke lever to close position b1 If engine is hot set choke to open position b2 Turn engine switch to ON e1 Open throttle by moving it slightly to left d1 Pull starter rope c Note f 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 w
21. achine must not be accessed or operated by e children e people impaired by alcohol or drugs Personal Protective Equipment PPE 1 3 1 Wear the following Personal Protective Equipment PPE while operating this machine e Close fitting work clothes that do not hinder movement e Safety glasses with side shields e Hearing protection e Safety toed footwear Do not allow anyone to operate this equipment without proper training People operating this equipment must be familiar with the risks and hazards associated with it 11 WACKER NEUSON Safety Information PT 2 3 1 3 2 1 3 3 1 3 4 1 3 5 1 3 6 1 3 7 1 3 8 1 3 9 1 3 10 1 3 11 1 3 12 1 3 13 1 3 14 1 3 15 1 3 16 1 3 17 1 3 18 WACKER NEUSON Do not use accessories or attachments that are not recommended by Wacker Neuson Damage to equipment and injury to the user may result Do not touch the engine or muffler while the engine is on or immediately after it has been turned off These areas get hot and may Cause burns Do not pump volatile flammable or low flash point fluids These fluids could ignite or explode Do not pump corrosive chemicals or water containing toxic substances These fluids could create serious health and environmental hazards Contact local authorities for assistance Do not open the priming plug when the pump is hot Do not loosen or remove inlet or discharge hose fittings when the pump is hot Hot water
22. at the TDC mark d Check valve clearance with feeler gauge f Note Refer to the Technical Data for valve clearances If valve clearances require adjusting slacken off screw g and turn hex nut h until feeler gauge can be pulled through with just slight resistance when screw is retightened Fit cover for cylinder head and tighten evenly always using a new gasket Re attach parts previously removed from engine Note Don t forget to replace the rubber cap e at the inspection hole Cover Carry out a brief test run then check the cover for leaks 42 wc tx001776gb fm PT 3 PT3A PT 3H Maintenance wc_gr008242 tn WACKER _tx001776gb f 43 NEUSON Maintenance PT 3 PT3A PT 3H 5 12 Fuel Filter Hatz See Graphic wc_gr000031 A WARNING 9 12 1 5 12 2 5 12 3 5 12 4 Fuel filter maintenance intervals depend on the purity of the diesel fuel used If operating the machine with dirty fuel perform this operation at 250 hours When working on the fuel system keep the work area clean Make sure no dirt reaches the fuel Dirty fuel may damage the engine Fire hazard Diesel fuel is flammable and must be treated with care Do not smoke when working with diesel fuel Do not expose diesel fuel to sparks or open flames Remove the fuel tank cap a and pull the fuel filter b and fuel hose out of the fuel tank Pull the fuel hose from the fuel filter Install a new fuel filter onto the fuel hose P
23. derate injury from this type of hazard obey all safety messages that follow this signal word NOTICE Used without the safety alert symbol NOTICE indicates a situation which if not avoided could result in property damage Note A Note contains additional information important to a procedure 9 WACKER NEUSON wc_si000003gb fm Safety Information PT 2 3 1 2 Machine Description and Intended Use WACKER NEUSON This machine is a centrifugal trash pump The Wacker Neuson Trash Pump consists of a tubular steel frame surrounding a gasoline or diesel engine a fuel tank and an impeller pump with ports for water suction and discharge The engine rotates the impeller during operation Waste water is drawn into the pump through the suction port and expelled through the discharge port The operator connects hoses to the pump and routes them so that water and solids are drained from the work area and discharged into an appropriate location This machine is intended to be used for general de watering applications This machine is intended for the pumping of clear water or water containing solids up to the size stated within the product specifications and up to the flow head and suction lift limits also stated within the product specifications This machine has been designed and built strictly for the intended use described above Using the machine for any other purpose could permanently damage the machine or seriously injure the
24. dual however warranty repairs must be performed by a dealer service center authorized by WACKER NEUSON The use of service parts that are not equivalent in performance and durability to authorized parts may impair the effectiveness of the emission control system and may have a bearing on the outcome of a warranty claim 5 2 Periodic Maintenance Schedule The chart below lists basic machine and engine maintenance Refer to your engine operators manual for additional information on engine maintenance Every Every 100 300 hrs hrs Check external hardware Inspect for leaks between pump and engine Remove cover and clean sediment out of pump housing rae 32 wc_tx001776gb fm PT 3 PT3A PT 3H Maintenance Wacker Neuson Honda Daily before starting hrs CZAT ECT A O A ec engine lie repo a fir Repaceasneeded tango ng Semardeane lan sedimento Grek na deansparkpug Daily Every Every Every before i 50 250 500 starting hrs hrs hrs Replace fuel filter g WACKER _tx001776gb f 33 NEUSON Maintenance PT 3 PT 3A PT 3H 53 Engine Oil System Hatz See Graphic wc_gr008241 5 3 1 80 2 9 3 3 9 3 4 A WARNING 9 3 0 A WARNING 9 3 6 5 3 7 9 3 8 9 3 9 9 3 10 5 3 11 5 3 12 WACKER NEUSON Checking the engine oil level Check the engine oil level with the machine on a level surface and the engine stopped Clean the area around the dipstick a Remove
25. e Allow the equipment to cool completely e Slowly and cautiously vent the pump e Refer to the manufacturer s instruction manual before restarting the unit e Remove hoses carefully Heated water can be in hoses and static head produces pressure FIG 10 e f safety related defects or malfunctions are detected SHUT DOWN the equipment Correct the problem or notify your supervisor DO NOT OPERATE EQUIPMENT WITH DEFECTS OR MALFUNCTIONS UNTIL CORRECTED If an unsafe condition cannot be remedied immediately notify your supervisor and tagout lockout the pump on the start switch and or appropriate prominent location FIG 11 14 WORK SAFELY Engine Driven Pumps SAFE WORKING PROCEDURES Do not jump start engine battery When operating internal combustion engines in an enclosed area always make provisions to pipe exhaust fumes to the outside EXHAUST FUMES CAN KILL Do not operate engine driven pump equipment in a confined or enclosed space without adequate ventilation Exhaust gases are odorless and deadly poison DO NOT TOUCH The exhaust system components get very hot and stay hot for some time after shutting the engine off Follow engine manufacturer s instructions explicitly on hand cranking Do not shut down high head pumps quickly A Throttle back slowly B Open by pass line C Should have a check valve D Slowly close gate valve on discharge if so equipped Check for fuel oil and
26. e severe physical burns and injury Operating a pump with the suction and or discharge valve closed is a principal cause of overheating Approach cautiously any pump that has been in operation DO NOT remove hoses from a pump until the system is properly cooled to ambient temperature WORK SAFELY Pumps In General BEFORE STARTING Check the pump thoroughly at delivery for any shipping damage Locate the pump in an accessible location as close to the liquid as possible Secure the pump after it is placed in its intended operating position so it does not tip roll slide or fall IMMEDIATELY ON STARTING THE PUMP Observe gauges instruments and warning lights to ensure that they are functioning and their readings are within the normal operating range e Be sure the immediate work area is safe for operation Operate controls make certain all operate properly and feel right Accustom yourself to the feel of the equipment e Listen for any unusual noises smell for any unusual odors look for any signs of trouble e Be sure to open all manual valves slowly to prevent WATER HAMMER e Check all warning and safety devices and indicators WORK SAFELY Pumps In General DO NOT remove the cover plate or drain plugs from any overheated pump Allow the pump to cool Check pump temperature before opening fill port or drain plug If overheating of the pump casing occurs e STOP the pump immediately
27. ed personnel to INSTALL WIRE AND OPERATE electric motor driven pumps Whenever electricity is present there is the possibility of electrocution NEVER use a pump motor in an explosive atmosphere if it is not exclusively designed for the application Always ground electrical units Make certain to connect pump motor to the right phase and voltage Do not run pump if voltage is not within limits Make sure motor rotation is in accordance with impeller rotation which should be indicated somewhere on the pump check the manufacturer s manual Make all electrical installations in accordance with National Electric Code State and Local electrical codes Never use gas piping as an electrical ground Make sure the related electrical circuits are dead and locked out before performing any maintenance Follow motor manufacturers recommended maintenance and operation instructions If circuit breaker or fuse is tripped examine the system for the problem before restarting pump NEVER use the power cord to aid lifting the pump NEVER operate a pump with a plug in type power cord without a ground fault circuit interrupter NEVER use cords with frayed cut or brittle insulation Check the cord on the pump for nicks in the insulation and for sound connections to the ground fault interrupter plug and motor NEVER let extension cords or the plug connections lay in water Locate the pump so that the cord cannot fall into any
28. ely ventilated FIG 6 damaging your eyes Normal glasses do NOT provide adequate protection ALWAYS wear a hard hat and safety shoes FIG 2 ALWAYS wear hearing protectors when exposed to high noise levels for extended periods ALWAYS wear a respirator when painting or exposed to dusty conditions ALWAYS keep your pockets free of loose objects which can fall out and drop into machinery FIG 5 Heavy gloves should be worn for many operations FIG 6 HEAVY PARTS Handle tools and heavy parts sensibly with regard for yourself and other persons Lower items don t throw or drop them ALWAYS use proper hoisting equipment for lifting heavy loads ALWAYS use a back brace when lifting by hand FIG 5 PERFORM MAINTENANCE SAFELY FIRE PREVENTION Whenever possible use a nonflammable solvent to clean parts Do not use gasoline or other fluids that give off harmful vapors If flammable fluids such as gasoline or diesel fuel must be used extinguish open flames or sparks and DO NOT smoke Store dangerous fluids in a suitable place in approved containers which are clearly marked NEVER smoke in areas where flammable fluids are used or stored FIG 7 Use proper nonflammable cleaning solvents Follow solvent manufacturer s instructions for use FIG 7 Always remove all flammable material in the vicinity of welding and or burning operations ALWAYS keep the floor in the work area clean and dr
29. ent Cup Honda See Graphic wc_gr000029 5 9 1 Turn the fuel valve off 5 9 2 Remove the sediment cup a and the O ring b 59 3 Wash both thoroughly in a nonflammable solvent Dry and reinstall them 5 9 4 Turn the fuel valve on and check for leaks wc_gr000029 wc_gr001093 See Graphic wc_gr001093 5 10 Cleaning the Fuel Strainer 5 10 1 To remove water and dirt close the fuel lever and remove the fuel strainer 5 10 2 Inspect the fuel strainer a for water and dirt 5 10 3 After removing any dirt and water wash the fuel cup with a nonflammable solvent 5 10 4 Reinstall securely to prevent leakage WACKER wc_tx001776gb fm 41 NEUSON Maintenance PT 3 PT3A PT 3H 5 11 Valve Clearances Hatz See Graphic wc_gr008242 9 11 1 9 11 2 9 11 3 9 11 4 9 11 5 9 11 6 9 11 7 9 11 8 9 11 9 9 11 10 5 11 11 WACKER NEUSON Only carry out adjustments when the engine is cold 42 62 F 10 30 C Remove air cleaner cover a and noise insulating hood b Remove any contamination adhering to the cover for the cylinder head Remove screws c and take off the cylinder head cover with gasket d Remove rubber cap e from the inspection hole cover Turn the engine over in the normal direction of rotation until the valves are in the overlap position exhaust valve not yet closed inlet valve starts to open Turn crankshaft through 360 in direction of rotation and position it precisely
30. equipment Follow the manufacturer s operation manual to the letter DO NOT operate a pump without all guards and shields in place If OSHA required guards are damaged or misplaced contact the manufacturer for a replacement When lifting pump use only lifting equipment in good repair and with adequate capacity Follow manufacturer s lifting recommendation Check all lubricant levels before pump installation in accordance with manufacturer s maintenance programs PREPARE FOR SAFE OPERATION CHECK IT OUT Know what safety devices your machine is equipped with and see that each item is securely in place and in operating condition FIG 9 For example e Drawbar Coupling Chains and Pins Alarms and Warning Lamps Reflectors Guards and Shields Drain Covers Plugs and Caps Shut Down Devices Leveling Jacks Pressure Relief Devices Lifting Devices NEVER START OR OPERATE A PUMP KNOWN OR SUSPECTED TO BE DEFECTIVE OR MALFUNCTIONING If your daily check uncovers any items that need attention repair replacement or adjustment report them promptly The most minor malfunction could be the result of more serious trouble or can cause it if pump is operated When in doubt attach an OSHA Lockout Tagout device tag to the control panel to disconnected electrical power supply at breaker on electrically driven pumps and disconnect the battery and or spark plug wire on engine driven pumps FIG 9
31. er pump volatile flammable or low flash point fluids These fluids could ignite or explode CAUTION Use only clean filtered diesel fuel NOTICE Lifting point WACKER wc_si000580gb fm 19 NEUSON Labels wee CC I L U S PAT Nos OTHER U S AND FOREIGN PATENTS PENDING NS LL WACKER NEUSON PT 3 PT 3A PT 3H A nameplate listing the model number item number revision number and serial number is attached to each unit Please record the information found on this name 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 to specify the model number item number revision number and serial number of the unit Guaranteed sound power level in dB A This machine may be covered by one or more pat ents 20 wc_si000580gb fm PT 2 3 Lifting and Transporting 3 Lifting and Transporting Lifting the machine This pump is heavy enough to cause injury if proper lifting techniques are not used Observe the following guidelines when lifting the pump e Do not attempt to lift the pump unassisted Use appropriate lifting equipment such as slings chains hooks ramps or jacks e Make sure lifting equipment is attached securely and has enough weight bearing capacity to lift or hold the pump safely e Remain aware of the location of other people nearby when lifting the pump Tra
32. es removed during the service or repair before returning pump to operation NEVER use the power cord to aid in lifting the pump Sizing Extension Cords Use the following chart to select the correct size extension cord to prevent excessive amperage draw or voltage drop which would cause the motor to overheat Cables that are too long or coiled can cause a voltage drop Be aware that strong sunlight can cause a voltage drop Wire Gauge and Cord Length in feet Amperes 6 8 50 100 150 16 14 14 14 12 12 16 14 16 12 10 16 12 18 SAFE WORKING PROCEDURES ALLOW only qualified personnel to INSTALL WIRE and OPERATE submersible pumps Whenever electricity is present there is the possibility of electrocution NEVER use a pump motor in an explosive atmosphere if it is not exclusively designed for that application ALWAYS ground the pump Make certain to connect the pump to the right phase and voltage DO NOT run the pump if voltage is not within limits Make all electrical installations in accordance with National Electric Code State and Local electrical codes Mount electrical control box in a vertical position protected from the elements NEVER attempt to use the power cord or hydraulic hoses as a lifting or lowering device for submersibles Attach a lifting cable to the manufacturer s recommended attachment point on the pump for lowering and lifting the pump FIG 12 WORK SA
33. falling pump To protect yourself and others make sure you thoroughly read and understand the safety information presented in this manual before operating the machine 13 Operating Safety wc_si000003gb fm A WARNING Notice State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters be used on internal combustion engines that use hydrocarbon fuels A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust Spark arresters are qualified and rated by the United States Forest Service for this purpose In order to comply with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Administrator Familiarity and proper training are required for the safe operation of the machine Machines operated improperly or by untrained personnel can be hazardous Read the operating instructions contained in this manual and the engine manual and familiarize yourself with the location and proper use of all controls Inexperienced operators should receive instruction from someone familiar with the machine before being allowed to operate it Operator qualifications Only trained personnel are permitted to start operate and shut down the machine They also must meet the following qualifications e have received instruction on how to properly use the machine e are familiar with required safety devices The m
34. hem Know where to get proper aid and assistance when needed Use common sense to avoid accidents If an accident does occur be prepared to react to it quickly and effectively NEVER PANIC FOLLOW A SAFETY PROGRAM KNOW WHAT IT IS Consult your supervisor for specific instructions and personal safety equipment required For instance you may need e Hard Hat e Reflector Vests e Safety Shoes Hearing Protection e Eye Protection Face Protection e Respirators e Back Supports e Heavy Gloves Other job related specific items Do not wear loose clothing or any accessory flopping cuffs untied shoe laces dangling neckties and scarves rings wrist watches or other jewelry that can catch on protruding or moving parts or controls Long hair should be securely bound to prevent entanglement with moving parts FIG 3 FIG 3 FIG 4 FOLLOW A SAFETY PROGRAM Remember that YOU are the key to safety Good safety practices not only protect you but also protect the people around you Study this manual and the manufacturer s manual s for your specific pump Make them a working part of your safety program Keep in mind that this safety manual is written for only this type of equipment Practice all other usual and customary safe working precautions and above all FIG 1 REMEMBER SAFETY IS UP TO YOU YOU CAN PREVENT SERIOUS INJURY OR DEATH FIG 1 BE ALERT Know where to get assistance K
35. ill come on while pulling the starter rope Open choke as engine warms b2 Open throttle fully to operate wc_gr000014 48 To Stop Honda See Graphic wc_gr000014 wc_tx001779gb fm 4 8 1 4 8 2 4 8 3 Reduce engine RPM to idle by moving throttle completely to right d2 Turn engine switch to OFF e2 Close fuel valve by moving lever to the left a2 27 WACKER NEUSON Operation PT3 PT3A PT3H 49 To Start Hatz See Graphic wc_gr000016 4 9 1 4 9 2 4 9 3 4 9 4 4 9 5 WACKER NEUSON Set speed control lever a either to 1 2 START or max START position as desired or necessary Note Starting at a lower speed will help to prevent exhaust smoke Pull the starting cable out by hand until you feel a slight resistance b Let the cable run back in this way the entire length of the starting cable can be used to start the engine Grip the handle with both hands Commence pulling the starting cable vigorously and at an increasing speed do not jerk it violently until the engine starts Note f after several attempts of starting the exhaust begins to emit white smoke move the speed control lever to the STOP position and pull the starting cable out slowly 5 times Repeat the starting procedure HATZ DIESEL we gr000016 2 8 wc_tx001779gb fm PT 3 PT 3A PT 3H Operation 4 10 Cold Weather Starting Hatz See Graphic wc_gr000016 4 10 1 4 10 2 4 10 3 4 10 4 Set speed contro
36. ing rings Do not attempt to clean or service the machine while it is running Rotating parts can cause severe injury 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 Keep the area around the muffler free of debris such as leaves paper cartons etc A hot muffler could ignite the debris and start a fire When replacement parts are required for this machine use only Wacker Neuson replacement parts or those parts equivalent to the Original in all types of specifications such as physical dimensions type strength and material Disconnect the spark plug on machines equipped with gasoline engines before servicing to avoid accidental start up Do not use gasoline or other types of fuels or flammable solvents to clean parts especially in enclosed areas Fumes from fuels and solvents can become explosive Handle impeller carefully The impeller can develop sharp edges which can cut Do not tip the machine for cleaning or for any other reason 15 WACKER NEUSON PT 3 PT3A PT 3H Labels Labels 2 Label Locations PT 2A PT 3A PT 2 PT3 2 1 SST KZ amp 3 q CZ j wc gr000009 wc si000580gb fm 16 w WACKER NEUSON PT 3 PT 3A PT 3H Labels 2 2 Label Locations PT 2H PT 3H y ATO s Y T g A Wa Z Jy yy As Y J amp gt 4 ANY ZA A A BRZEG e K
37. 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 Do not open pump housing cover while pump is operating or start pump with the cover off The rotating impeller inside the pump can cut or sever objects caught in it Do not block or restrict flow from inlet line or discharge line Remove kinks from discharge line before starting pump Operation with a blocked inlet line or discharge line can cause water inside pump to overheat Be sure operator is familiar with proper safety precautions and operation techniques before using machine Read understand and follow procedures in the Operators Manual before attempting to operate the machine Be sure the machine is on a firm level surface and will not tip roll slide or fall while operating Close fuel valve on engines equipped with one when machine is not being operated Store the machine properly when it is not being used The machine should be stored in a clean dry location out of the reach of children Do not pump fluid into an inappropriate location Do not place hoses where they may become a tripping hazard Do not operate the pump without the strainer or with an incorrect strainer Do not transport the machine while it is running Do not operate the machine with unapproved accessories or attachments 1 2 wc_si000003gb fm
38. l lever a either to 1 2 START or max START position as desired or necessary Remove the top of the air cleaner and the soundproofing enclosure c Pull the oil feed knob up to its limit d and then push it back down to its seat Note This ensures that the correct amount of oil will be fed to the engine when starting The oil feed device automatically refills when the engine is running NOTICE The oil feed device should only be used once per starting attempt Re attach parts previously removed to the engine then start it immediately 4 11 To Stop Hatz See Graphic wc_gr000016 4 11 1 4 11 2 4 12 Operation Move engine speed control lever a to the STOP position Press in the STOP pin e for as long as it takes to stop the engine Pump should begin pumping water within a minute depending on length of suction hose and height of pump above water Longer hoses will require more time If pump does not prime check for loose fittings or air leak in suction hose Make sure strainer in water is not blocked Run engine at full speed while operating pump Do not pump corrosive chemicals or water containing toxic substances These fluids could create serious health and WARNING environmental hazards Contact local authorities for assistance wc_tx001779gb fm 29 WACKER NEUSON Operation PT3 PT3A PT3H 4 13 Hoses and Clamps See Graphic wc_gr000021 WACKER NEUSON Suction hoses a must be rigid enough n
39. lace the fuel filter and fuel hose into the fuel tank and install the fuel tank cap Note Bleeding of the fuel injection system takes place automatically HATZ DIESEL WACKER NEUSON we_gr000031 44 wc_tx001776gb fm PT 3 PT 3A PT 3H Maintenance 5 13 Adjusting the Impeller Clearance See Graphic wc gr000035 wc tx001776gb fm 9 13 1 9 13 2 If it is necessary to replace the impeller or the volute insert be sure clearance between impeller and insert is adjusted correctly The impeller a should be as close to the insert b as possible without rubbing against it Clearance is adjusted by adding or removing shims c Remove spark plug on units with Hatz engine place speed control lever in STOP position so that engine will not start Check clearance between impeller and insert by slowly pulling starter rope to turn impeller If starter rope is difficult to pull or rubbing is heard from inside pump the impeller and insert are too close to each other Remove a shim from behind insert and check again for rubbing Continue removing shims until impeller turns easily Note t is important not to remove too many shims or the clearance between the impeller and insert will become too wide and pump performance will be reduced As the impeller wears down additional shims may be required to maintain the clearance between the impeller and insert wc_gr000035 45 WACKER NEUSON Maintenance PT 3 PT 3A PT 3H 5 14 C
40. leaning the Pump See Graphic wc_gr000036 Clean inside of pump housing after every use 5 14 1 Remove drain plug a from pump housing and drain any water left in pump 5 14 2 Loosen the four knobs holding the pump cover b and remove cover 5 14 3 Clean out dirt and debris Inspect impeller and volute insert for wear The impeller may develop sharp edges Use care when cleaning around impeller to avoid getting cut WARNING gt No y LY FEAS Ta N UY A O YA a we_gr000036 WACKER NEUSON 46 wc_tx001776gb f PT3 PT3A PT 3H Maintenance 5 15 Storage If pump is being stored for more than 30 days A Do not open priming plug discharge plug or cover when pump is hot WARNING 5 15 1 After pump has cooled remove discharge plug from pump housing and drain out any water left in the housing 5 15 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 5 15 3 Tape up suction and discharge ports to prevent anything from falling into pump 5 15 4 Change engine oil and follow procedures described in engine manual for engine storage 5 15 5 Cover pump and engine and store in a clean dry area 5 16 Accessories Wacker Neuson offers a complete line of fittings hoses and clamps to properly connect the pump to match various job conditions WACKER wc_tx001776gb fm 47 NEU
41. mmmm mmmmmmmmmmmmmmmmmmmmcka rr 29 4 13 HOses SING Ri nada AGA AE OO REA REAR 30 4 14 Emergency Shutdown Procedure esaaaaaaa aaa aaa a aaaaaaasazaaaaac 31 Maintenance 32 5 1 Maintaining the Emission Control System cooccccccncccncocncccnccncnnacnnos 32 5 2 Periodic Maintenance Schedule ooccccocccocccocncoccconcncncnoncncncnconcnnanonos 32 5 3 Engine Oil System Hatz cooococcncconccncnconccnonononoconononccnanonanonanenanenos 34 5 4 Engine Oil Wacker Neuson Honda ccocccoccccccncocncccnconncocnconcnnncnnos 36 wc_bo5000185222 11TOC fm WACKER NEUSON Table of Contents PT 3 PT 3A PT 3H 5 5 Air Cleaner Wacker Neuson ccoocccccccocccccnccococccncocncnanonnnnoncnnnnnonnnnnons 37 5 6 A GICAMIGE Honda score E 38 5 7 Air Cleaner Hatz PA 39 5 8 Spark Plug Wacker Neuson Honda occcocccoccccccccccncocncocncocnconcncnnnnos 40 5 9 Sediment Cub COMO GE recintos 41 5 10 Cleaning the Fuel Strainer c oooccoccccccncocncocnconnooonnconnnnnnconnnonncnnnonononos 41 5 11 Valve Clearances Hatz cooccccocccconoccnocononannnocnonanonnnonanocannoncnonanenono 42 5 12 EUSEENENNNIIZ A ea o A Z O da Ado 44 5 13 Adjusting the Impeller Clearance au aaa aaa aaa aaa aaa aaa eeseeeeeeeeaes 45 5 14 cleaning the PUMI zawo o ARA Ak OE GAY ER EEE AEO ERA EWA oska 46 5 15 e ei o 47 9 16 ACCESSOMES mm ns 47 9 17 Basic TOUBIESNOOGNO mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm i 48
42. now how to use a first aid kit and fire extinguisher or fire suppression system FIG 4 BE AWARE Take advantage of training programs offered Safety programs should require that one person at each jobsite be assigned the overall responsibility and authority for safety Know who the person is and COMMUNICATE with them Know what the jobsite rules are and FOLLOW THE RULES Be safety conscious responsible and reliable Think about safety BEFORE something happens BE CAREFUL Human error is caused by many factors carelessness fatigue overload preoccupation incompatibility between operator and the equipment drugs and alcohol to name a few Damage to the equipment can be fixed in a short period of time but injury or death has a lasting effect For your safety and safety of others encourage your fellow workers to act within safety rules PERFORM MAINTENANCE SAFELY CLOTHING AND PERSONAL EXHAUST FUMES PROTECTIVE ITEMS Engine exhaust fumes can cause sickness or ALWAYS wear appropriate safety glasses goggles death lf itis necessary to run an engine in an or face shield when working FIG 2 Proper eye enclosed area remove the exhaust fumes from the protection can keep flying particles from grinding area with an exhaust pipe extension li you do not drilling or hammering operations or fluids such as have an exhaust pipe extension be positive the fuel solvents lubricants and brake fluids from area is adequat
43. nsporting the machine Observe the following guidelines when transporting the pump to and from the job site e Drain the fuel tank before transporting the pump e Ensure that the pump is securely strapped down in the transport vehicle to prevent it from sliding or tipping e Do not refuel the pump in or on the transport vehicle Move the pump to its operating location and then fill the fuel tank mm WACKER c_tx001352gb f 21 NEUSON Operation 4 Operation PT3 PT3A PT3H 4 1 Preparing the Machine for First Use Preparing for first use 4 1 1 4 1 2 4 1 4 4 1 5 WACKER NEUSON To prepare your machine for first use Make sure all loose packaging materials have been removed from the machine Check the machine and its components for damage If there is visible damage do not operate the machine Contact your Wacker Neuson dealer immediately for assistance Take inventory of all items included with the machine and verify that all loose components and fasteners are accounted for Attach component parts not already attached Add fluids as needed and applicable including fuel engine oil and battery acid Move the machine to its operating location 22 wc_tx001779gb fm PT 3 PT 3A PT 3H Operation 4 2 Recommended Fuel Wacker Neuson Honda The engine requires regular grade unleaded gasoline Use only fresh clean gasoline Gasoline containing water or dirt will damage fuel system Consult engine owners ma
44. nt must be fully operational and all personnel accounted for Except in cases of emergency the removal of the LOCKOUT TAGOUT should be done ONLY by the initiating person prior to the return to start up see page 12 Fig 11 BEFORE doing any major work disconnect the ignition and battery if so equipped Always replace safety devices removed during service or repair before returning pump to operation Battery Servicing Always wear safety glasses and gloves when servicing or working with batteries Before servicing battery turn off electrical systems then disconnect ground terminal clamp Before installing a battery turn off electrical equipment then connect the battery ground clamp last Maintain electrolyte at the recommended level Check level frequently Add distilled water to batteries only when starting up never when shutting down Use a flashlight to check level NEVER use a flame Do not short across battery terminals the spark could ignite the battery gases Battery acids will burn skin eat holes in clothing and can cause blindness if splashed in eyes If you spill acid on yourself flush skin immediately with lots of water Apply baking soda to help neutralize the acid If acid gets into the eyes flush immediately with large amounts of water and seek proper medical treatment immediately 13 16 WORK SAFELY Electric Motor Driven Pumps SAFE WORKING PROCEDURES Allow only gualifi
45. nts and certain vehicle components contain Proposition or emit chemicals known to the State of California to cause cancer and birth 65 Warning defects or other reproductive harm Laws NOTICE State Health Safety Codes and Public Resources Codes specify that in pertaining to certain locations spark arresters be used on internal combustion engines that use spark hydrocarbon fuels A spark arrester is a device designed to prevent accidental dis arresters charge of sparks or flames from the engine exhaust Spark arresters are qualified and rated by the United States Forest Service for this purpose In order to comply with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Administrator wc_tx001780gb fm 3 WACKER NEUSON Foreword PT 3 PT3A PT 3H Manufacturer s This manual contains references to approved parts attachments and modifica approval tions The following definitions apply Approved parts or attachments are those either manufactured or provided by Wacker Neuson Approved modifications are those performed by an authorized Wacker Neu son service center according to written instructions published by Wacker Neu son a Unapproved parts attachments and modifications are those that do not meet the approved criteria Unapproved parts attachments or modifications may have the following conse quences m Serious injury hazards to the operator and persons in the work area
46. nual for complete fuel specifications Use of oxygenated fuels Some conventional gasolines are blended with alcohol These gasolines are collectively referred to as oxygenated fuels If you use an oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel confirm the fuel s contents Some states Provinces require this information to be posted on the fuel pump The following are Wacker Neuson approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume commonly referred to as E10 Gasoline containing more than 10 ethanol such as E15 E20 or E85 may not be used because it could damage the engine If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty 4 3 Recommended Fuel Hatz The engine requires No 2 diesel fuel Use only fresh clean fuel Fuel containing water or dirt will damage the fuel system Consult the engine owners manual for complete fuel specifications WACKER wc_tx001779gb fm 23 NEUSON Operation PT3 PT3A PT3H 44 Before Starting See Graphic wc_gr000013 4 4 1 4 4 2 4 4 3 WARNING 4 4 4 4 4 5 4 4 6
47. o CZ wc_gr000011 WACKER wc_si000580gb fm 17 NEUSON Labels 2 3 Label Meanings PT 3 PT3A PT 3H gt COnN 117034 178715 117039 17871 178714 WACKER NEUSON DANGER Asphyxiation hazard Engines emit carbon monoxide Do not run the machine indoors or in an enclosed area NEVER use inside a home or garage EVEN IF doors and windows are open Only use OUTSIDE and far away from windows doors and vents Read the Operator s Manual No sparks flames or burning objects near the machine Stop the engine before refueling WARNING Hot surface CAUTION Read and understand the supplied Opera tor s Manual before operating this machine Failure to do so increases the risk of injury to yourself and others 1 8 wc_si000580gb fm PT 3 PT 3A PT 3H NEVER PUMP VOLATILE FLAMMABLE OR LOW FLASH POINT FLUIDS THESE FLUIDS COULD IGNITE OR EXPLODE NIEMALS PUMPE FUER LEICHT VERDUNSTBARE ODER BRENNBARE FLUESSIGKEITEN MIT NIEDRIGEM FLAMMPUNKT VERWENDEN DIESE FLUESSIGKEITEN KOENNTEN ENTZUENDEN ODER EXPLODIEREN NUNCA BOMBEAR LIQUIDOS VOLATILES INFLAMABLES O DE PUNTO BAJO DE ENCENDIDO ESTOS FLUIDOS PUEDEN ENCENDERSE O EXPLOTAR NE JAMAIS POMPER DES LIQUIDES VOLATILES INFLAMMABLES OU A BAS POINT D ECLAIR CES LIQUIDES POURRAIENT PRENDRE FEU OU EXPLOSER 178731 Labels WARNING Do not open if pump is hot Hot water and or steam inside could be pressurized WARNING Nev
48. operator or other persons in the area Machine damage caused by misuse is not covered under warranty The following are some examples of misuse e Pumping flammable explosive or corrosive fluids e Pumping hot or volatile fluids that result in pump cavitation e Operating the pump outside of product specifications due to incorrect diameter hoses incorrect length hoses other inlet or outlet restrictions or excessive suction lift or head e Using the machine as a ladder support or work surface e Using the machine to carry or transport passengers or equipment e Operating the machine outside of factory specifications e Operating the machine in a manner inconsistent with all warnings found on the machine and in the Operators Manual This machine has been designed and built in accordance with the latest global safety standards It has been carefully engineered to eliminate hazards as far as practicable and to increase operator safety through protective guards and labeling However some risks may remain even after protective measures have been taken They are called residual risks On this machine they may include exposure to e Heat noise exhaust and carbon monoxide from the engine e Fire hazards from improper refueling techniques e Fuel and its fumes e Personal injury from improper lifting techniques 1 0 wc_si000003gb fm PT 2 3 Safety Information e Projectile hazard from discharge e Crushing hazards from a tipping or
49. ot 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 used as discharge hoses Note Suction and discharge hoses are available from Wacker Neuson Contact your nearest dealer for more information 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 For other hose connections one T bolt or worm gear type clamp is usually sufficient to hold hoses in place In some cases slight variances in hose diameters may make it necessary to add more clamps in order to maintain tight connections wc_gr000021 3 0 wc_tx001779gb fm PT 3 PT 3A PT 3H Operation 4 14 Emergency Shutdown Procedure wc_tx001779gb fm 4 14 1 4 14 2 4 14 3 4 14 4 4 14 5 4 14 6 If a breakdown accident occurs while the machine is operating follow the procedure below Stop the engine Turn off the fuel supply Remove any obstructions Unkink the hoses Allow the machine to cool Contact the rental yard or machine owner 34 WACKER NEUSON Maintenance PT 3 PT 3A PT 3H 5 Maintenance 5 1 Maintaining the Emission Control System Normal maintenance replacement or repair of emission control devices and systems may be performed by any repair establishment or indivi
50. s until no further dirt emerges NOTICE The air pressure must not exceed 73 psi 5 bar Moist or Oily Contamination Replace the filter cartridge Checking the Filter Cartridge Check filter cartridge s gasket surface d for damage Check the filter cartridge for cracks or any other type of damage to the paper filter by holding it inclined towards the light or by shining a light source through it NOTICE lf there is the slightest damage to the paper filter do not re use Re assemble the filter cartridge in reverse order we gr00002 7 39 WACKER NEUSON Maintenance PT3 PT3A PT 3H 5 8 Spark Plug Wacker Neuson Honda See Graphic wc_gr000028 Clean or replace the spark plug as needed to ensure proper operation Refer to your engine operator s manual The muffler becomes very hot during operation and remains hot for a while after stopping the engine Do not touch the muffler while it is hot WARNING Note Refer to section Technical Data for the recommended spark plug type and the electrode gap setting 5 8 1 Remove the spark plug and inspect it 5 8 2 Replace the spark plug if the insulator is cracked or chipped 5 8 3 Clean the spark plug electrodes with a wire brush 5 8 4 Set the electrode gap a 5 8 5 Tighten the spark plug securely NOTICE A loose spark plug can become very hot and may cause engine damage WACKER 40 NEUSON wc tx001776gb fm PT 3 PT 3A PT 3H Maintenance 5 9 Sedim
51. t the engine if fuel has spilled or a fuel odor is present Move the machine away from the spill and wipe the machine dry before starting Refueling safety When refueling the engine e Clean up any spilled fuel immediately e Refill the fuel tank in a well ventilated area e Replace the fuel tank cap after refueling When refueling the engine e Do not smoke WACKER wc_si000003gb fm 13 NEUSON Safety Information PT 2 3 e Do not refuel a hot or running engine e Do not refuel the engine near sparks or open flames e Do not refuel if the machine is positioned in a truck fitted with a plastic bed liner Static electricity can ignite the fuel or fuel vapors NEUSON 1 4 wc_si000003gb fm PT 2 3 Safety Information 1 5 Service Safety A WARNING A poorly maintained machine can become a safety hazard In order for the machine to operate safely and properly over a long period of time periodic maintenance and occasional repairs are necessary Personal Protective Equipment PPE 1 5 1 5 2 1 5 3 1 5 4 1 5 5 1 5 6 1 5 7 1 5 8 wc_si000003gb fm Wear the following Personal Protective Equipment PPE while servicing or maintaining this machine e Close fitting work clothes that do not hinder movement e Safety glasses with side shields e Hearing protection e Salety toed footwear In addition before servicing or maintaining the machine e Tie back long hair e Remove all jewelry includ
52. the dipstick and wipe it clean Screw the dipstick into the engine then remove it Check the oil level on the dipstick lf necessary add oil so that the oil level reaches the max mark Reinstall the dipstick The engine may be hot enough to cause burns Wear appropriate clothing and use care when working with a hot warm engine Changing engine oil Change the engine oil with the machine on a level surface Run the engine for a few minutes to warm the oil then stop the engine Note n the interests of environmental protection place a plastic sheet and a container under the machine to collect any liquid which drains off Dispose of this liquid in accordance with environmental protection legislation Burn hazard Use care when draining hot engine oil Hot oil can burn Unscrew the oil drain plug b and drain the engine oil into a container Clean the oil drain plug and install a new seal c Reinstall the oil drain plug torque it to 50 Nm 37 ft lb Oil filter Loosen the filter screw d and pull the oil filter out e of its housing Use compressed air to blow dirt from the oil filter e Blow the air dirt from the inside of the oil filter outward Check the gaskets f Replace them if they are damaged Lightly oil the gaskets before reinstalling the oil filter Reinstall the oil filter press until limit stop Tighten screw Check the engine oil and add oil if necessary 34 wc_tx001776gb fm PT 3 PT 3A P
53. ting your equipment 19 This manual is another in a series on the safe operation of machinery published by AEM For additional publications visit our web site at www aem org _ ASSOCIATION OF Association of Equipment Manufacturers Toll free 1 866 AEM 0442 e mail aem aem org MANUFAGIURERS www aem org FORM PP 130 2
54. used engine oil gt Wash skin thoroughly after exposure to used engine oil WACKER 36 NEUSON wc_tx001776gb fm PT 3 PT 3A PT 3H Maintenance 5 5 Air Cleaner Wacker Neuson See Graphic wc_gr000656 wc tx001776gb fm A WARNING 5 5 1 9 9 2 9 9 3 NEVER use gasoline or other types of low flash point solvents for cleaning the air cleaner A fire or explosion could result NOTICE NEVER run the engine without the air cleaner Severe engine damage will occur The engine is equipped with a dual element air cleaner Under normal operating conditions the elements should be cleaned once every week Under severe dry and dusty conditions the elements should be maintained daily Replace an element when it is saturated with dirt that cannot be removed 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 Wash the foam element b in a solution of mild detergent and warm water Rinse it thoroughly in clean water Allow the element to dry thoroughly Tap the paper element c lightly to remove excess dirt or blow compressed air through the filter from the inside out Replace the paper element if it appears heavily soiled wc gr000656 37 WACKER NEUSON Maintenance PT 3 PT 3A PT 3H 5 6 Air Cleaner Honda See Graphic wc_gr000025 The engine is equipped with a dual element air cleaner Service air cleaner
55. water or be submerged by rising water unless the pump is designed for such use NEVER handle energized power cords with wet hands MOTOR OVERLOAD do not exceed the manufacturer s recommendation for maximum lift or discharge head See manufacturer s published curve for proper sizing of motors A misapplied motor can overheat 15 WORK SAFELY Electric Motor Driven Pumps Pump Maintenance and Repair MAKE SURE the pump is disconnected from the power source or the appropriate circuits are dead and OSHA Lockout Tagout is applied before doing any maintenance or repair work on the pump Maintenance work can be hazardous if not done in a careful manner All personnel should realize the hazards and strictly follow safe practices NEVER perform any work on the equipment unless authorized to do so FIG 11 Before performing any maintenance or repair work consult the manufacturer s instruction manual for recommended procedures Pumps with float switches or other automatic devices can start without warning if not properly locked out BEFORE ANY maintenance work is to be done a LOCKOUT TAGOUT standard device and procedure should be implemented Prior to removal of LOCKOUT TAGOUT the equipment must be fully operational and all personnel accounted for Except in cases of emergency the removal of the LOCKOUT TAGOUT should be done ONLY by the initiating person prior to the return to start up ALWAYS replace safety devic
56. y Oily greasy floors can easily lead to falls Wet spots especially near electrical equipment can be hazardous FIG 7 Know where fire extinguishers are kept how they operate and for what type of fire they are intended Check readiness of any fire detectors and fire suppression systems 10 LEARN TO BE SAFE NEVER operate a pump which is new to you without first being instructed in it s proper operation READ the operator s manual If one has not been provided GET ONE AND STUDY IT BEFORE OPERATING THE PUMP Know the meaning of all identification symbols on your controls and gauges FIG 8 Know the location of the emergency shut down control if the machine is so equipped Before attempting to operate the pump know the capabilities and limitations of the pump Familiarize yourself with controls and instruments their locations and functions Keep hands levers and knobs clean of oil or grease to prevent slipping Carefully read and follow the instructions on all safety signs and decals on the pump Keep safety signs in good condition Replace missing or damaged safety signs FIG 8 WORK SAFELY Pumps In General SAFE WORKING PROCEDURES USE COMMON SENSE Most accidents can be avoided by using common sense and concentrating on the job to be done ONLY EXPERIENCED AND QUALIFIED personnel should install and operate pump equipment KNOW THE PROPER starting procedure for your
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