Wacker 0620769 Instructions / Assembly
Contents
1. 3 Take inventory of all items included with the machine and verify that all loose components and fasteners are accounted for 4 Attach component parts not already attached 5 Add fluids as needed and applicable including fuel engine oil and battery acid 6 Move the machine to its operating location 4 2 Hoses and Clamps Guidelines Follow the guidelines below for hoses and clamps m Use only noncollapsible hoses for the suction side of the pump Note Suction and discharge hoses are available from Wacker Neuson Contact your nearest dealer for more information Use two clamps for connecting suction hoses to the inlet coupling of the pump Note This connection is important Even a small air leak on the suction side of pump will prevent the pump from priming m For other hose connections one T bolt or worm gear type clamp is usually suffi cient 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 connec tions a WACKER ana w NEUSON 22 _tx001331gb f PD 2A PD 3A Operation 4 3 Recommended Fuel Type Use of oxygenated fuels wc_tx001331gb fm This engine equipment requires regular unleaded gasoline m Use only fresh no older than three months old clean gasoline Use a fuel stabilizer per the fuel stabilizer manufacturer s instructions Some conventional gasolines are blended with alcohol These gasolines are2. Page CPR It is your responsibility to read and understand this safety manual and the manufacturers manual s before operating your pump 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 SSR SRR eee CR eee ee SSCS SEE TCC Section N Ww j 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 fla
3. WARNING Burn hazard The engine and muffler become very hot while running gt Allow the engine to cool before performing this procedure 1 Stop the engine and allow it to cool 2 Remove the spark plug 3 Inspect the spark plug Replace the spark plug if the insulator is cracked or chipped or if the electrode is damaged 4 Clean the spark plug with a wire brush 5 Set the electrode gap a See chapter Technical Data for the recommended gap wc_gr007185 6 Reinstall the spark plug and tighten it to the recommended torque from the engine owner s manual NOTICE A loose spark plug can become very hot and may cause engine dam age WACKER oF Ww NEUSON Maintenance PD 2A PD 3A 5 8 Changing the Gearbox Oil When Requirements Procedure A Change the gearbox oil every 100 hours of operation or every 6 months m Machine shut down Engine warm API GL 5 rated gear oil Container for used oil Perform the procedure below to change the gearbox oil WARNING Burn hazard The engine and muffler become very while running Stop the engine before performing this procedure 1 Stop the engine 2 Remove the drain plug a and drain the oil into a suitable container wc_gr007186 3 Reinstall the drain plug 4 Remove the fill plug b and the level plug c 5 Slowly pour gear oil into the fill hole until it comes out of the level hole 6 Reinstall the fill and level plugs Note
4. m Do not refuel a hot or running engine m Do not refuel the engine near sparks or open flames m 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 WACKER WY NEUSON Labels PD 2A PD 3A 2 Labels 2 1 Label Locations wc_g9r007188 WACKER 16 NEUSON wc_si000392gb fm PD 2A PD 3A 2 2 Label Meanings 178715 Og ADANGER Re somite A APEL IGRO Ayes 117034 borer CAUTION sd GREASE CONNECTING ROD BEARING MONTHLY ATENCI N aE PANNE MONAT SCHMIEREN ENAURA NENTE wc_si000392gb fm 1 1 ANVORSICHT PLEUELLAGER JEDEN AN ATTENTION ae af eo TOUS GRAISSER ROULEMENT Labels 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 NOTICE Lifting point CAUTION Grease connecting rod bearing monthly Read the Operator s Manual WACKER NEUSON Labels PD 2A PD 3A WARNING Pinch point Do not operate without safety guards Read and understand the Operator s Manual NO OPERE SiN LOS DISPOSITIVOS DE S
5. DC 20210 Milwaukee WI 53202 NFPA National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 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 TEST YOUR 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
6. Static electricity can ignite the fuel or fuel vapors gt Refuel only when the machine is outdoors gt Clean up spilled fuel immediately 1 Remove the fuel cap a wc_gr008400 wc_gr008401 2 Fill the fuel tank to the bottom of the fuel tank neck b CAUTION Fire and health hazard Fuel expands when heated Expanding fuel in an over filled A tank can lead to spills and leaks gt Do not overfill the fuel tank 3 Reinstall the fuel cap Result The procedure to refuel the machine is now complete WACKER wc_ tx m w NEUSON 24 _tx001331gb f PD 2A PD 3A Operation 4 5 Before Installing the Pump Requirements API GL 5 rated gear oil Machine off Tasks Perform the following tasks before installing the pump Read the safety instructions at the beginning of this manual Place the pump on a firm flat level surface Check fuel level Add fuel as needed Check engine oil level Add engine oil as needed Check condition of air filter Replace the air filter if needed O GV FP W N gt Fill the pump s gearbox with oil a Remove the fill plug a wc_gr00 154 b Remove the level plug b c Slowly pour gear oil into the fill hole until it comes out of the level hole d Reinstall the fill and level plugs Result The pump is now ready to be installed wc_tx001331gb fm 25 W NEuso Operation PD 2A PD 3A 4 6 Installing the Pump Requirements Completed before installing the pump proc
7. 50 88 Maximum suction lit 0000 suction lift immun _____ mW _sr _ 7 3 Sound Measurements The required sound specification Paragraph 1 7 4 u of 2006 42 EC Machinery Directive is a the guaranteed sound power level Lwa 97 dB A the sound pressure level at operator s location Lpa PDT 2 85 PDI 2 85 PDT 3 85 PDI 3 85 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 operator s location a WACKER u a w NEUSON 44 _td000379gb f PD 2A PD 3A 7 4 Dimensions PD2 590 23 PD3 590 23 wer PD2 1000 40 PD3 1070 42 PD2 590 23 PD3 590 23 PD2 460 18 PD3 460 18 wc_td000379gb fm 45 Technical Data PD2 580 23 gt PD3 680 27 PD2 1000 40 PD3 1070 42 wc_gr007189 WACKER NEUSON Emission Control Systems Information and Warranty 8 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 8 1 Emission Control Systems Warranty Statement See the supplied engine owner s manual for the applicable exhaust and evaporative emission warranty statement a WACKER ana w NEUSON 46 _tx001753gb f PORTABLE PUMPS Wwww aem org A SAFETY MANUAL FOR OPERATING AND MAINTENANCE PERSONNEL SAFETY ALERT SYMBOL A Ul Be ae aca Why is SAFETY important to YOU
8. 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 23 Wy WACKER NEUSON Operation PD 2A PD 3A 4 4 Refueling the Machine Requirements Machine shut down Engine cool Machine fuel tank level with the ground Fresh clean fuel supply Procedure Perform the procedure below to refuel the machine WARNING Fire hazard Fuel and its vapors are extremely flammable Burning fuel can cause severe burns gt Keep all sources of ignition away from the machine while refueling A gt Do not refuel if the machine is positioned in a truck fitted with a plastic bed liner
9. machine m Do not pump volatile flammable or low flash point fluids m Do not change hoses while the engine is running Do not attempt to move the machine while the engine is running Wear the following Personal Protective Equipment PPE while operating this machine m Close fitting work clothes that do not hinder movement Safety glasses with side shields Hearing protection a Safety toed footwear y 1 2 wc_si000391gb fm PD2 PD3 PD2A PD3A Safety Information 1 4 Service Safety Service training Precautions Personal Protective Equipment PPE Machine modifications Replacing parts and labels wc_si000391gb fm Before servicing or maintaining the machine Read and understand the instructions contained in all manuals delivered with the machine Familiarize yourself with the location and proper use of all controls and safety devices m Only trained personnel should troubleshoot or repair problems occurring with the machine Contact Wacker Neuson for additional training if necessary When servicing or maintaining this machine m Do not allow improperly trained people to service or maintain the machine Per sonnel servicing or maintaining the machine must be familiar with the associ ated potential risks and hazards Follow the precautions below when servicing or maintaining the machine Read and understand the service procedures before performing any service to the machine All adj
10. 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 dry 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 PREPARE FOR SAFE OPERATION CHECK IT OUT Know what safety devices your machine is equipped with and see that each item is securely in pla
11. to check the oil level Fill the crankcase so that the oil level reaches the upper mark on the dipstick Note u crankcase upper limit crankcase lower limit 8 Reinstall the dipstick Note n the interests of environmental protection dispose of waste oil and soiled rags in accordance with environmental protection legislation D WACKER 2 W NEUSON Maintenance PD 2A PD 3A 5 6 Cleaning the Sediment Cup When Requirements Procedure Clean the engine sediment cup every 100 hours or 6 months Machine shut down sa Nonflammable solvent Perform the procedure below to service the sediment cup 1 Stop the engine 2 Move the fuel valve to the OFF position 3 Remove the sediment cup a and the O ring b wc_gr007183 WARNING Fire hazard Gasoline or low flash point solvents are flammable and may ignite if used to clean the machine gt Use only nonflammable solvents when cleaning the sediment cup 4 Wash the sediment cup and the O ring thoroughly in a nonflammable solvent Dry and reinstall them 5 Move the fuel valve to the ON position and check for leaks WACKER a 2 w NEUSON 36 _tx001332gb f PD 2A PD 3A Maintenance 5 7 Spark Plug When Requirements Procedure A wc_tx001332gb fm Clean the spark plug every 100 hours of operation or every 6 months Replace the spark plug as needed m Machine shut down Engine cool Perform the procedure below to clean the spark plug
12. 00nnne nennen 32 5 3 servicing the Air Cleaner 222u0220022400000 0000 nano nano nnnn nenn ann nnnnennnenn 33 5 4 Greasing the Connecting Rod Bearing 202200222002n0nnnn nennen 34 5 9 Changing the Engine Oil u022002200200002n0 nenn nano nenn nenn nano nnnennen 35 5 6 Cleaning the Sediment Cup u22220220002n0nnnn nano nano nnnennnnnnnn nennen 36 0 1 SPE PIC anne ee een oT 5 8 Changing the Gearbox Oil 2 00222022400000 0200 none nano anne nnnn anne namen 38 5 9 Cleaning Ne PUMD esse een 39 5 10 OAS aeea een 40 6 Troubleshooting 41 7 Technical Data 43 7 1 ENGINE sece era 43 1 2 UTC ee ap 44 1 8 Sound Measurements 22402220020000000n0nn nenn nnnnennnn anne nenn anne namen 44 1 4 DIMENSION S rererere ee ee 45 8 Emission Control Systems Information and Warranty 46 8 1 Emission Control Systems Warranty Statement senni 46 9 AEM Safety Manual 47 A WACKER wc_b05000184784_03TOC fm W NEUSON 8 PD2 PD3 PD2A PD3A 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 DANGE
13. 5 Nm 70 ft lbs NOTICE Do not over torque or under torque the lockscrew Improper torque can break the connecting rod or cause premature wear of internal parts 5 Re install the metal guard handle and bolts 29 Operation PD 2A PD 3A 4 11 Emergency Shutdown Procedure If a breakdown accident occurs while the machine is operating follow the procedure below Stop the engine Turn off the fuel Remove the obstruction Unkink the hoses Allow the machine to cool Oona A OO N gt Contact the rental yard or machine owner w NEUSOR 30 wc_tx001331gb fm PD 2A PD 3A Maintenance 5 Maintenance 5 1 Maintaining the Emission Control System wc_tx001332gb fm Normal maintenance replacement or repair of emission control devices and systems may be performed by any repair establishment or individual however warranty repairs must be performed by a dealer service center authorized by the engine manufacturer See the supplied engine owner s manual for the applicable emission warranty information WACKER 31 Ww NEUSON Maintenance PD 2A PD 3A 5 2 Periodic Maintenance Schedule The table below lists basic machine and engine maintenance Tasks designated with check marks may be performed by the operator Tasks designated with square bullet points require special training and equipment Refer to the engine owner s manual for additional information Interval Task hours of service Daily poset M
14. Diaphragm Pump PDIZA PDISA PDT2A PDT3A 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 N92VV 15000 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 PD 2A PD 3A Foreword Foreword Machine documentation Expectations for information in this manual CALIFORNIA Proposition 65 Warning Laws pertaining to spark arresters Manufacturer s approval wc_tx001329gb fm SAVE THESE INSTRUCTIONS This manual contains important instructions for the machine models below These instructions have been written expressly by Wacker Neuson Production Americas L
15. EGURIDAD LEA Y ENTIENDA PRIMERO LAS INSTRUCCIONES A AVERTISSEMENT CAUTION Read and understand the supplied Operator s Manual before operating this machine Failure to do so increases the risk of injury to yourself and others O O ammon F WARNING Hot surface WACKER 18 NEUSON wc_si000392gb fm PD 2A PD 3A Labels Guaranteed sound power level in dB A Notice Do not exceed 60 strokes per minute with the diaphragm pump Read the Operator s Manual Do not expeed 60 strokes per minute with the diaphragm pump 60 Schlage pro Minute mit dieser Membranpumpe nicht ubertreten oon la bomba de diafragma CAMS avec la pompe a diaphragme Notice Use noncollapsible hose or pipe on suction side of pump Read the Operator s Manual 182178 j WACKER E 19 NEUSON Labels WACKER NEUSON 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 I 7R764 20 PD 2A PD 3A WARNING Never pump volatile flammable or low fl
16. In the interests of environmental protection dispose of waste oil and soiled rags in accordance with environmental protection legislation y 38 wc_tx001332gb fm PD 2A PD 3A Maintenance 5 9 Cleaning the Pump Requirements Machine shut down Machine cool Background When pumping heavy sludges or water containing large amounts of dirt and solids clean the pump often Materials left in the pump can dry and harden which may lead to damage of the valves or the diaphragm Procedure Perform the procedure below to clean the machine WARNING Fire hazard Gasoline or low flash point solvents are flammable and may ignite if used to clean the machine gt Do not use flammable solvents to clean the machine Pump clean water through the pump for a few minutes Stop the engine and allow the machine to cool Remove the dirt from in between the engine cooling fins A WwW N gt Remove the pump cover a and clean dirt and grease build up from the connecting rod and from the inside of the pump cover wc_gr007188 5 Reinstall the pump cover we_tx m WACKER _tx001332gb f 39 W NEUSON Maintenance PD 2A PD 3A 5 10 Storage Requirements Machine shut down m Machine cool Machine clean Procedure Perform the procedure below to store the machine for more than 30 days WARNING Fire hazard The machine may cause a fire if it is covered while it is hot Do not cover the machine while it is running or while i
17. LC and must be followed during installation operation and maintenance of the machines PDT 2A 0620769 PDT 3A 0620773 PDI 2A I 0620772 PDI 3A 0620775 PDI 3A I 0620776 From this point forward in this documentation Wacker Neuson Production Americas LLC will be referred to as Wacker Neuson 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 Ifyou are missing either 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 This manual provides information and procedures to safely operate and main tain the above Wacker Neuson model s For your own safety and to reduce the risk of injury carefully read understand and observe all instructions described in this manual Wacker Neuson expressly reserves the right to make technical modifications even without notice which improve the performance or safety standards of its machines 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 Engine exhaust some of its constituents and certain vehicle components contain or
18. R 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 messages that follow this signal word WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury To avoid possible death or serious injury from this type of hazard obey all safety mes sages 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 moderate injury from this type of hazard obey all safety mes sages 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 wc_si000391gb fm 9 u NEUSON Safety Information PD2 PD3 PD2A PD3A 1 2 Machine Description and Intended Use This machine is a diaphragm pump The Wacker Neuson Diaphragm Pump consists of a gasoline engine a fuel tank a handle a set of wheels and a diaphragm pump with ports for fluid suction and discharge The engine raises and lowers the diaphragm via a connecting rod 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 i
19. The Safety Alert Symbol identifies important safety 3 BIG REASONS messages on machines safety signs in manuals f or elsewhere When you see this symbol be alert j Accidents en DISABLE to the possibility of personal injury or death Follow z Accidents 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 ee a 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 eae eae health regulations and standards under the Publishes a list Operator Precautions SAE J153 authority of the Occupational Safety and Health Act MAY 87 for the general construction and mining industries AEM Association of Equipment Manufacturers U S Department of Labor 111 East Wisconsin Avenue Washington
20. Y 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 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 o 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 Proper operating procedures Proper shutdown procedures e Proper maintenance procedures Proper loading and unloading pr
21. a grease gun pump grease into the fitting until new grease seeps out between the bearing and the journal 34 wc_tx001332gb fm PD 2A PD 3A Maintenance 5 5 Changing the Engine Oil When Requirements A Procedure wc_tx001332gb fm Change the engine oil after the first 20 hours of operation and then after every 100 hours of operation or 6 months whichever comes first a Warm engine m Plastic sheet to protect against drips or spills Container of sufficient volume to collect waste oil Replacement oil see Technical Data for quantity and type New gasket 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 periods of time Take steps to avoid inhaling or ingesting used engine oil gt Wash skin thoroughly after exposure to used engine oil Perform the procedure below to replace the engine oil Position the machine on a flat level surface Stop the engine Place the plastic sheet and container under the engine A W N gt Remove the drain plug a and allow the oil to drain wc_gr007167 5 Reinstall the drain plug with a new gasket 6 Remove the dipstick b and wipe it clean 7 Fill the engine crankcase with fresh oil through the filler opening c Check the oil level by inserting the dipstick into the filler opening Do not thread the dipstick into the engine
22. acturer 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 hydraulic fluid leaks worn and damaged hoses lines or power cables 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 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 13 WORK SAFELY Engine Driven Pumps Maintenance and Repair All installations operations and maintenance should be in accordance with pump and engine manufacturers 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
23. afe 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 Know 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 If it is 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 e
24. apacity Follow manufacturer s lifting recommendation Check all lubricant levels before pump installation in accordance with manufacturer s maintenance programs pumps 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 pum
25. ash point fluids These fluids could ignite or explode Read the Operator s Manual wc_si000392gb fm PD2 PD3 PD2A PD3A Lifting and Transporting 3 Lifting and Transporting Requirements Transport vehicle capable of carrying at least 70 kg 150 Ibs a Use lifting equipment capable of lifting at least 70 kg 150 Ibs WARNING Fire hazard Spilled fuel can ignite and cause severe burns gt Lift and transport the machine in an upright position Guidelines Follow the guidelines below when lifting and transporting this machine Close the fuel valve Lift and transport it in an upright position a Use the lifting hook d to lift the machine a MOL N LA NSS Q Vi A i Ne ASI TIL I i i LY CNY aa NR CAN wc_gr007150 To secure the machine to the transport vehicle attach strapping b across the handle Also attach strapping a across the frame of the machine NOTICE Do not use the wheels or the casting c as tie down locations wc_gr007149 WACKER wc_tx001371gb fm 21 NEUSON Operation PD 2A PD 3A 4 Operation 4 1 Preparing the Machine for First Use Preparing for To prepare your machine for first use first use 1 Make sure all loose packaging materials have been removed from the machine 2 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
26. 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 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 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 ihe 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 f acid gets into the eyes flush immediately wit
27. ce 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 m FIG 9 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 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 c
28. e the flapper valves valves Pump not secured to firm Secure the pump foundation Restricted suction hose Clean or replace the suction hose Hoses are Hoses are damaged 41 V WACKER NEUSON Troubleshooting PD 2 PD3 PD2A PD 3A Water accumulates on top Diaphragm has crack or Replace the diaphragm of the diaphragm hole screw loose holding dia Tighten the screw phragm Pump stalls repeatedly or Discharge hose height over Lower the discharge hose stops for no apparent rea 25 feet of head N Pump housing filled with dirt Clean the pump and debris WACKER BR n Wy NEUSON 42 _tx001382gb f PD2A PD3A Technical Data 7 Technical Data 7 1 Engine Engine Power Net power rating per SAE J1349 Actual power output may vary due to conditions Rating of specific use Enger on Te Mander Meo ROTOR Maximum rated power at rated speed kW rpm 2 6 3600 hp rpm 3 5 3600 Displacement om 118 in 7 2 Number of cylinders Oil capacity ee 0Z 20 Oil type o 10W30 API SJ SL or equivalent Fuel type Regular unleaded gasoline Fuel tank capacity 2 5 a 2 6 Fuel consumption L hr 1 1 qt hr 1 2 Rimnoime BE BE TE Spark plug type NGKBPREHS NGKBPREHS BPR6HS Electrode gap ww 0 70 0 80 0 023 0 031 wc_td000379gb fm 43 WY Neu En Technical Data PD 2A PD 3A 7 2 Pump Machine po PDI 2 PDT 2 PDI 3 PDT 3 Maximum discharge head Maximum discharge head head T Tr 38 gpm
29. ections 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 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 manufacturers 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 Exc
30. edures Procedure Perform the procedure below to install the pump NOTICE Do not use collapsible hoses on the suction side of the pump 1 Place the pump as near to the water to be pumped as possible 2 Check that hose couplings nipples b are installed and secure wc_gr007137 3 Make sure the suction strainer e is clean and securely attached to the end of the suction hose 4 Connect the suction hose d to the pump with two clamps c Position the suction hose so that a there is a continual upward slope from the water source to the pump the suction hose strainer in the water source will stay submerged as the water source level drops m the suction hose is as short as possible there are no loops in the suction hose a there are no air leaks 5 Connect the discharge hose f to the pump with clamp g 6 Lay the discharge hose f out as straight as possible Position the discharge hose so that there are no sharp bends or loops in the hose m the hose is less than 8 1 m 25 ft above or away from the pump a the hose is not a tripping hazard on the job site NOTICE Maximum discharge head is 8 1 m 25 ft or 0 8 bar 10 9 psi Operating the pump over this head or pressure will cause the pump to stall and or gearbox damage WACKER wc_ tx m w NEUSON 26 _tx001331gb f PD 2A PD 3A Operation 4 7 Starting Requirements Procedure wc_tx001331gb fm Completed installation procedures m Engine owner s man
31. emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm 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 dis 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 This manual contains references to approved parts attachments and modifica tions The following definitions apply WACKER 3 W NEUSON Foreword PD 2A PD 3A Approved parts or attachments are those either manufactured or provided by Wacker Neuson m Approved modifications are those performed by an authorized Wacker Neu son service center according to written instructions published by Wacker Neu son 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 Serious injury hazards to the operator and persons in the work area Permanent damage to the machine which will not be covered under warranty Contact your Wacker Neuson dealer immediately if you have questions abou
32. ept 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 devices 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 50 100 150 6 16 8 14 14 14 12 12 16 10 16 12 14 14 14 16 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 lowerin
33. g 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 SAFELY Submersibles WORK SAFELY Submersibles FIG 1 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 17 18 Pu Maintenan nd air 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 ONL
34. gs 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 them 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 Reflector Vests e Safety Shoes Hearing Protection Eye Protection Face Protection 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 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 manufacturers 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 s
35. h large amounts of water and seek proper medical treatment immediately 16 WORK SAFELY Electric Motor Driven Pumps SAFE WORKING PROCEDURES Allow only qualified personnelto 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 manufacturers 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 A Follow motor manufacturer s 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 io 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 conn
36. has two elements a foam element and a paper element 4 Remove the foam element e from the paper element d 5 Clean the elements if they are to be reused Paper element a Tap the paper element on a hard surface to remove dirt or blow low pressure less than 207 kPa 30 psi through the paper element from the inside NOTICE Do not try to brush dirt off the paper element Brushing will force dirt into the fibers of the paper element Foam element a Wash the foam element in a solution of mild detergent and warm water b Rinse the foam element thoroughly in clean water and allow it to dry completely lt a WACKER W NEUSON Maintenance PD 2A PD 3A c Soak the foam element in clean engine oil until saturated Squeeze out excess oil 6 Reinstall the filter elements and air cleaner cover Note n the interests of environmental protection dispose of waste oil and soiled rags in accordance with environmental protection legislation 5 4 Greasing the Connecting Rod Bearing When Grease the connecting rod bearing every 40 hours of operation or monthly Requirements General automotive grease m Machine shut down Procedure Perform the procedure below to grease the connecting rod bearing 1 Stop the engine 2 Access the grease fitting of the connecting rod bearing through the access hole a EN EN za X r SUN i 4 N Say T ps ee NEN Za B S Q m wc_gr007184 3 Using
37. ications have received instruction on how to properly use the machine are familiar with required safety devices The machine must not be accessed or operated by children people impaired by alcohol or drugs Be aware of the application area m Keep unauthorized personnel children and pets away from the machine Remain aware of changing positions and the movement of other equipment and personnel in the application area job site Be aware of the application area m Do not operate the machine in areas that contain flammable objects fuels or products that produce flammable vapors Only operate the machine when All safety devices and guards are in place and in working order All controls operate correctly The machine is set up correctly according to the instructions in the Operator s Manual he machine is clean m he machine s labels are legible To ensure safe operation of the machine m Do not operate the machine if any safety devices or guards are missing or inop erative m Do not modify or defeat the safety devices m Do not use accessories or attachments that are not approved by Wacker Neu son WACKER 11 W NEUSON Safety Information PD2 PD3 PD2A PD3A Operating guidelines Personal Protective Equipment PPE When operating this machine Ensure that the machine is on a firm level surface and that it will not tip roll slide or fall while operating When operating this
38. nded Use 2202202200220220ennennenneen 10 1 3 Operating SAIEN zes ee ne re 11 1 4 CIVICS SAY ee E E E 13 1 5 Operator Safety while Using Internal Combustion Engines 15 2 Labels 16 2 1 Lapel LOCallONS sncccsececswanceenosecongcesaeabaiatesabesceierenSrenstsnorieraiuceactersiasebies 16 2 2 Label MeaniNgS zensiert ne ee E REEE E 17 3 Lifting and Transporting 21 4 Operation 22 4 1 Preparing the Machine for First Use u22u02220ssneeenennnnenenenenenn 22 4 2 HOSeS SING CAMPS anne ee 22 4 3 Recommended Fuel 2200200020002000nn0nnnonnnnnnn anno nnn nee nnnn anne anne 23 4 4 Refueling the Machine 2220224020000200 0200 nnno anno nenn nenn ann ennnen nenn 24 4 5 Before Installing the Pump 22u0222020000200 nenn anno nnne anne nero nennen 25 4 6 installing TAG PUMP u unes neseenenreeeeire 26 4 SUNS EPE E PEET E EE E E EEEE EE TS 27 4 8 SHOPPING vs Sense ee E AA 28 4 9 RUNNING Ne PUMP zes eeeneeeeneunereernen 28 4 10 Cleanng DANS scscasceescarassenerctoesesiansanteseenaneaseecudenetcosivestesbdenesuenishesancoans 29 4 11 Emergency Shutdown Procedure cccccccecccsecceeeeseceeeeeseeeseeeseeeeaes 30 wc_b05000184784_03TOC fm 4 WACKER 7 W NEUSON Table of Contents PD 2A PD 3A 5 Maintenance 31 5 1 Maintaining the Emission Control System 2 2022400220 nennen 31 5 2 Periodic Maintenance Schedule 2022200220022
39. ne transporting Make sure slings chains hooks ramps jacks and other types of lifting devices are attached securely and have enough weight bearing capacity to lift or hold the machine safely See chapter Technical Data m Remain aware of the location of other people when lifting the machine Make sure the transporting vehicle has sufficient load capacity and platform size to safely transport the machine See chapter Technical Data To reduce the possibility of injury m Do not stand under the machine while it is being lifted or moved m Do not get onto the machine while it is being lifted or moved Cleaning When cleaning and servicing the machine Keep the machine clean and free of debris such as leaves paper cartons etc Keep the labels legible When cleaning the machine m Do not clean the machine while it is running Never use gasoline or other types of fuels or flammable solvents to clean the machine Fumes from fuels and solvents can become explosive s WACKER Ues w NEUSON 14 _si000391gb f PD 2 PD3 PD2A PD 3A Safety Information 1 5 Operator Safety while Using Internal Combustion Engines A A Operating safety Refueling safety wc_si000391gb fm 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 e
40. ngine 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 When operating the pump Keep the area around exhaust pipe free of flammable materials Check the fuel lines and the fuel tank for leaks and cracks before starting the engine When operating the pump m Do not smoke while operating the machine m Do not run the machine if fuel leaks are present or the fuel lines are loose Do not run the engine near sparks or open flames m Do not touch the engine or muffler while the engine is running or immediately after it has been turned off m Do not operate a machine when its fuel cap is loose or missing m Do not start 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 When refueling the engine Clean up any spilled fuel immediately Refill the fuel tank in a well ventilated area Replace the fuel tank cap after refueling When refueling the engine m Do not smoke
41. ocedures 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 operating 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 IRSSOCIATION OF Association of Equipment Manufacturers Toll free 1 866 AEM 0442 e mail aem aem org PMN CLUES www aem org FORM PP 130 2 Wacker Neuson Produktion GmbH amp Co KG Preu enstra e 41 D 80809 M nchen Tel 49 0 89 3 54 02 0 Fax 49 0 89 3 54 02 390 Wacker Neuson Production Americas LLC N92W15000 Anthony Ave Menomonee Falls WI 53051 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Neuson Limited Room 1701 03 amp 1717 20 17 F Tower 1 Grand Century Place 193 Prince Edward Road West Mongkok Kowloon Hongkong Tel 852 3605 5360 Fax 852 2758 0032
42. onthly mas az Yearly 40 100 300 eama fy O BE I A A Inspect air cleaner elements Replace as v needed Grease connecting rod bearing Change engine oil engine Change engine oil Check oil level in pump gearbox Clean spark plug Clean spark plug plug Change oil in pump gearbox Check and adjust valve engine clearances Check and adjust idle speed Replace fuel filter Use whichever comes calendar time or service hours w NEUSOR 32 wc_tx001332gb fm PD 2A PD 3A Maintenance 5 3 Servicing the Air Cleaner When Requirements A Procedure wc_tx001332gb fm Inspect the air cleaner elements daily Clean the air cleaner elements as needed Replace the air cleaner elements if they are damaged or cannot be cleaned m Machine shut down Mild detergent and warm water Clean engine oil WARNING Fire or explosion hazards Gasoline or low flash point solvents are flammable and must not be used to clean the air cleaner or filter element Use only mild detergent and warm water to clean the air cleaner and filter element NOTICE Do not run the engine without the air cleaner or filter elements Severe engine damage will occur Follow the procedure below to service the air cleaner 1 Stop the engine 2 Remove the wing nut a and remove the air cleaner cover b wc_gr007168 3 Remove the second wing nut c and remove the air filter Note The air filter
43. ot prime a check for loose fittings air leaks and plugged strainer b stop the engine remove plug a add water reinstall plug and restart the engine S aa J ZI gt a RS ID T 1 I i I wc _gr007161 WACKER 28 NEUSON wc_tx001331gb fm PD 2A PD 3A Operation 4 10 Clearing Jams Overview Prerequisites If the pump has stalled If the crank is slipping wc_tx001331gb fm Large solids or accumulated sand and sediment may become lodged in the pump housing This debris prevents the plunger arm from making a full stroke causing the pump to stall or the crank to slip on the output shaft The debris must be cleared before resuming operation m Engine is stopped sm Machine is cool to the touch Follow the procedure below to clear a jam ifthe pump has stalled EN i V v ZI N Mt 5 Al NG iD T Li l 1 lt I wc_gr008182 1 Remove the handle a 2 Remove the four bolts b securing the pump housing c 3 Clean all debris and obstructions from the pump housing 4 Re install the four bolts and handle Follow the procedure below to re tighten the crank if a jam has caused it to slip 1 Loosen the hand knob screws d and remove the metal guard e 2 Remove the handle and bolts as described in the above procedure 3 Clean all debris and obstructions from the pump housing 4 Loosen the crank lockscrew f Re torque the crank lockscrew to 9
44. ping equipment during electrical storms It can attract lightning FIG 10 OVERHEATING PRECAUTIONS Overheated pumps can cause severe damage to the equipment and can cause 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 Be sure the immediate work area is safe for operation e 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 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 o
45. s 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 m Heat noise exhaust and carbon monoxide from the engine Fire hazards from improper refueling techniques Fuel and its fumes Personal injury from improper lifting techniques a Projectile hazard from discharge Crushing hazards from a tipping or 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 G WACKER N en W NEUSON 10 _si000391gb f PD2 PD3 PD2A PD3A Safety Information 1 3 Operating Safety Operator training Operator qualifications Application area Safety devices controls and attachments wc_si000391gb fm Before operating the machine Read and understand the operating instructions contained in all manuals deliv ered with the machine Familiarize yourself with the location and proper use of all controls and safety devices Contact Wacker Neuson for additional training if necessary When operating this machine m Do not allow improperly trained people to operate the machine People operat ing the machine must be familiar with the potential risks and hazards associated with it Only trained personnel are permitted to start operate and shut down the machine They also must meet the following qualif
46. s 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 operator or other persons in the area Machine damage caused by misuse is not covered under warranty The following are some examples of misuse m Pumping flammable explosive or corrosive fluids m Pumping hot or volatile fluids that result in pump cavitation Operating the pump outside of product specifications due to incorrect diameter hoses incorrect length hoses other inlet or outlet restrictions or excessive SUC tion lift or head m Using the machine as a ladder support or work surface a Using the machine to carry or transport passengers or equipment Operating the machine outside of factory specifications Operating the machine in a manner inconsistent with all warnings found on the machine and in the Operator s 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 guard
47. t approved or unapproved parts attachments or modifications WACKER nn Wy NEUSON 4 _tx001329gb f 2011 CE PD2A_PD3A_en fm WACKER NEUSON EC Declaration of Conformity Manufacturer Wacker Neuson Production Americas LLC N92W15000 Anthony Avenue Menomonee Falls Wisconsin USA Product Product PDT 2A PDT2 PDI 2A i PDT 3A PDT 3 PDI 3A PDI 3A i Product category Water Pump Units Product function To pump fluid Item number 0620769 0620772 0620773 0620775 0620776 Net installed power PDT 2A PDI 2A i PDT 3A PDI 3A PDI 3A i 2 6 kW PDT 2 PDT 3 3 2 kW Measured sound power level 96 dB A Guaranteed sound power level 97 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 EN 809 1998 Authorized Person for Technical Documents Axel Haret Wacker Neuson SE Preu enstra e 41 80809 Munchen Menomonee Falls WI USA 28 04 11 Pee brn Bin See bt William Lahner Dan Domanski Vice President of Engineering Manager Product Engineering Original Declaration of Conformity PD 2A PD 3A Table of Contents Foreword 3 EC Declaration of Conformity 5 1 Safety Information 9 1 1 Signal Words Used in this Manual ccccccceeceseeeaeeeseeeseeeeeeeeaeeees 9 1 2 Machine Description and Inte
48. t is hot 1 Stop the engine 2 Change the engine oil 3 Cover the pump 4 Store the pump in a clean dry location WACKER en r Wy NEUSON 40 _tx001332gb f PD2 PD3 PD2A PD3A 6 Troubleshooting Problem Engine does not start Pump does not prime Flow rate is slow Pump runs but no fluid is pumped Pump pumps erratically Excessive noise while pumping wc_tx001382gb fm Troubleshooting Engine oil level too low Add oil to engine Pump housing filled with dirt Clean pump and debris Air leak in suction line Repair or replace suction line Defective flapper valve Replace the flapper valves Clogged strainer Clean or replace the strainer No liquid in suction line Fill the pump and suction line with water Pump housing filled with dirt Clean pump and debris Incorrect eine speed Check eet speed Replace the hoses the hoses Too many bends in the Straighten the hoses hoses Hoses are too long Shorten the hoses Faulty suction hose Replace the suction hoses Pump located too far from Place the pump closer to fluid source the source Flapper valve closed Clean or replace the flapper valves Clogged strainer Unclog or replace the strainer Height of discharge hose Lower the discharge hose above pump is too great Leak in suction hose Repair or replace the suc tion hose Diaphragm has crack or Replace the diaphragm hole Defective or clogged flapper Clean or replac
49. ual read and understood Perform the procedure below to start the machine 1 Move the fuel valve lever a to the OPEN position a4 wc_gr007159 2 Move the choke lever b to the CLOSED position b4 If the engine is warm the choke lever may be left in the OPEN position b3 3 Move the throttle lever c approximately 1 3 of the way to the MAX position 4 Turn the engine switch d to the ON position d4 5 Pull the starter rope until the engine starts wc_gr007157 wc_gr007158 6 Move the choke lever to the OPEN position as the engine warms 7 Move the throttle to MAX position to run the pump WACKER 27 NEUSON Operation PD 2A PD 3A 4 8 Stopping Procedure Perform the procedure below to stop the machine Note To stop the engine in an emergency move the engine switch to the OFF position In all other circumstances use the following procedure 1 Move the throttle lever c to MIN position wc_gr007 160 2 Turn the engine switch d to the OFF position d3 3 Move the fuel valve lever a to the CLOSED position a3 4 9 Running the Pump Guidelines Follow the guidelines below when running the pump Run the engine at full speed NOTICE Pump speed must not exceed 60 strokes per minute The pump should begin pumping water within one minute of being started depending on hose length and height above water Longer hoses will require more time a lf the pump does n
50. ustments and repairs must be completed before operation Do not oper ate the machine with a known problem or deficiency All repairs and adjustments shall be completed by a qualified technician Turn off the machine before performing maintenance or making repairs Wear the following Personal Protective Equipment PPE while servicing or maintaining this machine m Close fitting work clothes that do not hinder movement Safety glasses with side shields Hearing protection m Safety toed footwear In addition before servicing or maintaining the machine a Tie back long hair Remove all jewelry including rings When servicing or maintaining the machine m Use only accessories attachments that are approved by Wacker Neuson When servicing or maintaining the machine m Do not defeat safety devices m Do not modify the machine without the express written approval of Wacker Neu son Replace worn or damaged components Replace all missing and hard to read labels WACKER a WY NEUSON Safety Information PD2 PD3 PD2A PD3A m When replacing electrical components use components that are identical in rat ing and performance as the original components When replacement parts are required for this machine use only Wacker Neu son replacement parts or those parts equivalent to the original in all types of specifications such as physical dimensions type strength and material Lifting and When lifting the machi
51. verheated 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 Allow the equipment to cool completely Slowly and cautiously vent the pump Refer to the manufacturer s instruction manual before restarting the unit Remove hoses carefully Heated water can be in hoses and static head produces pressure FIG 10 If 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 Refueling When refueling the following precautions must be followed 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 manuf
52. xtension If 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 adequately 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
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