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1. 3 3 Sound Measurements T m required sound specification Paragraph 1 7 4 f 89 392 EEC Machinery Directive is Guaranteed sound power level Lwa PT 2A 102 dB A PT 2V 99 dB A PT 2H 107 dB A PT 2 101 dB A The sound pressure level at operator s location PT 2A 91 dB A PT 2V 88 dB A PT 2H 99 dB A PT 2 89 These sound values were determined according to ISO 3744 for the sound power level Lwa and ISO 6081 for the sound pressure level at the operator s location wc td000002gb fm 1 6 2 3 4 Maintenance 4 1 Periodic Maintenance Schedule The chart below lists basic machine and engine maintenance Refer to engine manufacturer s Operator s Manual for additional information on engine maintenance Check and tighten external hardware Inspect for leaks between pump and engine Remove cover and clean sediment out of pump housing Check housing cover O rings Inspect shockmounts for damage Wacker Honda Vanguard starting Check fuel level Check engine oil level Inspect air filter Replace as needed Change engine oil Clean air cleaner Clean sediment cup Check and clean spark plug wc_tx000013gb fm 1 7 2 3 Change engine oil and filter Maintenance Dai
2. Engine Make Wacker Honda Briggs amp Stratton Hatz Engine Model WM270 GX 240 1 QA Vanguard 138432 0134 E1 1B 30 Rated Power 6 6 9 6 8 5 6 7 6 5 0 7 0 Displacement 265 16 17 242 14 8 215 13 1 347 21 2 Spark Plug NGK BR 6HS Champion RL86C NGK BPR 6ES BOSCH WR7DC Champion Electrode Gap 0 028 0 031 0 7 0 8 0 028 0 031 0 7 0 8 Engine Speed load Engine Speed idle 3500 1600 100 Valve Clearance cold intake exhaust 0 10 0 004 0 20 0 25 0 008 0 01 Air Cleaner Dual Element Dry Pleated Paper Ele ment Engine Lubrication SAE 10W30 Service Class SF SE SD or SC CD CE CF CG Rated Engine Oil Capacity 1 1 37 0 9 30 1 1 37 Fuel Regular Unleaded Gasoline No 2 Diesel Fuel Tank Capacity wc td000001gb fm 6 0 6 4 11 4 5 4 6 5 0 5 2 3 Technical Data 22 Pump Part No PT 3 PT 3V PT 3H 0009321 0009099 0009100 0009322 0009102 0009103 0009323 0009241 0009242 Weight kg Ibs Max Suction Lift m ft Max Total Head m ft Max Pressure bar psi Max Discharge l min gpm Suction Discharge Dia mm Max Solid Size mm in Based on pump operating at sea level Maximum suction lift will be less at higher altitudes wc td00000
3. 163 9 4 182 11 1 232 14 2 Spark Plug NGK BR 6HS Champion RL86C NGK BPR 6ES BOSCH WR7DC Champion Electrode Gap 0 024 0 028 0 6 0 7 0 028 0 031 0 7 0 8 Engine Speed load Engine Speed idle rpm rpm 3500 1600 100 Valve Clearance cold intake exhaust mm 0 10 0 004 0 20 0 25 0 008 0 01 Air Cleaner type Dual Element Dry Pleated Paper Ele ment Engine Lubrication oil grade SAE 10W30 Service Class SF SE SD or SC CD CE CF CG Rated Engine Oil Capacity oz 0 6 20 7 24 0 9 34 Fuel Regular Unleaded Ga soline No 2 Diesel Fuel Tank Capacity wc td000002gb fm 15 4 0 4 2 3 0 3 2 2 Technical Data 3 2 Pump No PT 2 PT 2A PT 2V PT 2H 0009318 0009092 0009093 0009094 0009319 0009095 0009096 0009097 0009320 0009237 0009238 0009239 Pump Dimensions mm in 550 x 465 x 500 590 x 495 x 510 21 7 x 18 3 x 19 6 23 2 x 19 4 x 20 Weight kg Ibs 43 96 49 107 59 131 Max Suction Lift m ft 7 5 25 Total Head m ft 32 106 Max Pressure bar psi 3 2 46 Max Flow Rate m3 hr 48 gpm 210 Suction Discharge Dia mm in 50 2 Max Solid Size mm in 25 1 Based on pump operating at sea level Maximum suction lift will be less at higher altitudes
4. Wy SS POINT FLUID COULD IGNITE OR Qu 5 X SS on NS wc 97000009 wc si000156gb fm 6 2 3 Repair Safety Information 1 3 Label Locations PT 2V 4 DANGER PELIGRO DANGER 8 wc 41000010 wc_si000156gb fm 7 2 3 Repair Safety Information 1 4 Label Locations PT 2H PT 3H DANGER L A GEFAHR PELIGRO A DANGER VORSICHT VORSICHT CS NN NS ZZ 2 7 E FAAS 7 2 91000011 wc_si000156gb fm 8 2 3 Repair 1 5 Safety Labels Safety Information Wacker machines use international pictorial labels where needed These labels are described below Label Meaning DANGER amp A PELIGRO A DANGER Engines emit carbon monoxide operate only in well ventilated area Read the Operator s Manual No sparks flames or burning objects near machine Shut off engine before refueling 117039 WARNING Hot surface VORSICHT 117045 CAUTION Read and understand the supplied Operator s Manuals before operating this machine Failure to do so increases the risk of injury to yourself or others WARNING Do not
5. ve 5 0113781 DIN 125 0152303 6 Uu 4x10 a LICHE EA nes 1 2 mue EU d wc tx000479gb fm 43 2 3 Repair 5 5 wc tx000479gb fm Disassembly Assembly Procedures Impeller and Mechanical Seal See Graphic gr002494 CAUTION 5 5 1 5 5 2 5 5 3 5 5 4 5 5 5 5 5 6 5 5 7 5 5 8 5 5 9 5 5 10 Impeller Disassembly Impeller edges can be extremely sharp use care when removing Loosen the knobs a securing housing cover volute assembly b to the pump housing and remove housing cover volute assembly Remove impeller by turning nut c molded into impeller casting counterclockwise If impeller is hard to remove use special tool d PN 0159381 Position the tool so that it holds the vanes of impeller Insert socket extension and use an impact wrench to turn impeller off of shaft Impeller Assembly Apply Loctite 246 or an equivalent thread locking sealant to the engine shaft and screw impeller onto engine shaft Reinstall housing cover volute assembly b to the housing and tighten with knobs a Mechanical Seal Disassembly Open pump housing and remove impeller Pull the front half of mechanical seal e off engine shaft Pry the back half f of the mechanical seal from engine shaft Mechanical Seal Assembly Note Always replace both halves of the mechanical seal as a set Clean the mating
6. 24 4 8 Spark Plug Wacker Honda Vanguard 25 4 9 Sediment Oup Horida s oe re ERE p aen ec rs 25 4 10 Cleaning Fuel Strainer Wacker 26 4 11 Fuel Filter Vanguard d red iE 26 4 12 Fuel Filter ioni YP ti Et E S ER 27 4 13 Carburetor Wacker Honda soc bei redet ctis 28 4 14 Carburetor Vanguard 29 br0161539001enTOC fm 1 Table Contents PT Pumps Repair 4 15 Valve Clearances Hatz aec ee 30 4 16 Adjusting Impeller Clearance 2 32 417 Cleaning Q a A ee Aur Geet here Ad 33 418 Storage o Lu ir Ga Sh a 34 4 19 JNGCOSSOLTOS Listes erbe 34 4 20 Troubleshooting UA y 35 5 Disassembly Assembly 36 5 1 PT 2 Exploded View cuyo te ales 36 5 2 PE 2 Compollelllss dna 37 5 3 PT 3 Exploded A 40 5 4 ET Componeta dt settle rins 41 5 5 Impeller and Mechanical Seal 44 5 6 Volute and Shims 46 5 7 Flapper Valve and Pump Housing 48 5 8 Ghecklhg Og ease uwa 48 2 3 Repair 1 Safety Information wc_si000156gb fm DANGER WARNING CAUTION Safety I
7. which aim at improving our machines or their safety standards wc tx000478gb fm II PT Pumps Repair Table of Contents 1 Safety Information 3 1 1 Operating Safely NW u OE 4 1 2 Operator Safety while using Internal Combustion Engines 5 1 3 Label Locations PT 2V PT iios itae Y 7 1 4 Label Locations PT ZH PT 3H 8 1 5 Safety Labels Mem 9 1 6 Inforiiation iato i te RR bc Uo 10 2 Technical Data 11 2 1 ENGINE usu dE be ae 11 2 2 12 2 3 Sound Measurements lt a a eb ob bts totu iih eo isa 13 2 4 DIImernsiofis e qi 13 3 Technical Data 15 3 1 ENGINE osa ee patas Eos 15 3 2 t E 16 3 3 Sound Measurements eie tiet Rad io CS 16 4 Maintenance 17 4 1 Periodic Maintenance Schedule 17 4 2 Engine System Hatz 18 4 3 Engine Wacker Honda Vanguard 20 4 4 Air Cleaner Wacker ue ue dne a i Re e n e n 21 4 5 Air Cleaner Honda te IRE ues Y Rd 22 4 6 Air Cleaner Vanguard eee 23 4 7 GIG Aner
8. 2 3 4 18 4 19 wc tx000013gb fm Maintenance Storage If pump is being stored for more than 30 days NEVER open priming plug discharge plug or cover when pump is hot WARNING 4 18 1 Remove discharge plug from pump casing and drain out any water left in the housing after pump has cooled 4 18 2 Remove pump cover and clean inside of pump housing Coat inside of pump with a light film of oil to reduce corrosion A spray can of oil works well for this 4 18 3 Tape up suction and discharge ports to prevent anything from falling into pump 4 18 4 Change engine oil and follow procedures described in engine manual for engine storage 4 18 5 Cover pump and engine and store a clean dry area Accessories Wacker offers a complete line of fittings hoses and clamps to properly connect the pump to match various job conditions 34 Maintenance PT 2 3 4 20 Troubleshooting Problem Symptom Reason Remedy Pump does not take in water Not enough priming water in housing Engine speed too low Adjust speed Strainer plugged Clean strainer e Suction hose damaged Replace or repair hose e 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 Pump takes in water little or no discharge Engine speed too lo
9. mounts f to the frame 5 7 6 Support the engine with a block of wood g Remove the four screws h securing the housing to the engine and remove the housing from the engine Pump Housing Reassembly 5 7 7 Remove the block of wood g 5 7 8 Apply Loctite 243 or equivalent on the screws h and secure the housing to the engine 5 7 9 Secure the front shock mounts f to the frame with two nuts 5 8 Checking O rings See Graphic wc gr002541 Inspect housing cover O rings before each use 5 8 1 Loosen the knobs a securing housing cover volute assembly to the pump housing and remove housing cover volute assembly 5 8 2 Inspect the O rings b for tears rips or cracks 5 8 3 Replace damaged O rings wc tx000479gb fm 48 Disassembly Assembly 2 3 Repair wc 041002495 01002541 wc 1x000479gb fm 49 2 3 Repair Disassembly Assembly Procedures wc tx000479gb fm 50 Threadlockers and Sealants Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual by a notation of 5 plus a number S and should be used where indicated Threadlocking compounds normally break down at temperatures above 175 C 350 F If a screw or bolt is hard to remove heat it using a small propane torch to break down the sealant When applying sealants follow instructions on container The sealants listed are recommended for use on Wacker Neuson equipmen
10. 1gb fm 1 2 3 Technical Data 2 3 Sound Measurements Lwa D The required sound specification per paragraph 1 7 4 of 89 392 EEC Machinery Directive is Guaranteed sound power level Lwa PT 110 dB A 103 dB A PT 108 dB A PT 3 104 dB A The sound pressure level at operator s location Lpa PT 101 dB A PT 91 dB A PT 99 dB A PT 3 92 dB A These sound values were determined according to ISO 3744 for the sound power level and ISO 6081 for the sound pressure level at the operator s location 2 4 Dimensions _ 505 _ m 675 26 570 L eal a 23 gt 3 9 000012 wc td000001gb fm 1 3 3 Technical Data wc td000001gb fm 1 4 2 3 Technical Data 3 1 Engine Item No PT2 0009318 0009319 0009320 Engine PT 2A 0009092 0009095 0009237 Technical Data PT 2V 0009093 0009096 0009238 PT 2H 0009094 0009097 0009239 Engine Type 4 stroke overhead valve single cylinder 4 stroke sin gle cylinder air cooled 4 stroke air cooled die sel engine Engine Make Wacker Honda Briggs amp Stratton Hatz Engine Model WM170 GX 160 K1 TX2 Vanguard 117432 0235 E2 1B 20 Rated Power 4 5 6 4 5 5 4 5 6 3 4 4 6 Displacement 169 10 3
11. 300 F Loctite 515 Purple Form in place gasket for flexible joints 70735 50 ml Hernon 910 Fills gaps up to 1 3 mm 0 05 Omnifit 10 Temp range 54 to 149 C 65 to 300 F Threadlockers and Sealants Threadlockers and Sealants continued Threadlocking adhesives and sealants are specified throughout this manual by a notation of S plus a number 54 and should be used where indicated Threadlocking compounds normally break down at temperatures above 175 C 850 If a screw or bolt is hard to remove heat it using a small propane torch to break down the sealant When applying sealants follow instructions on container The sealants listed are recommended for use on Wacker Neuson equipment TYPE PART NO Europe COLOR USAGE SIZE Loctite 496 Clear Instant adhesive for bonding rubber 52676 102 Hernon 110 metal and plastics general purpose Omnifit Sicomet 7000 For gaps up to 0 15 mm 0 006 Read caution instructions before using Temp range 54 to 82 C 65 to 180 F Loctite Primer T Aerosol Fast curing primer for threadlocking 2006124 6 oz Hernon Primer 10 Spray _ retaining and sealing compounds Must Omnifit VC Activator be used with stainless steel hardware Recommended for use with gasket sealants Torque Values Torque Values Metric Fasteners DIN TORQUE VALUES Based on Bolt Size and Hardness WRE
12. 4 NEVER allow anyone to operate this equipment without proper training People operating this equipment must be familiar with the risks and hazards associated with it 1 1 2 NEVER use accessories or attachments that are not recommended by Wacker Damage to equipment and injury to the user may result 1 1 3 NEVER 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 NEVER pump volatile flammable or low flash point fluids These fluids could ignite or explode NEVER pump corrosive chemicals or water containing toxic substances These fluids could create serious health environmental hazards Contact local authorities for assistance 1 1 4 NEVER open priming plug when pump is hot Never loosen or remove inlet or discharge hose fittings when pump is hot Hot water inside could be pressurized much like the radiator on an automobile Allow pump to cool to the touch before loosening plug and before loosening or removing inlet or discharge hose fittings 11 5 NEVER 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 1 1 6 NEVER 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 1 4 7 ALWAYS be s
13. 80809 M nchen gt Tel 49 0 89 3 5402 0 Fax 49 0 89 3 54 02 3 90 Wacker Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Asia Pacific Operations Skyline Tower Suite 2303 23 F 39 Wang Kwong Road Kowloon Bay Hong Kong Tel 852 2406 60 32 Fax 852 2406 60 21
14. ATION RESERVES THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION WITHOUT NOTICE 5 CALIFORNIA Proposition 65 Warning A Engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California WARNING to cause cancer and birth defects or other reproductive harm Laws Pertaining to Spark Arresters 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 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 All rights especially copying and distribution rights are reserved Copyright 2004 by Wacker Corporation No part of this publication may be reproduced in any form or by any means electronic or mechanical including photocopying without express written permission from Wacker Corporation Any type of reproduction or distribution not authorized by Wacker Corporation represents an infringement of valid copyrights and will be prosecuted We expressly reserve the right to make technical modifications even without due notice
15. D 70019259111 PM 1 9152592 NE 9152525 I FN on 0152594141 a cria NT 100 0119412 2 ER ne 101 0152595 1 ER 102 0119410 1 ie 103 0152596 1 ER A SINE 104 0152597 1 Hum A 1020078684 1 25 Hebr NM 122 0182598 Seivaube ve ee CEA xm 124 0928949 4 E eo c 0029311 125 0152303 6 a 2 DIN7991 LO a o e wc tx000479gb fm 3 9 Disassembly Assembly 2 3 Repair PT 3 Exploded View 5 3 wc_ex0009098100 gb fm wc 1 000479 Disassembly Assembly 54 PT 3 Components See Graphic 0009098100 2 3 Repair Measurem Abm Norm Ref Part Qty Description Descripci n Artikel Nr St Beschreibung Description Torque Drehim Sesli TT Frame Chasis 1 0119398 1 Rahmen Ch ssis oe 1 Motor Moteur Housing Caja S 9117804 1 Geh use Carter Impeller Impulsor 011 805 71 Pumpenlaufrad Turbine Volute Voluta qS s Spiralgeh use Volute Cover Tapa Gr Couvercle Flange Brida T 011781001 Flansch Collerette 10 0117819 1 Mechanical seal Gleitringdichtung Sello mec nico Garniture m canique 10 0158126 1 Mechanical seal Gleitringdichtung Sello mec nico Garniture m
16. NCH SIZE O OD OO OC 8 8 10 9 12 9 Size Nm ft Ib Nm ft Ib Nm ft Ib Metric Inch Metric Inch M3 1 2 11 1 6 14 2 1 19 5 5 7 32 2 5 M4 2 9 26 4 1 36 4 9 43 7 9 32 3 B M5 6 0 53 8 5 6 10 7 8 5 16 4 _ M6 10 7 14 10 17 13 10 5 25 18 35 26 41 30 13 1 2 6 10 49 36 69 51 83 61 17 11 16 8 12 86 63 120 88 145 107 19 3 4 10 14 135 99 190 140 230 169 22 7 8 12 M16 210 155 295 217 355 262 24 15 16 14 18 290 214 405 298 485 357 27 1 1 16 14 m M20 410 302 580 427 690 508 30 1 1 4 17 1 ft lb 1 357 in lb 1 inch 25 4 Torque Values Torque Values continued Inch Fasteners SAE H SAE 5 8 amm Size Nm ft Ib Nm ft Ib Nm ft Ib Metric Inch Metric Inch No 4 0 7 6 1 0 14 1 4 12 5 5 1 4 3 32 6 1 4 12 1 9 17 2 4 21 8 5 16 zx 7 64 No 8 2 5 22 3 5 31 4 7 42 9 11 32 9 64 10 3 6 32 5 1 45 6 8 60 3 8 5 32 1 4 8 1 6 12 9 16 12 7 16 3 32 5 16 18 13 26 19 33 24 13 1 2 1 4 3 8 31 23 45 33 58 43 9 16 5 16 7 16 50 37 71 52 94 69 16 5 8 3 8 1 2 77 57 109 80 142 105 19 3 4 3 8 9 16 111 82 156 115 214 158 13 16 5 8 152 112 216 159 265 195 24 15 16 1 2 3 4 271 200 383 282 479 353 1 1 8 5 8 1 ft lb 1 357 Nm in lb 1 inch 25 4 mm Wacker Construction Equipment PreuBenstraBe 41 D
17. Voluta 0119779121 Spiralgeh use Volute Cover Tapa BH s Couvercle Flange Brida 7 0119783 d Flansch Collerette 10 0119784 1 Mechanical seal Gleitringdichtung Sello mec nico Garniture m canique 10 0158125 1 Mechanical seal Gleitringdichtung Sello mec nico Garniture m canique 11 0119785 1 insert Inserto de voluta Einsatz Insertion de volute Valve V lvula 12 0119 80 1 Ventil Soupape 13 2 Nipple fitting Niple Stutzen Raccord 0029311 14 0152600 1 Lifting bracket M nsula alzadora Hebeb gel Support de rel vement ts ota a VEU 0117916 LD 17 0119406 4 Knob zs 19 0119626 Ps 20 0152399 2 2 38 25 21 0152400 2 22 1 rm IT 2 zm 0026918 1 Couping 2 21 0028681 32 0030550 1 Strainer tx000479gb fm 37 2 3 Repair Disassembly Assembly Procedures PT 2 Exploded View wc ex0009092100 wc tx000479gb fm 38 Disassembly Assembly 2 3 2 Components PartNo Description Descripci n Measure Artikel Nr St Beschreibung Description gsm EN
18. ating hours at the latest Remove the air cleaner cover 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 outwards until no further dirt emerges CAUTION 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 CAUTION If there is the slightest damage to the paper filter do not re use Re assemble the filter cartridge in reverse order wc tx000013gb fm wc 9 000027 24 Maintenance PT 2 3 4 8 4 9 tx000013gb fm Spark Plug Wacker Honda Vanguard See Graphic wc_gr000028 Clean or replace spark plug as needed to ensure proper operation Refer to the engine owner s manual The muffler becomes very hot during operation and remains hot for a while after stopping the engine Do not touch the muffl
19. canique 11 0119403 1 Volute insert Inserto de voluta Einsatz Insertion de volute 12 0117814 1 vae 2 43 2 Nipple fitting Niple Stutzen Raccord 0029311 14 biting ove racket INR 15 0117817 4 Drente Pivot ODD De eee ii nm 17 0119406 4 Knob Roe c Hand 5 191 0119626 os o1ieeod 2 Shackmoun dn 21 2 Shackmour 22 0152275 1 Einsatz 0928 7 1 a1 0020699 1 Same 32 030549 1 Stainer 4 2 70 0119419111 as oe ii wc tx000479gb fm 4 1 2 3 Repair Disassembly Assembly Procedures PT 3 Exploded View wc 0009098100 tx000479gb fm 42 Disassembly Assembly 3 Components 2 3 Repair Ref PartNo Description Descripci n Artikel Nr St Beschreibung Description Torque Drehm s TA 0119416141 SA il 9 0119418 d PETS oe E IR Res TA vedono 0369 um ns 1 Se om s 105 0075991 ener Behan n i M DIN 120 0119977 4 6x20 one 122 0119979 5 ae Mg g0 is 123 0119413 4 V us n 124 008 023
20. d or confined area ALWAYS refill fuel tank in well ventilated area ALWAYS replace fuel tank cap after refueling Service Safety Poorly maintained equipment can become a safety hazard In order for the equipment to operate safely and properly over a long period of time periodic maintenance and occasional repairs are necessary DO NOT attempt to clean or service 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 ALWAYS keep area around muffler free of debris such as leaves paper cartons etc A hot muffler could ignite them starting a fire ALWAYS replace worn or damaged components with spare parts designed and recommended by Wacker ALWAYS disconnect 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 ALWAYS handle impeller carefully The impeller can develop sharp edges which can cut 2 3 Repair Safety Information 1 2 18 Label Locations PT 2A PT PT 2 PT 3 4 DANGER 4 GEFAHR 9 PELIGRO DANGER 117034 CAUTION A LL a 4 enecaumon CAUTION Bw
21. er while it is hot WARNING Note Refer to the Technical Data for the recommended spark plug type and the electrode gap setting 4 8 1 Remove spark plug and inspect it 4 8 2 Replace plug if the insulator is cracked or chipped 4 8 3 Clean spark plug electrodes with a wire brush 484 Set the electrode gap a 4 8 5 Tighten spark plug securely CAUTION A loose spark plug can become very hot and may cause engine damage Sediment Cup Honda See Graphic 9000029 4 9 1 Turn fuel valve off 492 Remove sediment cup and O ring b 4 9 3 Wash both thoroughly in nonflammable solvent Dry and reinstall them 4 9 4 Turn fuel valve and check for leaks 25 2 3 Maintenance 4 10 Cleaning Fuel Strainer Wacker See Graphic wc_gr001093 4 10 4 To remove water and close the fuel lever and remove fuel strainer 4 10 2 Inspect fuel strainer a for water and dirt 4 10 3 After removing dirt and water wash the fuel cup with kerosene or gasoline 4 10 4 Reinstall securely to prevent leakage wc gr001093 d wc gr000030 4 11 Fuel Filter Vanguard See Graphic wc gro00030 4 11 1 Turn fuel valve off 4 11 2 Remove bowl a gasket b and screen 4 11 3 Wash them thoroughly a nonflammable solvent Dry them and reinstall 4 11 4 Turn fuel valve on and check for leaks tx000013gb fm 26 Mainte
22. he limiter cap cannot be removed without breaking the pilot screw wc gr000032 28 Maintenance PT 2 3 4 14 wc_tx000013gb fm Carburetor Vanguard See Graphic wc_gr000033 4 14 1 Start engine and allow it to warm up to operating temperature 4 14 2 Place throttle control in idle position Hold carburetor throttle lever a against idle speed screw Turn idle speed screw b to obtain 1300 RPM 4 14 3 While still holding carburetor throttle lever against idle speed screw turn idle mixture screw c clockwise lean or counterclockwise rich until engine runs smoothly Release carburetor throttle lever 4 14 4 Adjust governed idle screw d to 1400 RPM Move throttle control to the fast position Engine should accelerate smoothly If it does not readjust carburetor usually to a slighly richer mixture by turning idle mixture screw c 1 8 turn counterclockwise 4 14 5 Adjust top speed screw f to 3500 RPM oM TL wc gr000033 2 3 4 15 Valve Clearances Hatz tx000013gb fm See Graphic 000034 4 15 1 4 15 2 4 15 3 4 15 4 4 15 5 4 15 6 4 15 7 4 15 8 4 15 9 4 15 10 4 15 11 4 15 12 4 15 13 Only carry out adjustments when the engine is cold 42 62 10 30 C Remove air cleaner cover and noi
23. ine oil and squeeze out excess oil 453 Tap paper element c lightly to remove excess dirt Replace paper element if it appears heavily soiled 9 000025 wc tx000013gb fm 22 Maintenance PT 2 3 4 6 tx000013gb fm Air Cleaner Vanguard See Graphic wc_gr000026 Service air cleaner frequently to prevent carburetor malfunction CAUTION 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 fire or explosion could result WARNING The engine is equipped with a dual element air cleaner To service air cleaner 4 6 1 Loosen cover knobs and remove cover from air cleaner assembly Remove both elements and retainer b Inspect elements for holes or tears Replace damaged elements Foam element pre cleaner c 4 6 2 Wash in solution of mild detergent and warm water 46 3 Rinse thoroughly in clean water Allow element to dry thoroughly 4 6 4 Soak element in clean engine oil and squeeze out excess oil Paper element d 4 6 5 Tap element lightly to remove excess dirt Replace paper element if it appears heavily soiled Do not oil paper element wc gr000026 23 PT 2 3 4 7 Maintenance Air Cleaner Hatz See Graphic wc 01000027 4 7 1 4 7 2 4 7 3 The filter cartridge should always be replaced after 500 oper
24. l element air cleaner Under normal operating conditions elements should be cleaned once every week Under severe dry and dusty conditions the elements should be maintained daily Replace an element when saturated with dirt that cannot be removed 441 Remove the air cleaner cover a Remove both elements and inspect them for holes or tears Replace damaged elements 442 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 443 Tap the paper element lightly to remove excess dirt blow compressed air through the filter from the inside out Replace the paper element if it appears heavily soiled wc gr000656 21 2 3 45 Air Cleaner Honda See Graphic wc 000025 The engine is equipped with a dual element air cleaner Service air cleaner frequently to prevent carburetor malfunction CAUTION 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 451 Remove air cleaner cover a Remove both elements and inspect them for holes or tears Replace damaged elements 4 5 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 eng
25. ller 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 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 32 Maintenance 2 3 4 17 Cleaning Pump See Graphic 9000036 Clean inside of pump housing after every use 4171 Remove drain plug a from pump housing and drain any water left in pump 4 17 2 Loosen the four knobs holding the pump cover b and remove cover 4 17 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 wc 97000036 wc tx000013gb fm 3 3 PT
26. ly before starting Clean cooling air system Check and adjust valve clearances Clean or replace air filter Replace fuel filter 4 2 wc tx000013gb fm Engine Oil System Hatz See Graphic 07000023 wc gr002682 4 2 1 4 2 2 4 2 3 WARNING 4 2 4 4 2 5 4 2 6 WARNING 4 2 7 4 2 8 Engine Oil Level Check the oil with the machine standing on a level surface Clean around the dipstick Check the oil level on the extended dipstick a If necessary top up to the mark Engine may be hot enough to cause burns Allow engine to cool prior to servicing Changing Engine Oil Change the oil with the machine standing on a level surface Run the engine for a few minutes and then stop the engine Drain the engine oil when it is still warm 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 Care must be taken when draining hot engine oil Hot oil can burn Unscrew the oil drain plug b and allow all the oil to drain into a container Clean the oil drain plug and attach a new seal c Insert and tighten the plug 18 4 2 9 4 2 10 4 2 11 4 2 12 4 2 13 4 2 14 2 3 Release filter screw d pull the oil filter ou
27. nance PT 2 3 4 12 FuelFilter Hatz See Graphic wc_gr000031 Fuel filter maintenance intervals depend on the purity of the diesel fuel used If your fuel is dirty perform this operation at 250 hours Danger of explosion Diesel fuel is flammable and must be treated with the necessary caution Do not smoke Avoid sparks and open flames WARNING 4 12 1 Remove the fuel tank cap a and drain fuel tank 4 12 2 Unscrew fuel line b at filter c and insert a new filter 4 12 3 Fit the fuel filter again and close the tank cap Note Bleeding of the fuel injection system takes place automatically HATZ DIESEL 9 000031 tx000013gb fm 2 7 2 3 4 13 wc_tx000013gb fm 2 Maintenance Carburetor Wacker Honda See Graphic wc 9 000032 4131 Start the engine and allow it to warm up to operating temperature 4 13 2 Set the pilot screw a 2 turns out See Note 4 13 3 With the engine idling turn the pilot screw in or out to the setting that produces the highest rpm 4 13 4 After the pilot screw is adjusted turn the throttle stop screw b to obtain the standard idle speed See Technical Data Note On some engines the pilot screw is fitted with a limiter cap c to prevent excessive enrichment of the air fuel mixture in order to comply with emission regulations The mixture is set at the factory and no adjustment should be necessary Do not attempt to remove the limiter cap T
28. nformation This manual contains DANGER WARNING CAUTION and NOTE callouts 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 injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION Used without the safety alert symbol CAUTION indicates a potentially hazardous situation which if not avoided may result in property damage Note Contains additional information important to a procedure 2 3 Repair Safety Information 11 Operating Safety Familiarity and proper training are required for the safe operation of equipment Equipment operated improperly or by untrained personnel can be dangerous Read the operating instructions contained in both WARNING this manual and the engine manual and familiarize yourself with the location and proper use all controls Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine 1 4
29. open if pump is hot Hot water and or steam inside could be pressurized WARNING Never pump volatile flammable or low flash point fluids These fluids could ignite or explode CAUTION AVORSICHT PRECAUCION DIESEL PRECAUTION CAUTION Use only clean filtered diesel fuel wc si000156gb fm 2 3 Repair Safety Information Meaning Lifting point 1 6 Information Labels A nameplate listing the Model Number Item Number Revision and Serial Number is attached to each unit Please record the informa tion found on this plate so it will be available should the nameplate become lost or damaged When ordering parts or requesting service infor mation you will always be asked to specify the model item number revision number and serial number of the unit U S PAT Nos OTHER U S AND FOREIGN PATENTS PENDING This machine may be covered by one or more patents Di si000156gb fm Guaranteed sound power level in dB A 10 PT 3 2 Technical Data 21 Engine Part No PT3 0009321 0009322 0009323 Engine Technical Data PT 3V 0009099 0009102 0009241 PT 3H 0009100 0009103 0009242 Engine Type 4 stroke overhead valve single cylinder 4 stroke sin gle cylinder air cooled 4 stroke air cooled die sel engine
30. se insulating hood Remove any contamination adhering to the cover for the cylinder head Pull oil feed knob as far as the limit stop Remove screws a and take off the cylinder head cover with gasket b Remove rubber cap from the inspection hole cover c 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 at the TDC mark d Check valve clearance with feeler gauge e Note Refer to the Technical Data for valve clearances If valve clearances require adjusting slacken off screw f and turn hex nut g until feeler gauge can be pulled through with just slight resistance when screw is retightened Check the O rings h on the oil feed for cracks and or damage 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 at the inspection hole cover Carry out a brief test run then check the cover for leaks 30 Maintenance PT 2 3 we_gr000034 wc tx000013gb fm 3 1 PT 2 3 Maintenance 4 16 Adjusting Impeller Clearance tx000013gb fm See Graphic wc_gr000035 4 16 1 4 16 2 If it is necessary to replace the impeller or the volute insert be sure clearance between impe
31. surfaces carbon and ceramic with alcohol before installing Note f the carbon face g has worn flush with surface of the seal replace the mechanical seal to prevent pump from leaking To ease installation apply a thin film of lubricant to the O ring h of the back half of the mechanical seal Position the back half f of the mechanical seal so that the grooved ceramic ring i faces the engine and then slide it onto the engine shaft Position the front half e of the mechanical seal so that the carbon portion faces the engine and then slide it onto the engine shaft 44 Disassembly Assembly 2 3 Repair NR 487 wc 01002494 wc 1x000479gb fm 45 2 3 Repair Disassembly Assembly Procedures 5 6 and Shims See Graphic gr002496 Volute and Shims Disassembly 5 6 1 Remove the housing cover volute assembly a from the pump 5 6 2 Remove the three screws b securing volute assembly c to the housing cover and remove the volute assembly 5 6 3 Remove the three screws d securing the shim plate e and shims f to the volute g Remove the shims and the shim plate Volute and Shims Assembly 5 6 4 Remove spark plug on units with Hatz engine place speed control lever in STOP position so that engine will not start 5 6 5 Make sure impeller is installed 5 6 6 Place 6 10 shims f between the shim plate e and the volute and secure them to the volute wi
32. t TYPE PART NO Europe COLOR USAGE SIZE Loctite 222 Purple Low strength for locking threads smaller 73287 10 ml Hernon 420 than 6 mm 1 4 Omnifit 1150 BOM Hand tool removable Temp range 54 to 149 C 65 to 300 F Loctite 243 Blue Medium strength for locking threads 29311 5 Hernon 423 larger than 6 mm 1 4 17380 50 ml Omnifit 1350 100M Hand tool removable Temp range 54 to 149 C 65 to 300 F Loctite 271 277 Red High strength for all threads up to 25 mm 29312 5 ml Hernon 427 17 26685 10 Omnifit 1550 220 parts before disassembly 73285 50 ml Temp range 54 to 149 C 65 to 300 F Loctite 290 Green Medium to high strength for locking 28824 5 ml Hernon 431 preassembled threads and for sealing 25316 10 ml Omnifit 1710 230LL weld porosity wicking Gaps up to 0 13 mm 0 005 Temp range 54 to 149 C 65 to 300 F Loctite 609 Green Medium strength retaining compound for 29314 5 ml Hernon 822 slip or press fit of shafts bearings gears Omnifit 1730 230L pulleys etc Gaps up to 0 13 mm 0 005 Temp range 54 to 149 C 65 to 300 F Loctite 545 Brown sealant 79356 50 947 Temp range 54 to 149 C 65 to 300 F Omnifit 1150 Loctite 592 White sealant with Teflon for moderate 26695 6 ml Hernon 920 pressures 73289 50 ml Omnifit 790 Temp range 54 to 149 C 65 to
33. t its housing Use an air line to blow out oil filter dirt from the inside outwards Lightly oil the gaskets c Refit the oil filter Apply slight pressure towards the engine block and tighten by hand Add engine oil Run for a short interval then check at drain plug b for any leaks Tighten if necessary wc 1x000013gb fm gr000023 wc gr002682 19 2 3 Maintenance 4 3 wc tx000013gb fm Engine Oil Wacker Honda Vanguard See Graphic 000022 4 3 1 Drain oil while the engine is still warm 432 Remove the oil fill plug and drain plug b to drain oil 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 4 3 3 Install drain plug 4 3 4 Fill the engine crankcase with recommended oil up to the level of the plug opening c See Technical Data for oil quantity and type 4 3 5 Install the oil filler plug 20 Maintenance PT 2 3 4 4 wc_tx000013gb fm Air Cleaner Wacker See Graphic wc_gr000656 NEVER use gasoline or other types of low flash point solvents for cleaning the air cleaner fire or explosion could result WARNING CAUTION NEVER run engine without air cleaner Severe engine damage will occur The engine is equipped with a dua
34. th three screws d 5 6 7 Install the volute assembly c to the housing cover 5 6 8 Install the housing cover volute assembly a to the pump housing 5 6 9 Pull the starter rope If the starter rope does not move the impeller is binding and shim s must be removed Disassemble the volute assembly and remove one shim Reassemble the volute assembly to the housing cover and remount the housing cover volute assembly a to the pump housing Pull the starter rope If the starter rope does not move the impeller is still binding remove another shim Continue in this manner until the impeller is snug yet moves freely when the starter rope is pulled Note 7he greater the distance between the impeller and volute the less efficient the pump will be wc tx000479gb fm 46 Disassembly Assembly 2 3 wc 9002496 tx000479gb fm 47 2 3 Repair Disassembly Assembly Procedures 5 7 Flapper Valve and Pump Housing See Graphic wc gr002495 Flapper Valve Disassembly 571 Remove four bolts a securing flange b and remove the flange 5 7 2 Remove flapper valve Flapper Valve Reassembly 5 7 3 When re installing flapper match tab d flapper valve with indent in flange e 5 7 4 Apply Loctite 243 or equivalent on the four screws a and secure the flapper valve c and flange b to the pump housing Pump Housing Disassembly 5 7 5 Remove the two nuts securing the front shock
35. ure operator is familiar with proper safety precautions and operation techniques before using machine 1 1 8 ALWAYS read understand and follow procedures in Operator s Manual before attempting to operate equipment 1 1 9 ALWAYS be sure machine is on firm level surface and will not tip roll slide or fall while operating 1 1 10 ALWAYS close fuel valve on engines equipped with one when machine is not being operated wc_si000156gb fm 4 2 3 Repair 1 2 wc_si000156gb fm 1 1 11 Safety Information ALWAYS store properly when it is not being used Eguipment should be stored in a clean dry location out of the reach of children Operator Safety while using Internal Combustion Engines N DANGER 1 2 1 1 2 2 1 2 3 1 2 4 1 2 5 1 2 6 1 2 13 1 2 14 1 2 15 1 2 16 1 2 17 Internal combustion engines present special hazards during operation and fueling Read and follow warning instructions in engine owner s manual and safety guidelines below Failure to follow warnings and safety guidelines could result in severe injury or death DO NOT smoke while operating machine DO NOT smoke when refueling engine DO NOT refuel hot or running engine DO NOT refuel engine near open flame DO NOT run engine near open flames DO NOT test for spark on gasoline powered engines if engine is flooded or the smell of gasoline is present A stray spark could ignite fumes NEVER operate pump in enclose
36. w Adjust speed e Suction strainer partially plugged Clean strainer Impeller worn Adjust clearance by adding shims replace impeller insert worn or damaged Adjust clearance or replace insert Suction hose leaks at inlet Clamps are not sealing properly Tighten replace or add clamp Hose diameter is too large Hose is damaged Discharge hose does not stay Pressure may be too high for clamps being used on coupling Add another clamp Hose kinked or end blocked Check hose Impeller does not turn pump Impeller jammed or blocked Open pump cover and is hard to start clean dirt and debris from inside of pump housing mpeller and insert binding Adjust clearance by removing shim from behind insert wc tx000013gb fm 3 5 2 3 Repair Disassembly Assembly 5 Disassembly Assembly 51 PT 2 Exploded View 0009092100 wc tx000479gb fm 36 Disassembly Assembly 5 2 2 Components See Graphic 0009092100 2 3 eU Measurem Abm Norm Ref Part No Qty Description Descripcion Pos Artikel Nr St Beschreibung Description Torque Drehm Chasis 1 0119402 1 Rahmen Ch ssis 2 1 Engine Motor Motor Moteur Housing Caja 3 ors 1 Geh use Carter Impeller Impulsor DD XI Pumpenlaufrad Turbine Volute
37. www wackergroup com 0161539en 001 0105 Pump PT 2 PT 3 REPAIR MANUAL 0 1 6 1 5 3 9 E PT PG Pumps Repair Foreword This manual covers machines with Item Number 0009321 0009322 0009323 0009098 0009101 0009240 0009099 0009102 0009241 0009100 0009103 0009242 0009318 0009319 0009320 0009092 0009095 0009237 0009093 0009096 0009238 0009094 0009097 0009239 tx000478gb fm Operating Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or make any repairs to it Basic operating and maintenance procedures are described in the Operators Manual supplied with the machine Keep a copy of it with the machine at all times Use the separate Parts Book supplied with the machine to order replacement parts If either of the documents becomes lost please contact Wacker Corporation to order a replacement Damage caused by misuse or neglect of the unit should be brought to the attention of the operator to prevent similar occurrences from happening in the future This manual provides information and procedures to safely repair and maintain the above Wacker model s For your own safety and protection from injury carefully read understand and observe all instructions described in this manual THE INFORMATION CONTAINED IN THIS MANUAL IS BASED ON MACHINES MANUFACTURED UP TO THE TIME OF PUBLICATION WACKER CORPOR

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