en Trash Pumps PT 6LT PT 6LS REPAIR MANUAL

Transcription

1 en Trash Pumps PT 6LT PT 6LS REPAIR MANUAL E N

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3 PT6 Repair Foreword This manual covers machines with Item Number: , Operating / Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or repair it. Basic operating and maintenance procedures are described in the Operator s Manual supplied with the machine. 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. If you are missing either of the documents, 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 CORPORATION RESERVES THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION WITHOUT NOTICE. wc_tx000556gb.fm i

4 Foreword PT6 Repair WARNING CALIFORNIA Proposition 65 Warning: Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California 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 a device designed to prevent accidental discharge of sparks or flames from the engine exhaust. Spark arresters are qualified and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator. All rights, especially copying and distribution rights, are reserved. Copyright 2006 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 violators will be prosecuted. We expressly reserve the right to make technical modifications, even without due notice, which aim at improving our machines or their safety standards. wc_tx000556gb.fm ii

5 PT6 Repair Table of Contents 1. Safety Information State Regulations Concerning Trailers Operating Safety Operator Safety While Using Internal Combustion Engines Service Safety Towing Safety Reporting Trailer Safety Defects Label Locations Safety Labels Technical Data Engine Pump Lubrication Trailer Dimensions Operation Operation and Service Locations Application Recommended Fuel Before Starting the Engine Before Starting the Pump To Start To Stop Automatic Shutdown System Important Operation Note Hoses Hose Couplings Hose Clamps Strainer Discharge Port Covers Hitching and Towing the Trailer wc_br entoc.fm 1

6 Table of Contents PT6 Repair 4. Maintenance Engine Fuel Delivery System Maintenance Storage Periodic Maintenance Schedule Air Cleaner Fuel Filter Priming the Fuel System Engine Lubrication Engine Oil Valve Clearances Fan Belt Pump Housing Mounting Bolts Mechanical Seal Lubrication Bearing Housing Lubrication Impeller Clearance Cleaning the Engine Cooling Fins Battery Lifting the Machine Tires Wheels and Lug Nuts Tongue Jack Safety Chains Lights Wiring Diagram Trailer Wiring Diagram ( > Rev 119; > Rev 122) Wiring Diagram Components Wiring Diagram ( < Rev 120; < Rev 123) Wiring Diagram Components Basic Troubleshooting Theory and Performance Evaluating the Pump s Performance Vacuum Test...54 wc_br entoc.fm 2

7 PT6 Repair Table of Contents 6. Lombardini Engine Troubleshooting Troubleshooting Flowcharts Engine Does Not Crank Flowchart 1A Checking Keyswitch and Wiring ( > Rev 119; > Rev 122) Checking Keyswitch and Wiring ( < Rev 120; < Rev 123) Replacing the Keyswitch Engine Cranks But Does Not Start Flowchart 1B Checking the Throttle Solenoid Checking the Auto Shutdown Circuit Checking Voltage to Glow Plug Checking Glow Plug Relay Replacing Glow Plug Relay Checking Glow Plug Engine Shuts Down Flowchart 1C Checking Oil Pressure and Coolant Temperature Switches General Engine Troubleshooting Disassembly/Assembly Procedures Tools Ordering Parts Reference Numbers ( ) Weight Block Replacing the Flapper Valve Replacing the Impeller Replacing the Mechanical Seal Removing the Pump and Bearing Housing Installing the Pump and Bearing Housing Replacing the Flex Coupling and Mounting Flange Bearing Housing Bearing Housing Components Bearing Housing Disassembly Bearing Housing Assembly Installing End Cap and Seal Housing wc_br entoc.fm 3

8 Safety Information PT 6 / Safety Information 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 DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could 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. 1.1 State Regulations Concerning Trailers Trailer laws covering such things as brakes, lights, safety chains, etc., will vary from state to state. Make certain that your trailer is in compliance with the regulations of the state in which the trailer will be used. If you are not sure what these regulations are, contact the state motor vehicle department for information. In some states, trailers must be registered and licensed by the State Department of Transportation. Before towing, be sure to check licensing requirements. wc_si000098gb.fm 4

9 PT 6 / Operating Safety Safety Information 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 this manual and the engine manual and familiarize yourself with the location and proper use of all controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine 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 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 use accessories or attachments that are not recommended by Wacker. Damage to equipment and injury to the user may result NEVER leave machine running unattended NEVER operate this machine in applications for which it is not intended NEVER open the priming plug when the pump is hot. Never loosen or remove inlet or discharge hose fittings when the pump is hot. Hot water inside could be pressurized much like the radiator on an automobile. Allow the pump to cool to the touch before loosening the plug and before loosening or removing the inlet or discharge hose fittings NEVER position the pump on a loose, uneven, or unstable surface where it can tip, roll, slide or fall! The pump must be secure before operating. Position the pump on a firm, flat surface; adjust the trailer jacks to be sure the pump is level and supported firmly NEVER open the pump housing cover while the pump is operating or start the pump with the cover off. The rotating impeller inside the pump can cut or sever objects caught in it NEVER block or restrict flow from the inlet line or the discharge line. Remove kinks from the discharge line before starting the pump. Operation with a blocked inlet line or discharge line can cause water inside the pump to overheat NEVER reach into or insert anything into the pump while the engine is on! The impeller inside the pump housing is turning at all times while the engine is running DO NOT allow anyone to stand in front of the discharge port when starting the engine or while priming the pump! The sudden out-rush of water could push or knock a person down. WARNING wc_si000098gb.fm 5

10 Safety Information PT 6 / ALWAYS make sure the hose connections on the pump are tight. A loose connection could cause water to spray or result in a hose falling off the pump while it is in operation ALWAYS make sure the water stream from the pump discharge is not directed in such a way so as to cause erosion to the surrounding ground or damage or weakening of nearby structures! 1.3 Operator Safety While Using Internal Combustion Engines DO NOT run the machine indoors or in an enclosed area such as a deep trench unless adequate ventilation, through such items as exhaust fans or hoses, is provided. Exhaust gas from the engine contains poisonous carbon monoxide gas; exposure to carbon monoxide can cause loss of consciousness and may lead to death DO NOT smoke while operating the machine DO NOT smoke when refueling the engine DO NOT refuel a hot or running engine DO NOT refuel the engine near an open flame ALWAYS refill the fuel tank in a well-ventilated area ALWAYS replace the fuel tank cap after refueling ALWAYS check the fuel lines and the fuel tank for leaks and cracks before starting the engine. Do not run the machine if fuel leaks are present or the fuel lines are loose ALWAYS keep the area around a hot exhaust pipe free of debris to reduce the chance of an accidental fire. 1.4 Service Safety WARNING 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 the machine while it is running. Rotating parts can cause severe injury 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 DO NOT attempt to clean or service the machine while it is running DO NOT operate the machine without an air cleaner ALWAYS replace worn or damaged components with spare parts designed and recommended by Wacker Corporation. wc_si000098gb.fm 6

11 PT 6 /... Safety Information ALWAYS keep the machine clean and labels legible. Replace all missing and hard-to-read labels. Labels provide important operating instructions and warn of dangers and hazards ALWAYS replace the safety devices and guards after repairs and maintenance ALWAYS check all external fasteners at regular intervals ALWAYS remain aware of moving parts and keep hands, feet, and loose clothing away from the moving parts of the equipment. 1.5 Towing Safety WARNING Towing a large trailer requires special care. Both the trailer and vehicle must be in good condition and securely fastened to each other to reduce the possibility of an accident ALWAYS check that the hitch and coupling on the vehicle are rated equal to, or greater than, the trailer's gross vehicle weight rating (GVWR) ALWAYS inspect the hitch and coupling for wear or damage. DO NOT tow the trailer using defective parts ALWAYS make sure the coupling is securely fastened to the vehicle ALWAYS check the tires on the trailer for tread wear, inflation, and condition. Replace worn tires ALWAYS connect the safety chains ALWAYS connect the breakaway cable safety hook to the bumper or rear of the vehicle. DO NOT attach it to the hitch ALWAYS test the surge brakes on the trailer and the brakes on the vehicle that will be used for towing ALWAYS make sure directional and trailer lights are connected and working properly ALWAYS check that the lug nuts holding the wheels are tight and that none are missing. wc_si000098gb.fm 7

12 Safety Information PT 6 / Reporting Trailer Safety Defects If you believe your trailer has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Wacker Corporation. If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Wacker Corporation. To contact NHTSA, you may either contact the Auto Safety Hotline tollfree at (or in Washington DC area), or write to NHTSA, U.S. Department of Transportation, 400 7th Street SW, (NSA-11), Washington, DC You can also obtain other information about motor vehicle safety from the Auto Safety Hotline. wc_si000098gb.fm 8

13 PT 6 / Label Locations Safety Information wc_gr wc_si000098gb.fm 9

14 Safety Information PT 6 / Safety Labels Ref. Label Meaning 1 DANGER! Engines emit carbon monoxide; operate only in well-ventilated area. Read the Operator s Manual. No sparks, flames, or burning objects near the machine. Shut off the engine before refueling. 2 CAUTION! Use only clean, filtered diesel fuel. 3 CAUTION! Read and understand the supplied Operator s Manuals before operating this machine. Failure to do so increases the risk of injury to yourself or others. 4 CAUTION! Lifting point 5 WARNING! Hot surface! 6 WARNING! Pressurized contents. Do not open when hot! 7 WARNING! Never pump volatile, flammable or low flash point fluids. These fluids could ignite or explode. wc_si000098gb.fm 10

15 PT 6 /... Safety Information Ref. Label Meaning TOWING INSTRUCTIONS ABSCHLEPPINSTRUKTIONEN INSTRUCCIONES DE REMOLQUE INSTRUCTIONS DE REMORQUAGE 8 1. READ OPERATOR'S MANUAL. 2. USE HITCH RATED FRO TRAILER'S "GROSS VEHICLE WEIGHT RATING". 3. SECURELY ATTACH TRAILER TO TOW VEHICLE. 4. ATTACH SAFETY CHAINS USING CROSS PATTERN. 5. ATTACH BREAKDOWN CHAIN TO VEHICLE. 6. CHECK TRAILER LIGHTS. 1. BETRIEBSVORSCHRIFT LESEN. 2. ANHANGEVORRICHTUNG VERWENDEN, DIE DER GESAMTBETRIEBSGEWICHTSKLASSE ENTSPRICHT. 3. ANHANGER SICHER AM ZUGFAHRZEUG BEFESTIGEN. 4. SICHERHEITSKETTEN KREUZWEISE ANBRINGEN. 5. ABREISSKETTE AM FAHRZEUG ANBRINGEN. 6. ANHANGERLEUCHTEN PRUFEN. 1. LEA EL MANUAL DEL OPERARIO. 2. UTILICE UN ACOPLE CORRECTAMENTE CLASIFICADO PARA LA "CLASE DE PESO BUTO" DEL VEHICULO DEL REMOLQUE. 3. ASEGURESE DE AMARRAR CORRECTAMENTE EL REMOLQUE AL VEHICULO DE REMOLQUE. 4. FIJE EN CRUZ LAS CADENAS DE SEGURIDAD. 5. FIJE EN EL VEHICULO DE REMOLQUE LA CADENA DE DESPRENDIMIENTO. 6. CONTROLE LAS LUCES DEL REMOLQUE. 1. LIRE LA NOTICE D'EMPLOI. 2. UTILISER UN GROCHET D'ATTELAGE CONFORME AU DEBIT NOMINAL DU POIDS BRUT DE VEHICULE DU TRACTEUR. 3. ATTACHER LA REMORQUE FERMEMENT AU VEHICULE TRACTEUR. 4. ATTACHER LES CHAINES DE SURETTE EN UTILISANT UNE METHODE CROISEE. 5. ATTACHER LA CHAINE DE REMORQUAGE AU VEHICULE. 6. VERIFIER LES LAMPES DE LA REMORQUE A nameplate listing the model number, item number, revision number, and serial number is attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model number, item number, revision number, and serial number of the unit CAUTION! Engine overheat - Check fan belt. This machine may be covered by one or more patents. wc_si000098gb.fm 11

16 Technical Data PT 6 / Technical Data 2.1 Engine Item No. Engine PT 6LT PT 6LS Engine type Engine make Engine model Three cylinder, 4-cycle air cooled, diesel engine Lombardini 11LD625-3 Rated power kw (Hp) 22 (30) Alternator Amp 14 Engine speed - full load rpm 2500 ± 100 Engine speed - idle rpm 1500 ± 100 Valve clearance (cold) intake: exhaust: mm (in.) 0.15 (0.006) 0.20 (0.007) Air cleaner type Oil Bath (Do not use oil lighter than 20W) Battery V / size 12V / 31 Fuel type No. 2 Diesel Fuel tank capacity l (gal.) 98 (26) wc_td000099gb.fm 12

17 PT 6 / Pump Technical Data Item No. Pump PT 6LT PT 6LS Weight kg (lbs.) 1090 (2400) 850 (1870) Max. suction lift m (ft.) 7.5 (25) Max. total head m (ft.) 30.5 (100) Max. discharge m³/h (gpm) 295 (1300) Suction / discharge dia. mm (in.) 150 (6) Max. solid size mm (in.) 50 (2) 2.3 Lubrication Item No. PT 6LT PT 6LS Lubrication Engine type / qty. SAE 15W40 CD Rated / 5.0 L (5 qts.) Pump seal housing type / qty. SAE 15W40 / 800ml (27oz.) Pump bearing housing type / qty. SAE 15W40 / 470ml (16oz.) wc_td000099gb.fm 13

18 Technical Data PT 6 / Trailer Item No. PT 6LT Trailer Power take-off type Direct Drive with Flex-Coupling Trailer tounge weight kg (lbs) 75 (165) Gross vehicle weight Rating kg (lbs) 1588 (3500) Tire size 205 / 75D-14 Tire load Rating C wc_td000099gb.fm 14

19 PT 6 / Dimensions Technical Data wc_gr wc_td000099gb.fm 15

20 Operation PT 6 / Operation 3.1 Operation and Service Locations See Graphic: wc_gr Ref. Description Ref. Description 1 Engine oil dipstick 14 Engine oil filter 2 Fuel filter 15 Battery box 3 Manual fuel pump lever 16 Trailer hitch 4 Engine oil drain plug 17 Jack stand 5 Engine throttle solenoid 18 Rear stabilizers 6 Control panel 19 Drain cover 7 Ignition switch 20 Front impeller cover 8 Hour meter 21 Suction port 9 Bearing/Seal housing 22 Priming cover 10 Lifting point 23 Discharge port 11 Engine oil fill cap 24 Fuel fill cap 12 Inspection cover 25 License plate holder 13 Air cleaner 26 Circuit breaker wc_tx000261gb.fm 16

21 PT 6 /... Operation wc_gr wc_tx000261gb.fm 17

22 Operation PT 6 / Application The PT6 is a self-priming, high performance trash pump designed to handle water and solids up to 50.8 mm (2.0 in). It is built for the demands of construction, mining, municipality, farm and marine applications. 3.3 Recommended Fuel The engine requires No. 2 diesel fuel. Use only fresh, clean fuel. Fuel containing water or dirt will damage the fuel system. Consult the engine owner s manual for complete fuel specifications. 3.4 Before Starting the Engine Read and understand the safety and operating instructions at the beginning of this manual Check: The oil level in the engine The fuel level The condition of the air cleaner The tightness of the external fasteners The condition of the fuel lines CAUTION: DO NOT run the engine without oil in the oil-bath air cleaner or severe engine damage will result. 3.5 Before Starting the Pump See Graphic: wc_gr Check the bearing/seal housing (f) for proper oil level. Also check the oil for water contamination. Do not operate the pump if contamination is found Position the pump as near to the water as possible, on a firm, flat surface. Keep the pump level Lower the rear stabilizers (a) until they contact the ground. Lock the stabilizers in position with the pins Crank down the jack stand (b) on the front of the trailer. Block both wheels to keep the pump from rolling during operation. wc_tx000261gb.fm 18

23 PT 6 /... Operation If necessary, rotate the discharge elbow to direct water flow in the desired direction Attach the suction hose to the suction port (d). Attach the discharge hoses to the discharge port (e). Check and tighten the clamps and coupling to make sure the hoses are securely fastened. WARNING A loose connection can create a serious safety hazard should it break loose while the pump is running Attach the suction strainer to the suction hose to prevent large debris from being pulled into the pump Prime the pump. To do so, open the cover (c) at the top of the pump and fill the pump housing with water. The pump will not prime unless this is done. e d f g c a b wc_gr wc_tx000261gb.fm 19

24 Operation PT 6 / To Start See Graphic: wc_gr Loosen the throttle lever knob (c) and set the engine throttle (d) to high speed. Tighten the throttle lever knob Open the cover on the battery box (a) and turn and hold the ignition key (b) to the ON position until the glow plug light on the control panel goes out. Then, turn the ignition key to the START position. Release the key after the engine starts. It will spring back into the ON position. Note: The engine will not start if the oil pressure is too low or the cylinder head temperature exceeds the preset value. The pump should prime and begin pumping within a minute or two. At high suction lifts or low engine speeds, the pump will require a longer period of time to prime. If the pump does not prime, shut off the engine and refer to the section on troubleshooting. CAUTION: DO NOT crank the starter for more than seconds at a time; the starter motor can overheat and be damaged. CAUTION: DO NOT run the pump dry for long periods of time or run the pump without oil in the bearing/seal housing. The mechanical seal could overheat and be damaged. Adjusting Pump Flow: Pump flow can be set by adjusting the speed of the engine To set the engine speed, loosen the throttle lever knob (c) and adjust the throttle lever (d) Tighten the throttle lever knob to hold the throttle lever in place while the pump is operating. When priming the pump, set the throttle lever at full speed until the pump flow begins; then, adjust the throttle lever to the desired speed. 3.7 To Stop See Graphic: wc_gr Turn ignition key (b) to OFF. CAUTION: If temperatures are expected to fall below freezing during the night, be sure to drain the pump housing (e) while the pump is not in use. wc_tx000261gb.fm 20

25 PT 6 /... Operation d b c e a wc_gr Automatic Shutdown System The engine is equipped with an automatic shutdown system to protect it from damage should a low oil pressure or a high cylinder temperature condition occur. During a low-oil-pressure condition, the low-oil-pressure switch opens cutting power to the throttle solenoid. During a high-cylindertemperature condition, the engine temperature switch shorts to ground. This trips the circuit breaker and cuts power to the throttle solenoid. Whenever power is cut to the throttle solenoid, it deenergizes. When the throttle solenoid is de-energized, the engine stops. If the engine stops unexpectedly and the circuit breaker trips, it is a sign of a problem with the fan belt. Check the fan belt and replace it if necessary. Reset the circuit breaker before resuming use of the pump. If the engine stops unexpectedly without the circuit breaker tripping, check the amount of oil in the engine crankcase. Fill the engine crankcase with oil as needed. 3.9 Important Operation Note CAUTION: DO NOT run the pump in less than 1.2 m (4.0 ft.) of water! At this level the water begins to form a funnel down to the bottom of the suction line and strainer, allowing the pump to draw in air. The mixture of air and water leads to a condition known as cavitation, which will quickly destroy the impeller and the water chamber inside the pump housing wc_tx000261gb.fm 21

26 Operation PT 6 / Hoses Suction hoses must be rigid enough not to collapse. Make sure the suction hose is in good condition. A hole or tear in the suction hose above the water line will prevent the pump from priming. CAUTION: Always use a strainer on the end of the suction hose to prevent pulling in large debris which could clog the pump or jam the impeller. Discharge hoses are usually thin-walled collapsible hoses; however, rigid hoses like those used on the suction side can also be used. Lay the discharge hose as straight as possible. Avoid sharp bends and turns. Note: Both suction and discharge hoses are available through Wacker Corporation Hose Couplings A variety of couplings are available to attach the hoses to the suction and discharge ports as well as to connect two hose lengths together Hose Clamps Suction Hose to Inlet Port Coupling At least two T-bolt clamps are recommended for connection of the suction hose to the pump inlet. Index clamps at 90 intervals for best seal. Add additional clamps if the pump has trouble priming. Note: The smallest air leak on the suction side of the pump will prevent the pump from priming. Other hose connections Normally only one T-bolt or worm gear clamp is required to hold the hoses in place. In some cases, variances in hose diameters may make it necessary to add extra clamps to maintain a reliable connection. wc_tx000261gb.fm 22

27 PT 6 / Strainer Operation 3.14 Discharge Port CAUTION: DO NOT use a strainer with holes larger than the maximum solid-size rating of the pump 50 mm (2 in.). DO NOT place the strainer directly into mud or sand. Always keep the strainer suspended in the liquid being pumped. Failure to follow the above directives may cause pump damage. See Graphic: wc_gr The discharge port (a) can be rotated 360 to direct water flow in any direction. To rotate the elbow: Remove the locknuts (b) which hold the port to the pump housing Lift the port off the studs and position it as desired. Always check the gasket and replace it if it is damaged Tighten the locknuts evenly. Torque them to 160 Nm (118 ft. lbs). a b wc_gr wc_tx000261gb.fm 23

28 Operation PT 6 / Covers See Graphic: wc_gr DO NOT open the covers or reach into the pump while the engine is running! The spinning impeller could cause a severe injury. DO NOT run the pump with any of the covers open or missing. WARNING Drain/Priming Cover: Clean-out covers are located on the top (a) and bottom (b) of the pump. The top cover is also used to add water to the pump housing for priming. To open a cover, loosen the knob and swing the cover to the side. Grease the rubber gasket under each cover occasionally to prevent it from sticking to the metal and tearing. Impeller Cover: The impeller cover (c) can be removed to clean the pump, set the impeller clearance, and inspect the pump interior. To remove the impeller cover and elbow: Turn the inner star wheel (d) in until it is seated tightly against the impeller cover Turn the outer star wheel (e) in until the cover is pulled out of the housing When the impeller cover is free of the housing, rotate the clamp (f) counterclockwise and pull the impeller cover from the housing. To install the impeller: Place the impeller cover assembly into the housing with the arrow on the casting pointing up. Rotate the clamp (f) into position Turn the outer star wheel out until it is seated against the end of the threaded shaft (g) Turn the inner star wheel out to push the impeller cover into the housing. Hand tighten the inner star only! After the impeller cover is installed, turn in the outer wheel to push the clamp down over the impeller cover and secure it in place. wc_tx000261gb.fm 24

29 PT 6 /... Operation a c b d f e g wc_gr wc_tx000261gb.fm 25

30 Operation PT 6 / Hitching and Towing the Trailer See Graphic: wc_gr Before hitching and towing the trailer, check the following: Check that the vehicle, towing hitch, and coupler have a rating equal to or greater than the trailer's Gross Vehicle Weight Rating (GVWR). See Technical Data for trailer weight. Check tread wear and inflation of the trailer s tires. Make sure all the lug nuts are in place and tight. Make sure that the trailer coupler and towing vehicle s hitch are compatible. The trailer is equipped with either a pintle-style coupler or a 2" or 2-5/16" ball coupler. Check the condition of the trailer s coupler and the hitch on the towing vehicle. DO NOT tow the trailer if the coupler or the hitch are damaged. Check that the coupler and the hitch ball are clean; then, apply a film of grease to the coupler and the hitch ball. A film of grease will extend the coupler and ball life and eliminate squeaking. Check that all the pins and bolts on the tongue are secure. To hitch the trailer: Back your vehicle as close as possible to the trailer. It is easier and safer to back the tow vehicle under the trailer than to pull the trailer to the vehicle Check that the coupler locking device (h) is released Raise the trailer coupler using the tongue jack (d) to a height just above the ball on the hitch. Carefully position the vehicle so the ball on the hitch is under the coupler. Lower the jack until the coupler is all the way down over the ball Check under the coupling to be sure that the ball clamp is below the ball and not riding on top of it Clamp the coupler to the hitch ball. To be sure it is clamped and securely in place, raise up on the trailer tongue. If it comes loose from the ball, release the ball clamp and repeat step After the trailer is hitched to the towing vehicle, lock the rear stabilizers (k) and the tongue jack (d) in the UP positions Make sure the wiring harness (g) is connected to the vehicle and that the tail, stop, and turn lights (e) and side marker lights (f) work Connect the safety chains (c) in a crossing pattern under the trailer tongue. wc_tx000261gb.fm 26

31 PT 6 /... Operation CAUTION When towing, maintain extra space between the vehicles and avoid soft shoulders, curbs, and sudden lane changes. If you have not pulled the trailer before, practice turning, stopping, and backing up in an area away from traffic. DO NOT exceed 55 mph when towing the trailer. In most states, large trailers must be registered and licensed by the State Department of Transportation. Before towing, be sure to check licensing requirements Always refer to the applicable Department of Transportation regulations before towing. WARNING k e h c g d f wc_gr wc_tx000261gb.fm 27

32 Maintenance PT 6 / Maintenance 4.1 Engine Fuel Delivery System Maintenance Maintenance to the engine fuel delivery system should be performed by an experienced mechanic familiar with diesel engines. For detailed maintenance procedures on the engine fuel system, refer to the engine manual supplied with the machine at the time of shipment. 4.2 Storage If storing the machine longer than 30 days the following steps are recommended Flush the pump and hose lines by pumping clean water for a few minutes. If the pump was used for pumping salt water, be sure to use fresh water when flushing it Change the engine oil Drain and clean the fuel tank. Replace the fuel filter Thoroughly clean the exterior of the pump and engine. Visually inspect the machine for signs of damage or loose bolts Remove the covers and clean the pump interior. Wipe or spray all interior surfaces with a rust-inhibiting oil Change the oil in the seal and bearing housings Replace the covers. Seal the suction and discharge openings with tape Remove the battery from the machine and store it in a clean dry area. Charge the battery once a month to maintain condition of the electrolyte Store the machine indoors in a clean, dry area. If the machine must be stored outside, wrap it tightly. wc_tx000567gb.fm 28

33 PT 6 / Periodic Maintenance Schedule Maintenance The chart below lists basic engine maintenance. Refer to the engine manufacturer s Operation Manual for additional information on engine maintenance. Lombardini 11LD625-3 Engine Daily before starting Every 125 hrs. Every 250 hrs. Every 500 hrs. Check engine oil. Fill to correct level. Clean air cleaner. Check condition and tension on fan belt. Change oil in engine crankcase.* Change engine oil filter. Change fuel filter Clean engine cooling fins. Check valve clearance. Tighten fittings and clean injectors Replace fan belt. * Change more often in dusty conditions. Refer to engine manufacturer s manual. Machine Daily before starting Every 100 hrs. Every 250 hrs. Every 500 hrs. Check and tighten external hardware. Open pump housing cover and remove any debris from inside of pump housing. Check oil level in seal housing. Fill to correct level. Check bearing/seal housing for oil or water leaks. Check oil level in bearing housing. Drain water from water separator in fuel line. Change oil in seal housing. Change oil in bearing housing. Check coupling bolt tightness. wc_tx000567gb.fm 29

34 Maintenance PT 6 / Air Cleaner See Graphic: wc_gr Inspect the air cleaner and change the oil in the oil bath daily before starting the engine. In dusty conditions, check the condition of the oil in the air cleaner several times during the day. Change the oil if it appears thick or gritty. Clean the air cleaner often. Keep the oil bowl filled with clean oil up to level mark (a). CAUTION: NEVER run the engine without oil in the air cleaner! Severe engine damage will result. To clean the air cleaner: Release the snap clips (b) and remove the oil bowl (c) Remove the filter element (d) from the oil bowl. Be careful not to damage the rubber seal ring (e) on the element Rinse the filter element with diesel fuel or kerosene. DO NOT use gasoline. Allow the filter element to air dry completely Change the oil in the oil bowl. Fill the oil bowl to the level mark (a). Place the filter element in the oil bowl and install the oil bowl on air the cleaner. d b O i l c e a wc_gr wc_tx000567gb.fm 30

35 PT 6 / Fuel Filter Maintenance See Graphic: wc_gr Change the engine fuel filter every 250 hours of operation Remove the filter (a) from the engine block Install a new filter. If necessary, prime the fuel lines as described in the next section. c c c a a b wc_gr wc_gr Priming the Fuel System See Graphic: wc_gr If the fuel tank has been run completely dry, it will be necessary to prime the fuel system. To prime fuel system: Remove the small plug from the top of the water separator and prefill the element with clean diesel fuel Loosen the bleed screw (a) on the fuel filter and pump the manual lever on the fuel pump (b) until fuel flows freely from the screw hole. Tighten the bleed screw Loosen the bleed screw (c), starting with the injector closest to the fuel filter, and manually pump until fuel flows freely from the screw hole. Tighten the bleed screw. Repeat for each injector. wc_tx000567gb.fm 31

36 Maintenance PT 6 / Engine Lubrication See Graphic: wc_gr & wc_gr Check the engine oil level daily. Add oil as required. To check oil: Place the machine on a level surface, remove the dipstick and check that the oil level is at the top mark. Add oil through the oil filler cap (a) on top of engine, checking occasionally with dipstick; DO NOT overfill. Suggested oil grades: Use only diesel engine oil API service rating CD or equivalent. ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE Ambient Temperature -25ºC (-13ºF) -20ºC (-4ºF) -15ºC (5ºF) 0ºC (32ºF) SAE 10W-30 15ºC (59ºF) 30ºC (86ºF) (Multi-grade) SAE 15W-40, 20W-40 SAE 5W-20 wc_gr a b c wc_gr wc_tx000567gb.fm 32

37 PT 6 / Engine Oil Maintenance See Graphic: wc_gr Change the oil and oil filter (b) every 250 hours. On new machines, change the oil after the first 50 hours of operation. Drain the oil while the engine is still warm Remove the oil drain plug (c) to the drain oil. Note: In the interests of environmental protection, place plastic sheeting and a container under the machine to collect the liquid which drains off. Dispose of this liquid properly Install the drain plug Remove the oil filler cap (a) and fill the engine crankcase with the recommended oil. Oil Capacity: 5 liters (5 qts.) SAE15W40, CD rated Install the oil filler cap. 4.9 Valve Clearances See Graphic: wc_gr Check and adjust the valve clearance every 500 hours. Set the clearance when the engine is cold Remove the rocker arm cover and check the gaskets for breakage Bring each cylinder piston to top dead center on the compression stroke and set the clearance. Valve clearance: 0.20 mm (0.008 in.) Replace the rocker arm cover and tighten bolts to 19 Nm (14 ft.lbs.). wc_gr wc_tx000567gb.fm 33

38 Maintenance PT 6 / Fan Belt See Graphic: wc_gr Check the tension on the fan belt every 125 hours. Replace the fan belt every 500 hours Remove the belt guard (a) and check the fan belt (b) for cracks or splitting To tighten the fan belt, add or remove spacers (c) located between the fan pulley halves (d). Spacers are 0.5, 1.0, 2.0 mm (0.017, 0.034, in.) thick To check fan belt tension, press the fan belt halfway between belt pulleys with a 10 kg (22 lb.) load or strong thumb pressure. The fan belt should deflect 1 cm (3/8 in.). a d c b wc_gr wc_tx000567gb.fm 34

39 PT 6 / Pump Housing Mounting Bolts Maintenance See Graphic: wc_gr Tighten the mounting bolts (a) on the pump housing after the first 50 hours of operation. Inspect the bolts periodically thereafter and tighten when required. Torque the bolts to 330 Nm (243 ft. lbs.). a wc_gr wc_tx000567gb.fm 35

40 Maintenance PT 6 / Mechanical Seal Lubrication See Graphic: wc_gr Check the oil in the seal housing daily before starting the pump. Check its level and check it for signs of water contamination. If water contamination is found, change the oil immediately. Otherwise, change the oil every 100 hours of pump operation. Note: It is normal for some water to pass through the mechanical seal; however, if water contamination is heavy and oil feels watered down, inspect the mechanical seal for signs of wear or damage. To check the oil level: Remove the plastic fill plug (a) from the top of the bearing housing. The oil level should touch the base of the plug opening. Add oil as required. To change the oil: Remove the drain plug (c) from the bottom of the bearing housing Replace the drain plug and add oil (approximately 800 ml (27 oz.) 15W40) through the port (a) on top of the bearing housing until the oil level is at the base of the fill plug opening. a b d c wc_gr wc_tx000567gb.fm 36

41 PT 6 / Bearing Housing Lubrication Maintenance See Graphic: wc_gr Check oil level in housing daily before starting. Add oil as required. Change oil every 300 hours. To check oil level: Remove plastic fill plug (b) from top of bearing housing. Oil level should be near center of drive shaft. Add oil as required. To change oil: Remove plug (d) from bottom of bearing housing Replace drain plug and add 470 ml (16 oz.) of 15W40 oil through port (b) on top of bearing housing. DO NOT overfill housing. Inspect drained oil. If oil is dirty or feels watered down, inspect pump and bearing housing seals. wc_tx000567gb.fm 37

42 Maintenance PT 6 / Impeller Clearance See Graphic: wc_gr Sand, dirt, and debris will cause the impeller to wear. If the pump s performance drops over time, check and adjust the clearance between the impeller and the insert Shut down the machine. DO NOT reach into or insert anything into the pump while the engine is running! DO NOT run the pump with the impeller cover removed. WARNING Open the bottom drain cover and drain the pump Remove the suction flange (a) and the flapper gasket (b) from the front of the pump. CAUTION Impeller edges can become extremely sharp; use care when working on the pump to reduce the risk of being cut Clean the impeller (d) with a mixture of bleach and water before working on it Reach inside the pump through the suction port, and use a feeler gauge (c) to check the gap between the impeller and the insert (e). The pump will operate most efficiently when the gap is maintained between mm ( in.). Larger gaps are allowable but may reduce pump output slightly If necessary, add shims (f) between the insert and the impeller cover (g) to decrease the gap between the impeller and the insert. The insert is attached to the back side of the impeller cover. To add shims: Remove the impeller cover. Remove the screws that secure the insert to the impeller cover. Add shims as required and recheck the clearance gap. After the proper shimming has been determined, use a highstrength threadlocking compound on the screws and secure the shims and insert to the impeller cover. Torque the screws to 26 Nm (19 ft.lbs.) Reinstall the suction flange and the flapper gasket. wc_tx000567gb.fm 38

43 PT 6 /... Maintenance a g b d g e c f e d e f g g mm ( in.) wc_gr wc_tx000567gb.fm 39

44 Maintenance PT 6 / Cleaning the Engine Cooling Fins See Graphic: wc_gr The engine is air-cooled and depends on the cylinder cooling fins to dissipate heat. In dusty conditions the cooling fins may become clogged or covered with dust, reducing engine cooling. Remove the engine cover and inspect the engine cooling fins every 100 hours. Remove dirt build-up using a brush and diesel fuel or kerosene. Dry the engine using compressed air. Replace the inspection cover before starting the engine. a wc_gr Battery See Graphic: wc_gr The battery (a) supplied on this machine is a heavy-duty, lead acid battery, rated at 12V, 160 Ah, BCI group 31. Check the level of the electrolyte in the battery periodically and add distilled water as required to keep the electrolyte at the correct level. Keep the battery terminals clean and tighten them as required. In cold weather, diesel engines must crank at a fairly high speed. Maintain your battery at full charge and use a replacement battery with the highest cold-cranking amperage available to improve your cold weather starting capabilities. wc_tx000567gb.fm 40

45 PT 6 / Lifting the Machine Maintenance See Graphic: wc_gr Attach a sling or chain to the lifting eye (a) using a suitable hook or shackle. Each lifting device must have capacity of at least 1090 Kg (2400 lbs.). WARNING CAUTION Only use steel ropes or chains for hoisting. The rope or chain must have the suitable specified lifting capacity of 1090 Kg (2400 lbs.). Do not use improvised ropes or chains. Never use any other part of the PT6 Pump to lift the machine, as severe damage may occur. WARNING Do not stand under or get onto the machine while it is being hoisted or moved. a wc_gr wc_tx000567gb.fm 41

46 Maintenance PT 6 / Tires WARNING Keep the tires properly inflated and make sure they have the proper load rating. Under-inflated tires may cause a blowout which could result in fishtailing or loss of control of the towing vehicle. Always maintain full air pressure as indicated by the tire manufacturer on the tire's sidewalls. Check air pressure when the tires are cold, before you move the trailer. When the trailer tires become worn or damaged, replace them promptly with the same type, size, and load capacity as the original tires. For convenience and safety, it is recommended that you carry a spare wheel and tire Wheels and Lug Nuts WARNING 4.20 Tongue Jack Loose or missing lug nuts can cause you to lose a wheel! Keep all lug nuts tight. Before each trip, check for loose or missing lug nuts. When replacing lug nuts, make sure the replacement nut matches the original nut exactly. While the threads of the nut may match, the nut may be a size that does not hold the wheel securely against the hub even when fully tightened. Torque nuts evenly in increments to 115 Nm (85 ft.lbs.). Note: During normal use, the lug nuts will seat during the first one hundred miles resulting in a drop in torque. Each nut should be checked at that time and torqued to the proper value. See Graphic: wc_gr All trailers are equipped with a tongue jack (d). Use the tongue jack to lift and lower the trailer coupling on or off the tow vehicle hitch. wc_tx000567gb.fm 42

47 PT 6 / Safety Chains Maintenance WARNING See Graphic: wc_gr Failure to properly attach the safety chains between your trailer and the tow vehicle can result in a runaway trailer; should the coupler and hitch separate while towing. Safety chains (c) on your trailer provide added protection that it will not become separated from the towing vehicle. Make sure the chains are correctly attached between the towing vehicle and the trailer before each trip. Chains should be attached in a crossing pattern under the trailer tongue. The chains will prevent the trailer tongue from dropping to the ground if the trailer separates from the hitch. Rig the chains as tight as possible with just enough slack to permit tight turns. If a chain must be replaced, do not substitute a lighter weight chain. This trailer must be equipped with two chains, each with a minimum breaking strength of no less than the Gross Vehicle Weight Rating (GVWR) of the trailer. All chain attachments, including hooks, must be at least as strong as the chain. Replace damaged chains. DO NOT weld or attempt to repair damaged chains. c d wc_gr wc_tx000567gb.fm 43

48 Maintenance PT 6 / Lights See Graphic: wc_gr Check and make certain that all trailer lights are working before towing the trailer. WARNING State and federal regulations require that all types of trailers be equipped with tail, stop and turn lights (e) and side marker lights (f). A special wiring harness (g) for connecting the trailer lights to the lighting system of the tow vehicle is supplied with the trailer. e g f wc_gr wc_tx000567gb.fm 44

49 PT 6 / Wiring Diagram Trailer Maintenance Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue wc_tx000567gb.fm 45

50 Maintenance PT 6 / Wiring Diagram ( > Rev 119; > Rev 122) W 1 W Y G/Y Y 3 20 G W/R V/B B P/B 2 L B 19 Y 4 L Or V 17 L 5 B Y 24 YYR 18 6 B W + B Y R + B Y/G G B L Y Br 15 R L R R B Br L Or W Br R WB L W Br R P/B G R V/B P/B W/R B 12 L R B Y 11 W G/W B W/B Gr Y/R Br R 15/ Br Br L L P wc_gr wc_tx000567gb.fm 46

51 PT 6 / Wiring Diagram Components Maintenance ( > Rev 119; > Rev 122) Ref. Component Ref. Component 1 Cylinder head temperature switch 14 Oil temperature sensor 2 Engine harness 15 Engine Control Unit (ECU) 3 Extension harness 16 Battery 4 Glow plug 17 Starter solenoid 5 Throttle solenoid 18 Voltage regulator 6 Hour meter 19 Low oil pressure switch - N.O. 7 Control panel 20 Low oil pressure switch - N.C. 8 Keyswitch 21 Diagnostic port 9 Glow plug relay 22 Cam RPM sensor 10 15A Fuse 23 Control solenoids 11 20A Circuit breaker 24 Engine alternator 12 Pump sensor 25 80A Fuse 13 Engine RPM sensor 26 Control panel harness Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue wc_tx000567gb.fm 47

52 Maintenance PT 6 / Wiring Diagram ( < Rev 120; < Rev 123) W 1 W Y G/Y 3 G 15 B 2 L 6 L Y V 14 L 5 R B Y YY R B W Y 4 + B + B R 13 W L Or Br B G Y Y/G 15/ Br R L wc_gr wc_tx000567gb.fm 48

53 PT 6 / Wiring Diagram Components Maintenance ( < Rev 120; < Rev 123) Ref. Component Ref. Component 1 Coolant temperature sensor 9 Voltage regulator 2 Engine harness 10 15A Fuse 3 Extension harness 11 20A Circuit breaker 4 Control panel harness 12 Engine alternator 5 Throttle solenoid 13 Battery 6 Hour meter 14 Starter solenoid 7 Control panel 15 Oil pressure failure sensor 8 Keyswitch Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue wc_tx000567gb.fm 49

54 Maintenance PT 6 / Basic Troubleshooting Problem / Symptom Reason / Remedy Engine does not start. Fuel tank empty. Wrong type of fuel. Old fuel. Drain tank, change fuel filter, and fill with fresh fuel. Fuel system not primed. Battery connections loose or corroded. Battery dead. Electrolyte low. Engine oil level low. Engine hot. Ignition switch defective. Throttle solenoid defective. Electrical connections loose or broken. Engine faulty. Engine is hard to start. Dirt or debris inside pump housing blocking movement of impeller. Battery charge low. Engine faulty. Engine starts but pump does not take in water. Pump takes in water but little or no discharge. Pump housing not filled with water. Strainer on suction hose plugged. Suction hose damaged. Air leak above water line. Air leak at suction port. Pump too high above water line. Engine speed too low. Debris collecting in pump housing. Suction strainer partially plugged. Impeller worn. Shim insert. Discharge hose kinked or blocked. Engine speed too low. Engines stops by itself. No fuel. Engine oil pressure low. Engine too hot. wc_tx000567gb.fm 50

55 PT 6 /... Notes Maintenance wc_tx000567gb.fm 51

56 Theory and Performance 5. Theory and Performance PT6 Repair 5.1 Evaluating the Pump s Performance See Graphic: wc_gr Certain factors outside the pump will influence the pump s output and its ability to lift water. These factors can be critical if the pump must operate near its maximum lift and head. Before servicing the pump, review its current application and the conditions under which it is operating. Determine the total head on the job site and refer to the performance chart to determine the maximum pump capacity. Suction Lift (A) Suction lift is the height of the pump inlet above the water to be pumped. As the height of the pump above the water to be pumped increases, the pump s capacity decreases. When operating the pump, locate it as close to the water to be pumped as possible. The maximum suction lift of a centrifugal pump is 7.5 m (25 ft.). Discharge Head (B) Discharge head is the height of the discharge hose above the water to be pumped. Total Head (C) Total head is the total vertical distance the pump must lift the water. Total head is the sum of the suction lift plus the discharge head. The pump s capacity decreases as the total head increases. As the pump approaches its maximum head, its pumping capacity will fall off dramatically. Frictional Losses The friction created by the liquid as it flows through a hose, pipe, strainer, or fitting creates a resistance that the pump must overcome. These losses increase with the length of the hose, number of fittings, and the amount of the flow (gpm). Frictional losses occur in both suction and discharge lines. In long hoses they can accumulate to significantly reduce the pump s output. wc_tx000568gb.fm 52

57 PT6 Repair Theory and Performance B A C wc_gr Note: Factors such as altitude and water temperature can also adversely affect pump capacity. wc_tx000568gb.fm 53

58 Theory and Performance 5.2 Vacuum Test PT6 Repair See Graphic: wc_gr The vacuum created at the inlet port of the pump determines the height of water a pump can lift at the inlet port. If the pump does not prime or takes a long time to prime, it probably is due to an air leak in the inlet side of the pump. The following test only checks for air leaks in the pump itself. More often, vacuum losses are due to poor hose connections at the inlet port, or air leaks in the inlet line. To check the vacuum: Insert a vacuum gauge in the gauge port (a) (1/4 in. NPT) and fill the pump case with water Start the engine and allow it to warm up to operating temperature. Check the engine speed with and adjust it if necessary to a no-load speed of 2600±100 rpm Turn off the engine Cap or seal the inlet port so it is air tight Refill the pump case with water Start the engine and read the vacuum gauge. The gauge reading should climb slowly and then hold steady. If the gauge reads inches of mercury (Hg) (68 82 kpa), the vacuum is excellent. If the gauge reads inches Hg (55 67 kpa), the vacuum is adequate. If the gauge reads less than 16 inches Hg (55 kpa), the vacuum is low. Check the nipple in inlet port for air leaks. Also check the screws securing the inlet port for the proper torque If the vacuum gauge reading is acceptable, turn off the engine and observe the gauge for 30 seconds. The vacuum should hold steady. If the vacuum drops, check the flapper valve gasket for damage. b a c wc gr wc_tx000568gb.fm 54

59 PT6 Repair Notes Theory and Performance wc_tx000568gb.fm 55

60 Lombardini Engine Troubleshooting 6. Lombardini Engine Troubleshooting PT6 Repair 6.1 Troubleshooting Flowcharts The troubleshooting flowcharts are designed to take you through the process of determining the source of a problem with engine starting or machine operation. Many of the tests involve live voltages and therefore should only be attempted by qualified personnel. Detailed procedures for carrying out the tests are included in this manual. All highlighted text within the flowcharts have matching sections in this manual. wc_tx000566gb.fm 56

61 PT6 Repair Lombardini Engine Troubleshooting 6.2 Engine Does Not Crank Flowchart 1A Engine Does Not Crank Check battery voltage. Checking Keyswitch and Wiring Does battery measure V? No Yes Reconnect black wire. Check connection of black wire at starter solenoid. No Is the black wire connected? Recharge or replace battery. Yes Check wire connections at keyswitch. Clean and tighten connections. No Are connections clean and tight? Yes Check for battery voltage between terminal 30 of keyswitch and ground. Check/repair wiring from terminal 30 through 80A fuse and wiring harnesses to battery. No Is battery voltage measured between 30 and ground? Yes Check for battery voltage between terminal 50 and ground when key is placed in the START position. Check for battery voltage between black wire at starter solenoid and ground when key is in START position. Yes Is battery voltage measured between 50 and ground? Consult Lombardini engine repair manual. Yes Is battery voltage measured between black wire and ground? No No Replace keyswitch. Repair/replace black wire. wc_gr wc_tx000566gb.fm 57

62 Lombardini Engine Troubleshooting PT6 Repair 6.3 Checking Keyswitch and Wiring ( > Rev 119; > Rev 122) See Graphic: wc_gr Electric shock hazard. Only qualified personnel should conduct these tests. WARNING When troubleshooting Lombardini engines that do not crank, first check that the B (black) wire (a) is connected to the starter solenoid. This wire provides voltage to the coil of the solenoid, if it is not connected, the solenoid will not function Remove the screws securing the control panel bracket (b) to the frame and lift the control panel and its bracket from the machine Remove the back cover (c) of the control panel box and check that the the wiring to the keyswitch (d) is clean and tight. Check that the appropriate wires are connected to the proper terminals of the keyswitch Check for 12V (battery voltage approximately 12) between terminal 30 of the keyswitch and ground. If no voltage is measured, repair the wiring from terminal 30 through the 80A fuse (e) and wiring harnesses back to battery. If voltage is measured, continue Place the keyswitch in the START position and check for 12V (battery voltage approximately 12) between terminal 50 of the keyswitch and ground. If no voltage is measured, replace the keyswitch. If voltage is measured, continue Place the keyswitch in the START position and check for 12V (battery voltage approximately 12) between the B (black) wire (a) and ground at the starter solenoid. If no voltage is measured, repair the wiring between terminal 50 of the keyswitch and the starter solenoid. If voltage is measured and the engine still will not crank, there is a problem with the starter motor. See the Lombardini engine repair manual for further information. wc_tx000566gb.fm 58

63 PT6 Repair Lombardini Engine Troubleshooting a b d c V 1000 F m V A V- COM e R 15/54 50 Br L 30 B wc_gr wc_tx000566gb.fm 59

64 Lombardini Engine Troubleshooting PT6 Repair 6.4 Checking Keyswitch and Wiring ( < Rev 120; < Rev 123) See Graphic: wc_gr Electric shock hazard. Only qualified personnel should conduct these tests. WARNING When troubleshooting Lombardini engines that do not crank, first check that the B (black) wire (a) is connected to the starter solenoid. This wire provides voltage to the coil of the solenoid, if it is not connected, the solenoid will not function Remove the screws securing the control panel bracket (b) to the frame and lift the control panel and its bracket from the machine Remove the back cover of the control panel (c) and check that the the wiring to the keyswitch (d) is clean and tight. Check that the appropriate wires are connected to the proper terminals of the keyswitch Check for 12V (battery voltage approximately 12) between terminal 30 of the keyswitch and ground. If no voltage is measured, repair the wiring from terminal 30 through the wiring harnesses and back to battery. If voltage is measured, continue Place the keyswitch in the START position and check for 12V (battery voltage approximately 12) between terminal 50 of the keyswitch and ground. If no voltage is measured, replace the keyswitch. If voltage is measured, continue Place the keyswitch in the START position and check for 12V (battery voltage approximately 12) between the B (black) wire (a) and ground at the starter solenoid. If no voltage is measured, repair the wiring between terminal 50 of the keyswitch and the starter solenoid. If voltage is measured and the engine still won t crank, there is a problem with the starter motor. See the Lombardini engine repair manual for further information. wc_tx000566gb.fm 60

65 PT6 Repair Lombardini Engine Troubleshooting a b R 15/54 50 Br L 30 B V 1000 F m V wc_gr A V- COM wc_tx000566gb.fm 61

66 Lombardini Engine Troubleshooting 6.5 Replacing the Keyswitch PT6 Repair See Graphic: wc_gr Disassembly: Shut down the engine and disconnect the battery Remove the six screws securing the control panel cover to the control panel Make note of the wire connections on the keyswitch and remove the wires (a) from the keyswitch Unscrew the locking ring (b) and remove the keyswitch from the panel. Reassembly: Insert the replacement keyswitch into the control panel and secure it with the locking ring (b) Attach the wires (a) to the appropriate terminals of the keyswitch Secure the control panel cover to the control panel with the six screws. R 50 15/54 30 Br L b a B wc_gr wc_tx000566gb.fm 62

67 PT6 Repair Lombardini Engine Troubleshooting 6.6 Engine Cranks But Does Not Start Flowchart 1B Engine Cranks But Does Not Start Make sure that the machine has fresh fuel and that the fuel filter and fuel hoses are in good condition. Also make sure that the engine is filled with the proper amount of oil. Check position of circuit breaker; reset it if tripped. Check battery condition. Replace battery. No Does battery provide correct voltage and CCA? Yes Checking Throttle Solenoid Check if throttle solenoid is functioning properly. Checking Auto Shutdown Circuit Check the components and wiring of the auto shutdown circuit. No Is throttle solenoid functioning properly? Yes Are the components and wiring OK? No Yes Replace throttle solenoid. Checking glow plugs Check glow plugs.* Repair/Replace components and/or wiring. Consult Lombardini engine repair manual. Yes Do glow plugs operate correctly? No Checking glow plug relay Check glow plug relay.* Replace glow plug. Yes Does glow plug relay operate correctly? No *( > Rev 119; > Rev 122) Replace glow plug relay. wc_gr wc_tx000566gb.fm 63

68 Lombardini Engine Troubleshooting 6.7 Checking the Throttle Solenoid PT6 Repair See Graphic: wc_gr The throttle solenoid must be energized in order for the engine to start. To check if the throttle solenoid is functioning, carry out the following procedure: Place the keyswitch in the START position and check the position of the throttle solenoid while the engine is cranking. If the throttle solenoid energizes (pulls in) the throttle solenoid is functioning. If the throttle solenoid does not energize, continue Check that the black wire (a) is secure and in good condition from the negative terminal of the throttle solenoid to ground Disconnect the yellow wire (b) from the positive terminal of the throttle solenoid. Place the keyswitch in the START position and check the voltage between the yellow wire and ground. There should be 12V (battery voltage approximately 12) measured. If 12V is measured, the throttle solenoid should function. If it does not, it has failed; replace the throttle solenoid. If 12V is not measured, check the auto shutdown circuit. a b wc_gr wc_tx000566gb.fm 64

69 PT6 Repair 6.8 Checking the Auto Shutdown Circuit Lombardini Engine Troubleshooting See Graphic wc_gr The auto shutdown circuit consists of the circuit breaker, the temperature switch, the oil pressure switch, and the wiring between the three components. Voltage is supplied to the throttle solenoid through the auto shutdown circuit. To check the auto shutdown circuit, do the following: Check that the wiring is clean and tightly connected to the temperature switch (a) and to the oil pressure switch (b). Try starting the engine. If the throttle solenoid does not energize, continue Disconnect the white wire from the temperature switch. Place the keyswitch in the ON position and measure the voltage between the white wire and ground. There should be 12V (battery voltage approximately 12) measured. If 12V is not measured, check the continuity of the white wire from the temperature switch to the harness connector (c). If 12V is measured, continue Check the continuity of the temperature switch to ground. There should be no continuity. If there is continuity between the temperature switch and ground, the switch has failed; replace it. If there is no continuity between the temperature switch and ground, continue Disconnect the yellow wire (d) from the oil pressure switch. Place the keyswitch in the ON position and measure the voltage between the yellow wire and ground. There should be 12V (battery voltage approximately 12) measured. If 12V is not measured, check the continuity of the wiring between the yellow wire of the oil pressure switch and the white wire of the temperature switch. Repair the wiring as needed. If 12V is measured, continue With the keyswitch in the ON position, touch the yellow wire (d) to outgoing yellow wire on the opposite side of the oil pressure switch (e). The throttle solenoid should energize. If the throttle solenoid does not energize, check the continuity of the yellow wire from the oil pressure switch to the throttle solenoid. If the throttle solenoid energizes, continue Check the engine oil pressure with an independent gauge. If the engine oil pressure checks OK, the oil pressure switch has failed; replace it. wc_tx000566gb.fm 65

70 Lombardini Engine Troubleshooting PT6 Repair If the engine oil pressure is not OK, refer to the Lombardini engine repair manual. b d e a c wc_gr wc_tx000566gb.fm 66

71 PT6 Repair 6.9 Checking Voltage to Glow Plug Lombardini Engine Troubleshooting See Graphic: wc_gr To check the voltage to the glow plug, disconnect the B (black) wire (c), place the keyswitch in the START position, and measure the voltage between the black wire and ground. There should be 12V (battery voltage approximately 12) measured. If 12V is not measured, check the continuity of the wiring; repair or replace the wiring as needed. If 12V is measured, check the function of the glow plug. c wc_gr wc_tx000566gb.fm 67

72 Lombardini Engine Troubleshooting 6.10 Checking Glow Plug Relay PT6 Repair See Graphic: wc_gr Remove the screws securing the engine control panel. Leave all wiring connected to the control panel Rotate the control panel to gain access to the rear of the control panel. Remove the enclosure cover to access the glow plug relay Place the keyswitch in the START position. A working relay will click when the keyswitch is in the START position. Check the continuity across the blue (L) and black (B) wires when the keyswitch is in the START position. If there is no continuity, the relay is faulty; replace it. b a B wc_gr Br L G/Y G/Y 6.11 Replacing Glow Plug Relay See Graphic: wc_gr Make note of the wire positions and disconnect all wires from the glow plug relay Bend back the tabs (a) securing the glow plug relay (b) and pull the glow plug relay from the enclosure. wc_tx000566gb.fm 68

73 PT6 Repair 6.12 Checking Glow Plug Lombardini Engine Troubleshooting See Graphic: wc_gr Remove the glow plug from the engine. Burn hazard. Glow plugs can reach temperatures up to 1200 F (649 C). Do not touch the element of the glow plug. Be extremely careful when testing the glow plug. WARNING Using 10-gauge wire, apply 12VDC to the glow plug positive on the upper portion and ground the base. If the glow plug does not heat (glow) within five seconds, replace the glow plug. + wc_gr wc_tx000566gb.fm 69

74 Lombardini Engine Troubleshooting 6.13 Engine Shuts Down Flowchart 1C PT6 Repair Engine Shuts Down Check engine oil level. Is machine oil level correct? No Fill machine with oil. Yes Check engine coolant level. Is engine coolant level correct? No Yes Checking oil pressure and coolant temperature switches Check wiring of oil pressure switch. Check wiring of coolant temperature switch. Fill engine with correct amount and type of coolant. Is oil pressure switch connected correctly? No Connect oil pressure switch and/or repair wiring. Yes Is coolant temperature switch connected correctly? No Connect coolant temperature switch and/or repair wiring. Yes Refer to the Lombardini repair manual. Call Wacker Service. wc_gr wc_tx000566gb.fm 70

75 PT6 Repair Lombardini Engine Troubleshooting 6.14 Checking Oil Pressure and Coolant Temperature Switches See Graphic: wc_gr If the engine starts but shuts down after approximately 10 seconds, check the following Check the engine oil level and add oil if necessary. Also check the coolant temperature. If the coolant temperature is high, allow the engine to cool. Flush and fill the radiator with the correct coolant Check the oil pressure switch (a) and coolant temperature switch (b) wiring. If the wiring of either switch is shorted to ground, the engine will shut down. Be sure the switches are functioning check each for continuity. The oil pressure switch is a normally closed (NC) switch that should have continuity when the engine is off. If the switch has no continuity when the engine is off, the switch is faulty; replace it. The high coolant temperature switch is a normally open (NO) switch. This switch should have no continuity when the engine is off. If this switch has continuity when the engine is off, it has shorted and is faulty; replace it. b a wc_gr wc_tx000566gb.fm 71

76 Lombardini Engine Troubleshooting 6.15 General Engine Troubleshooting PT6 Repair Possible Cause Symptom Engine will not crank Engine does not start Engine starts, but stops Poor acceleration Unsteady rpm Black smoke White smoke Blue smoke Low oil pressure Oil level rising Excessive oil consumption Wet exhaust Overheating Engine knocks Low fuel level Fuel supply/return lines clogged Clogged fuel tank vent Fuel pump faulty Fuel contaminated with air Unit injector(s) faulty/worn Unit injector settings incorrect Injection pump rack sticking Oil level too high Improper oil viscosity Oil diluted by fuel Oil pressure relief valve faulty Oil pick-up tube clogged Oil pump air contaminated at pick-up tube Glow plugs faulty Glow plug controller faulty Glow plug relay inoperable Starter defective wc_tx000566gb.fm 72

77 PT6 Repair Possible Cause Lombardini Engine Troubleshooting Symptom Engine will not crank Engine does not start Engine starts, but stops Poor acceleration Unsteady rpm Black smoke White smoke Blue smoke Low oil pressure Oil level rising Excessive oil consumption Wet exhaust Overheating Engine knocks Battery voltage too low Battery/battery cable connections corroded Key switch defective Air filter clogged Excessive idle/light load operation Incomplete engine run-in Engine overloaded Excessive secondary load Valve lash insufficient/ excessive Injection timing out of spec - advanced Injection timing out of spec - retarded Governor linkage adjustment incorrect Governor spring fatigued or defective Idle rpm too low Piston rings worn or stuck Piston worn or damaged Cylinders worn or damaged Valve/valve guides worn wc_tx000566gb.fm 73

78 Lombardini Engine Troubleshooting PT6 Repair Possible Cause Symptom Engine will not crank Engine does not start Engine starts, but stops Poor acceleration Unsteady rpm Black smoke White smoke Blue smoke Low oil pressure Oil level rising Excessive oil consumption Wet exhaust Overheating Engine knocks Valves sticking Bearings (main/rod) worn Governor/governor linkage malfunctioning Cylinder head gasket damaged Thermostat stuck or malfunctioning Engine seized Radiator clogged (external or internal) Coolant pump faulty Turbocharger faulty wc_tx000566gb.fm 74

79 PT6 Repair Disassembly/Assembly Procedures 7. Disassembly/Assembly Procedures 7.1 Tools 7.2 Ordering Parts Because all possible problems encountered while repairing the machine cannot be anticipated, it is up to the mechanic to use common sense and good judgement in tool selection. The use of any special tools is recommended only for those operations where the use of conventional tools proves inadequate. Before substituting another tool or procedure, you should be satisfied that neither personal injury nor damage to the component will result. The repair procedures contained in this manual do not include part numbers. For parts replacement information, refer to the Parts Book originally supplied with the machine. If the original Parts Book has been lost, a replacement may be ordered from Wacker Corporation. When ordering a replacement Parts Book, please list the model number, item number, revision level, and serial number of the machine. Parts Books are also available on the Wacker Corporation Web site. See Enter the site as a visitor. 7.3 Reference Numbers ( ) 7.4 Weight Block Repair procedures contain reference numbers enclosed in parentheses ( ). These numbers refer to the item numbers shown on the assembly drawings and other detailed drawings. They are included to aid the mechanic in identifying parts and assembling components. See Graphic: wc_gr The weight block symbol gives an approximate weight measurement to aid the mechanic when lifting/hoisting larger components. 250 kg (550 lbs.) wc_gr wc_tx000557gb.fm 75

80 Disassembly/Assembly Procedures 7.5 Replacing the Flapper Valve PT6 Repair See Graphic: wc_gr The flapper valve is located at the pump inlet. During pump operation, this valve is open allowing a path for water to flow into the pump case. When the pump stops, the valve closes and prevents water in the suction hose from draining out. A leak around the outside of the flapper gasket will cause the pump to lose its prime and may make it difficult or impossible to prime at start up. Removal: Remove the locknuts (a) and washers that secure the inlet port (f) to the pump and remove the inlet port Remove the rubber flapper valve (b) Remove the locknuts (c) that secure the plates (d and e) to the rubber flapper and remove the plates. Installation: Secure the plates (d and e) to the rubber flapper with locknuts (c) and screws. CAUTION: Do not over-tighten the locknuts. Over-tightening will crush the rubber flapper and may prevent it from sealing properly Install the rubber flapper valve (b) with the large plate (e) toward the inside of the pump Secure the inlet port (f) to the pump with washers and locknuts (a). Torque the locknuts to 160 Nm (118 ft.lbs.). wc_tx000557gb.fm 76

81 PT6 Repair Disassembly/Assembly Procedures b e a c d a b d c wc_gr wc_tx000557gb.fm 77

82 Disassembly/Assembly Procedures 7.6 Replacing the Impeller PT6 Repair See Graphic: wc_gr Removal: Shut down the machine and disconnect the battery. DO NOT reach into or insert anything into the pump while the engine is running! DO NOT run the pump with the impeller cover removed. WARNING Drain the seal housing cavity Remove the impeller cover (a) to expose the impeller (b). Impeller edges can become extremely sharp; use care when working on the pump to reduce the risk of being cut. CAUTION Clean the impeller with a mixture of bleach and water before working on it The impeller is threaded onto the drive shaft with right hand threads. To keep the drive shaft from turning while removing the impeller, hold the drive shaft by the flats (located near the flex coupling) Carefully pry the rotating half of the mechanical (c) seal from the back side of the impeller. Installation: Install the rotating half of the mechanical seal (c) onto the back side of the impeller (b). Refer to section Replacing the Mechanical Seal Thread the impeller onto the drive shaft. To keep the drive shaft from turning, hold it by the flats near the flex coupling Check the gap between the impeller and the insert (d). Add or remove shims (e) as necessary to obtain a gap of mm ( in.) When the correct gap is obtained, apply an anti-seize compound to the threads of the drive shaft; then, thread the impeller on Install the impeller cover (a). wc_tx000557gb.fm 78

83 PT6 Repair Disassembly/Assembly Procedures a b a c e d e a d e a b mm ( in.) wc_gr wc_tx000557gb.fm 79

84 Disassembly/Assembly Procedures 7.7 Replacing the Mechanical Seal PT6 Repair See Graphic: wc_gr Proper installation of the mechanical seal is crucial. It is extremely important that the seal faces remain clean and that the O-ring and rubber boot are seated properly. Improper installation may cause seal failure. During installation and handling of the mechanical seal, avoid scratching or contaminating the seal faces with oil or dirt. Removal: Drain the oil from the seal housing cavity Remove the impeller. See section Replacing the Impeller. By removing the impeller you will remove the rotating portion of the mechanical seal Remove the stationary portion (a) of the mechanical seal and O-ring (i) from the seal housing The stationary portion of the mechanical seal is held in place by a pin (b) in the seal housing. If this pin is loose or damaged, it will require replacement. In order to do so, the seal housing must be removed from the pump. To remove the seal housing, remove the four screws that secure the seal housing (c) to the bearing housing. Insert two M10 screws (d) into the threaded holes and use the M10 screws as pushers to push the seal housing from the bearing housing. Remove the set screw and drive the pin from the seal housing. Refer to section Installing End Cap and Seal Housing. Installation: If the seal housing (c) was removed, install it into the bearing housing Install the stationary portion (a) of the mechanical seal and the O-ring (i) into the seal housing. Match the notch in the mechanical seal with the pin in the seal housing (b) Thoroughly lubricate the impeller stem and the inside of the mechanical seal (e) with soapy water. Start the installation of the mechanical seal by hand; then, press it onto the impeller (f). Do not press on the face of the mechanical seal. Instead, use a piece of plastic pipe (g) to support the mechanical seal while pressing. Do not press the mechanical seal too deeply or the seal ring may pop out of the rubber boot Use a feeler gauge and check the gap around the bottom of the impeller. The ideal gap is 0.02 mm (0.008 in.). If a larger gap exists, repeat the pressing procedure Clean (h) the mating surfaces of the mechanical seal with alcohol Install the impeller and impeller cover. wc_tx000557gb.fm 80

85 PT6 Repair Disassembly/Assembly Procedures Fill the seal housing with oil. See sections Mechanical Seal Lubrication and Bearing Housing Lubrication. a c d b i a e f g h f g e wc_gr mm (3 in.) wc_tx000557gb.fm 81

86 Disassembly/Assembly Procedures 7.8 Removing the Pump and Bearing Housing PT6 Repair See Graphic: wc_gr It is only necessary to remove the pump and bearing housing when replacing the coupling flange plate, flex coupling, drive shaft, bearings, or the pump itself. It is not necessary to remove the pump and bearing housing to replace the mechanical seal, impeller, or volute Remove the screws (a) that secure the protective guards and remove the protective guards. This will expose the drive coupling Remove the screws (b) that secure the drive-coupling flange plate to the engine s flywheel Scribe or mark a line (c) next to each leg of the pump housing on the frame of the trailer. This will aid in reassembly of the pump Remove the four screws (d) and washers that secure the pump assembly to the frame. Take note of any shims (e) which may be under the legs This step requires an appropriate crane or other lifting device and two 4x4 s or similar blocks of wood. The discharge elbow (f) may be used for placement of a lifting sling. If the discharge elbow is facing the engine, a more-balanced load will result. If the discharge elbow is facing away from the engine, a lessbalanced load will result. Make sure the discharge elbow is securely fastened to the pump housing before lifting. Wrap the lifting sling around the discharge elbow and lift the pump off the trailer slowly and with caution. Place the pump on the 4x4 s on the ground Remove the six locknuts (g) that secure the bearing housing to the pump. Loosen the three nuts holding the three pusher bolts (h) to the housing. Use the three pusher bolts to push the bearing housing (i) free of the pump. wc_tx000557gb.fm 82

87 PT6 Repair Disassembly/Assembly Procedures a b d e 250 kg (550 lbs.) f c g h i wc_gr wc_tx000557gb.fm 83

88 Disassembly/Assembly Procedures 7.9 Installing the Pump and Bearing Housing PT6 Repair See Graphic: wc_gr This procedure requires a dial indicator capable of being mounted to the drive shaft. Note: The bearing housing assembly may be mounted to the pump with or without the impeller installed Position the bearing housing into the pump. Secure it to the pump using six locknuts Install the flex coupling and mounting flange to the drive shaft. See section Replacing the Flex Coupling and Mounting Flange This step requires an appropriate crane or other lifting device. The discharge elbow may be used for placement of a lifting sling. If the discharge elbow is facing the engine, a more balanced load will result. If the discharge elbow is facing away from the engine, a less balanced load will result. Make sure the discharge elbow is securely fastened to the pump housing before lifting. Wrap the lifting sling around the discharge elbow and lift the pump off the trailer slowly and with caution. Place the pump on the frame The axial and angular alignment of the pump to the engine will need to be checked using a dial indicator. To do so: Be certain the engine is installed correctly and that the engine mounting bolts are torqued to the correct specification. Position the pump so that the mounting flange (x) just touches the inside of the engine flywheel (y). Position a dial indicator so that it measures the angular alignment (squareness) of the drive shaft to the engine. This is done by clamping a dial indicator to the drive shaft and monitoring the distance to the face of the bell housing as the drive shaft is rotated. First check the top (A1); then, rotate the drive shaft and check the bottom (A2). The maximum allowable derivation (amount out of square) is 0.5 mm (0.020 in.). Reposition the dial indicator so that it measures the axial alignment (concentricity) of the drive shaft to the engine. This is done by clamping a dial indicator to the drive shaft and monitoring the distance to the inside shoulder of the bell housing as the drive shaft is rotated. First check the top (B1); then, rotate the drive shaft and check the bottom (B2). The maximum allowable value is 0.5 mm (0.020 in.). Shim the pump as needed to obtain the proper alignment. wc_tx000557gb.fm 84

89 PT6 Repair Disassembly/Assembly Procedures In the same manner, check the axial alignment and the squareness of the drive shaft to the engine at the left (A3, B3) and the right (A4, B4) sides of the pump. Move the pump in very small increments to obtain the correct alignment. When the pump is in the correct position, secure the pump to the frame with four screws, washers, and beveled shims. Torque the screws to 330 Nm (240 ft.lbs.). Secure the mounting flange to the engine flywheel with eight screws. Torque the screws to 19 Nm (14 ft.lbs.). A1 y x B1 B4 A4 A3 B3 B2 A2 0.5 mm (0.02 in.) A B 0.5 mm (0.02 in.) wc_gr wc_tx000557gb.fm 85

90 Disassembly/Assembly Procedures 7.10 Replacing the Flex Coupling and Mounting Flange PT6 Repair See Graphic: wc_gr Removal: Remove the screws (a) that secure the flex coupling to the coupling hub (b) and remove the flex coupling Remove the screws (c) that secure the flex coupling to the mounting flange and remove the mounting flange Loosen the setscrew (d) that secures the coupling hub to the drive shaft and remove the coupling hub and key (e) from the drive shaft. Installation: Place the key into the keyway of the drive shaft Position the coupling hub on the drive shaft so that it is approximately 3 mm (0.12 in.) from the end of the key (f). There should be no key showing on the engine side of the coupling hub (g) Apply a thin layer of grease to the under side (h) of the three screws that secure the flex coupling to the coupling hub. Also apply Loctite 242 or equivalent to the threaded holes of the coupling hub. Do not apply the Loctite to the screw threads. The Loctite could rub off on the inside of the flex coupling and interact with the rubber causing it to fail. Secure the flex coupling to the coupling hub. Torque the screws to 85 Nm (62 ft.lbs.). Secure the mounting flange to the flex coupling in the same manner. CAUTION: When installing the flex coupler, keep it as straight as possible. Do not allow it to twist. Failure of the flex coupling may occur. wc_tx000557gb.fm 86

91 PT6 Repair Disassembly/Assembly Procedures b a d c d f g h wc_gr wc_tx000557gb.fm 87

92 Disassembly/Assembly Procedures 7.11 Bearing Housing PT6 Repair wc_gr wc_tx000557gb.fm 88

93 PT6 Repair Disassembly/Assembly Procedures 7.12 Bearing Housing Components See Graphic: wc_gr Ref. Component Ref. Component 1 Socket head cap screw 16 Washer 2 O-ring 17 Shaft seal 3 Locking washer 18 Seal housing drain plug 4 Gasket 19 Roller plug 5 Bearing housing fill plug 20 Bearing plug drain plug 6 Vent 21 Sealing washer 7 Mechanical seal housing plug 22 Bearing housing 8 Retaining ring 23 Tapered roller bearing 9 Seal housing 24 Ring nut 10 O-ring 25 Cap 11 O-ring 26 Shaft seal 12 Drive shaft 27 Socket head cap screw 13 Impeller 28 Setscrew 14 Mechanical seal (rotating half) 29 Roll pin 15 Mechanical seal (stationary half) wc_tx000557gb.fm 89

94 Disassembly/Assembly Procedures 7.13 Bearing Housing Disassembly PT6 Repair See Graphic: wc_gr There are two bearings within the bearing housing. One is a tapered roller bearing and the other is a standard roller bearing. To avoid confusion, the tapered roller bearing will be referred to as the tapered bearing. The standard roller bearing will be referred to as the roller bearing Remove the pump and bearing housing from the frame. See section Removing the Pump and Bearing Housing Remove the flex coupling and mounting plate. See section Replacing the Flex Coupling and Mounting Flange Drain the oil from the bearing housing Remove the impeller. It is threaded on with right hand threads. Hold the drive shaft from turning by the flats near the engine end. Refer to section Replacing the Impeller If the mechanical seal is to be replaced, carefully pry it off the impeller. If it is not to be replaced, leave it attached to the impeller. Refer to section Replacing the Mechanical Seal Pull the stationary half of the mechanical seal from the seal housing Remove the four screws (a) that secure the seal housing (b) to the bearing housing. Insert two M10 screws (c) into the threaded holes and use the M10 screws as pushers to push the seal housing from the bearing housing On the opposite end of the bearing housing, remove the four screws that secure the housing cover (d) and remove the housing cover. This action will expose the ring nut (e) and locking washer that secure the tapered bearing Bend up the locking tab on the locking washer (f). Remove the ring nut and the locking washer from the shaft (g) Place the bearing housing in an Arbor press engine-side up. Press on the drive shaft until it breaks free from the tapered bearing. Once it breaks free it will drop from the bearing housing be ready catch it so it does not fall Remove the retaining ring (h) which holds the roller bearing Use a puller to pull the inner race (i) of the roller bearing from the drive shaft Press out the roller bearing (k) and the outer race of the tapered bearing (j) from the bearing housing. wc_tx000557gb.fm 90

95 PT6 Repair Disassembly/Assembly Procedures a d b b c e f e f g h i j j k k wc_gr wc_tx000557gb.fm 91

96 Disassembly/Assembly Procedures 7.14 Bearing Housing Assembly PT6 Repair See Graphic: wc_gr There are two bearings within the bearing housing. One is a tapered roller bearing and the other is a standard roller bearing. To avoid confusion, the tapered roller bearing will be referred to as the tapered bearing. The standard roller bearing will be referred to as the roller bearing Press the outer race of the tapered bearing (k) and the roller bearing (j) into the bearing housing Press the inner race of the roller bearing (i) onto the drive shaft. Secure it with the retaining ring (h) Position the bearing housing so that the impeller side is facing upward. Support it from underneath so that the drive shaft may be installed. Place the drive shaft into the bearing housing and guide it into the roller bearing. DO NOT use force when installing the shaft into the roller bearing Press the tapered bearing (l) onto the drive shaft. Press the race so that the drive shaft starts to bind. Then, using a dead blow or plastic hammer (m), rap the end of the drive shaft to release the tension. The drive shaft should now turn with ease Install the locking washer (f) onto the drive shaft. If necessary, bend the inside tang (n) so the locking washer can slide in the groove of the drive shaft Install the ring nut (e) with the tapered side toward the locking washer. Tighten the ring nut so that once again the drive shaft starts to bind. Notice how there are several notches in the ring nut into which tangs of the locking washer could fit. Find the tang-notch combination that is closest to fitting together. Back off the ring nut so that this combination fits. Before bending the tang to lock the ring nut, again, using a dead blow or a plastic hammer, rap the end of the drive shaft to release the tension. The drive shaft should now turn with ease with no noticeable end play. (It will have a free-rolling torque.) Bend the tang to lock the ring nut Install the end cap and the seal housing. See section Installing End Cap and Seal Housing. wc_tx000557gb.fm 92

97 PT6 Repair Disassembly/Assembly Procedures j j k h i k h i l m e f e f g n wc_gr wc_tx000557gb.fm 93

98 Disassembly/Assembly Procedures 7.15 Installing End Cap and Seal Housing PT6 Repair See Grapic: wc_gr Prepare the seal housing (a) for installation by replacing the seals (b) and O-rings (c). When installing the seals, lubricate them with soapy water. Install the seals so that both seals face the same direction (towards the inside of the seal housing). When installing the O-rings, lubricant them with oil Inspect the roll pin (d) which protrudes into the seal housing cavity. If the roll pin is loose or appears damaged, replace it. To do so, remove the set screw (e) and drive the roll pin out. Be careful not to damage the seal housing when replacing the pin. Drive a new roll pin into the hole so that it protrudes 5 mm (1/16 in.) into the cavity. Use Loctite 569 or equivalent on the set screw and install it into the threaded hole. Seal off the set screw with a silicone sealant Clean out any old thread locking compound from the threaded holes in the bearing housing. Apply fresh Loctite 242 or equivalent to the threaded holes Using the new sealing washers, secure the seal housing to the bearing housing with four screws (f). Torque the screws to 20 Nm (14 ft.lbs.) Prepare the housing cover (g) by installing two new seals (h) and a new O-ring (i) into it. When installing the seals and O-rings, lubricate them with oil. Install the new seals so that they are back to back (j) Apply Loctite 242 or equivalent on four screws and secure the housing cover to the bearing housing. Torque the screws to 20 Nm (14 ft.lbs.) Fill the bearing housing with oil Install the mechanical seal. See section Replacing the Mechanical Seal Install the impeller. It is threaded on with right hand threads. Keep the drive shaft from turning by holding it by the flats near the engine end. See section Replacing the Impeller Install the bearing housing to the pump and the pump to the engine. See section Installing the Pump and Bearing Housing. wc_tx000557gb.fm 94

99 PT6 Repair Disassembly/Assembly Procedures c a b e d 5 mm (3/16 in.) b f j h g g i wc_gr wc_tx000557gb.fm 95