en Pump PG 2 PG 3 OPERATOR S MANUAL

Transcription

1 en Pump PG 2 PG 3 OPERATOR S MANUAL E N

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3 PG 2/3 Table of Contents 1. Foreword 3 2. Emission Control System Information 4 3. Safety Information Laws Pertaining to Spark Arresters Operating Safety Operator Safety while using Internal Combustion Engines Service Safety Label Locations Safety Labels Technical Data Engine Pump Sound Specifications Operation Application Recommended Fuel Before Starting To Start To Stop Operation Hoses and Clamps wc_bo en_001toc.fm 1

4 Table of Contents PG 2/3 6. Maintenance Periodic Maintenance Schedule Cleaning Pump Adjusting Impeller Clearance Mechanical Seal Replacement Spark Plug Servicing Air Cleaner Changing Engine Oil Cleaning Fuel Strainer Storage Troubleshooting...36 wc_bo en_001toc.fm 2

5 WARNING CALIFORNIA Proposition 65 Warning: 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. 1. Foreword This manual provides information and procedures to safely operate and maintain this Wacker model. For your own safety and protection from injury, carefully read, understand and observe the safety instructions described in this manual. Keep this manual or a copy of it with the machine. If you lose this manual or need an additional copy, please contact Wacker Corporation. This machine is built with user safety in mind; however, it can present hazards if improperly operated and serviced. Follow operating instructions carefully! If you have questions about operating or servicing this equipment, please contact Wacker Corporation. The information contained in this manual was based on machines in production at the time of publication. Wacker Corporation reserves the right to change any portion of this information without notice. All rights, especially copying and distribution rights, are reserved. Copyright 2007 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, which aim at improving our machines or their safety standards. wc_tx000001gb.fm 3

6 Emission Control System Information 2. Emission Control System Information Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Wacker utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons. The U.S. and California Clean Air Acts EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems. The following instructions and procedures must be followed in order to keep the emissions from your Wacker engine within the emissions standards. Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit. Among those acts that constitute tampering are: Removal or alteration of any part of the intake, fuel, or exhaust systems. Altering or defeating the speed-adjusting mechanism to cause the engine to operate outside its design parameters. Problems That May Affect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption. wc_tx000239gb.fm 4

7 Emission Control System Information Replacement Parts The emission control systems on your Wacker engine were designed, built, and certified to conform with EPA and California emissions regulations. We recommend the use of genuine Wacker parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system. A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations. Maintenance Follow the maintenance schedule. Remember that this schedule is based on the assumption that your machine will be used for its designed purpose. Sustained high-load or high-temperature operation, or use in unusually wet or dusty conditions, will require more frequent service. OXYGENATED FUELS Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement. Before using an oxygenated fuel, try to confirm the fuel s contents. Some States / Provinces require this information to be posted on the pump. The following are EPA-approved percentages of oxygenates: ETHANOL - (ethyl or grain alcohol) 10% by volume. You may use gasoline containing up to 10% ethanol by volume. Gasoline containing ethanol may be marketed under the name Gasohol. MTBE - (methyl tertiary butyl ether) 15% by volume. You may use gasoline containing up to 15% MTBE by volume. wc_tx000239gb.fm 5

8 Emission Control System Information METHANOL - (methyl or wood alcohol) 5% by volume. You may use gasoline containing up to 5% methanol by volume, as long as it contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of your fuel system. If you notice any undesirable operating symptoms, try another service station, or switch to another brand of gasoline. Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty. wc_tx000239gb.fm 6

9 Emission Control System Information EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE This emission warranty is applicable in all States, except the State of California. Wacker Corporation, N92 W15000 Anthony Avenue, Menomonee Falls, WI , (herein "Wacker") warrant(s) to the initial retail purchaser and each subsequent owner, that this non-road engine (herein "engine") has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S. Environmental Protection Agency (EPA), and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period. For the components listed under PARTS COVERED, the service dealer authorized by Wacker will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine complies with applicable U.S. EPA regulations. EMISSISON COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of 2 years. wc_tx000239gb.fm 7

10 Emission Control System Information PARTS COVERED Listed below are the parts covered by the Emission Components Defect Warranty. Some of the parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part. (1) Fuel Metering System (i) Carburetor and internal parts (and/or pressure regulator or fuel injection system). (ii) Air/fuel ratio feedback and control system, if applicable. (iii) Cold start enrichment system, if applicable. (iv) Regulator assembly (gaseous fuel, if applicable). (2) Air Induction System (i) Intake manifold, if applicable. (ii) Air filter. (3) Ignition System (i) Spark plugs. (ii) Magneto or electronic ignition system. (iii) Spark advance/retard system, if applicable. (4) Exhaust manifold, if applicable (5) Miscellaneous Items Used in Above Systems (i) Electronic controls, if applicable. (ii) Hoses, belts, connectors, and assemblies. (iii) Filter lock assembly (gaseous fuel, if applicable). wc_tx000239gb.fm 8

11 Emission Control System Information OBTAINING WARRANTY SERVICE To obtain warranty service, take your engine to the nearest authorized Wacker service dealer. Bring your sales receipts indicating date of purchase for this engine. The service dealer authorized by Wacker will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order. All parts and accessories replaced under this warranty become the property of Wacker. WHAT IS NOT COVERED Conditions resulting from tampering, misuse, improper adjustment (unless they were made by the service dealer authorized by Wacker during a warranty repair), alteration, accident, failure to use the recommended fuel and oil, or not performing required maintenance services. The replacement parts used for required maintenance services. Consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc. Diagnosis and inspection charges that do not result in warrantyeligible service being performed. Any non-authorized replacement part, or malfunction of authorized parts due to use of non-authorized parts. OWNER'S WARRANTY RESPONSIBILITIES As the engine owner, you are responsible for the performance of the required maintenance listed in your owner's manual. Wacker recommends that you retain all receipts covering maintenance on your engine, but Wacker cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. As the engine owner, you should however be aware that Wacker may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. You are responsible for presenting your engine to the nearest service dealer authorized by Wacker when a problem exists. If you have any questions regarding your warranty rights and responsibilities, you should contact the WACKER CORPORATION Product Support Department (U.S.A , Canada ) for the information. wc_tx000239gb.fm 9

12 Emission Control System Information THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY: MAINTENANCE AND REPAIRS You are responsible for the proper maintenance of the engine. You should keep all receipts and maintenance records covering the performance of regular maintenance in the event questions arise. These receipts and maintenance records should be transferred to each subsequent owner of the engine. Wacker reserves the right to deny warranty coverage if the engine has not been properly maintained. Warranty claims will not be denied, however, solely because of the lack of required maintenance or failure to keep maintenance records. MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL; HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED BY A SERVICE DEALER AUTHORIZED BY WACKER. THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM. If other than the parts authorized by Wacker are used for maintenance replacements or for the repair of components affecting emission control, you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by Wacker in their performance and durability. HOW TO MAKE A CLAIM All repair qualifying under this limited warranty must be performed by a service dealer authorized by Wacker. In the event that any emissionrelated part is found to be defective during the warranty period, you shall notify WACKER CORPORATION Product Support Department (U.S.A , Canada ) and you will be advised of the appropriate warranty service dealer or service providers where the warranty repair can be performed. CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Wacker Corporation (herein Wacker ) are pleased to explain the emissions control system warranty on your small off-road engine. In California, new small offroad engines must be designed, built and equipped to meet the State's stringent anti-smog standards. Wacker Corporation must warrant the emissions control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine. wc_tx000239gb.fm 10

13 Emission Control System Information Your emission control system may include parts such as the carburetor or fuel-injection system, fuel lines and the ignition system. Also included may be hoses, clamps, connectors and other associated components. Where a warrantable condition exists, a Wacker authorized service center will repair your Wacker engine at no cost to you including diagnosis, parts and labor. MANUFACTURER'S WARRANTY COVERAGE: The emissions control system is warranted for two years. If any emissions-related part on your engine is defective, the part will be repaired or replaced by Wacker. OWNER'S WARRANTY RESPONSIBILITIES: As the Wacker engine owner, you are responsible for the performance of the required maintenance listed in your owner's manual. Wacker recommends that you retain all receipts covering maintenance on your Wacker engine, but Wacker cannot deny warranty solely for the lack of receipts. As the Wacker engine owner, you should however be aware that Wacker may deny you warranty coverage if your Wacker engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. You are responsible for presenting your Wacker engine to a Wacker dealer or service center as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your warranty rights and responsibilities, you should contact your local Wacker equipment dealer, service center or the WACKER CORPORATION Product Support Department (U.S.A , Canada ) for the information. wc_tx000239gb.fm 11

14 Emission Control System Information GENERAL EMISSIONS WARRANTY COVERAGE - California Only - Wacker warrants to the ultimate purchaser and each subsequent purchaser that this small off-road engine (1) has been designed, built and equipped so as to conform with all applicable regulations; and (2) is free from defects in materials and workmanship that cause the failure of a warranted part to conform with those regulations as may be applicable to the terms and conditions stated below. A. The warranty period begins on the date the engine is delivered to an ultimate purchaser or first placed into service. The warranty period is two years. B. Subject to certain conditions and exclusions as stated below, the warranty on emissions related parts is as follows: 1) Any warranted part that is not scheduled for replacement as required maintenance in your owner s manual is warranted for the warranty period stated above. If the part fails during the period of warranty coverage, the part will be repaired or replaced by Wacker according to subsection (4) below. Any such part repaired or replaced under warranty will be warranted for the remainder of the period. 2) Any warranted part that is scheduled only for regular inspection in your owner s manual is warranted for the warranty period stated above. Any such part repaired or replaced under warranty will be warranted for the remaining warranty period. 3) Any warranted part that is scheduled for replacement as required maintenance in your owner s manual is warranted for the period of time before the first scheduled replacement date for that part. If the part fails before the first scheduled replacement, that part will be repaired or replaced by Wacker according to subsection (4) below. Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part. 4) Repair or replacement of any warranted part under the warranty provisions herein must be performed at a warranty station at no charge to the owner. 5) Notwithstanding the provisions herein, warranty services or repair will be provided at all of our distribution centers that are franchised to service the subject engines. 6) The owner must not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective, provided that such diagnostic work is performed at a warranty station. wc_tx000239gb.fm 12

15 Emission Control System Information 7) Wacker is liable for damages to other engine components proximately caused by a failure under warranty of any warranted part. 8) Throughout the engine warranty period stated above, Wacker will maintain a supply of warranted parts sufficient to meet the expected demand for such parts. 9) Any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner. Such use will not reduce the warranty obligations of Wacker. 10) Add-on or modified parts that are not exempted by the Air Resources Board may not be used. The use of any nonexempted add-on or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claim. Wacker will not be liable to warrant failures of warranted parts caused by the use of a non-exempted add-on or a modified part. wc_tx000239gb.fm 13

16 Emission Control System Information C. Warranted Parts: The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if Wacker demonstrates that the engine has been abused, neglected, or improperly maintained, and that such abuse, neglect, or improper maintenance was the direct cause of the need for repair or replacement of the part. That notwithstanding, any adjustment of a component that has a factory installed, and properly operating, adjustment limiting device is still eligible for warranty coverage. The following emissions warranty parts list are covered. 1) Fuel Metering System i) Carburetor and internal parts (and/or pressure regulator or fuel injection system). ii) Air/fuel ratio feedback and control system, if applicable. iii) Cold start enrichment system, if applicable. iv) Regulator assembly (gaseous fuel, if applicable) 2) Air Induction System i) Intake manifold, if applicable. ii) Air filter 3) Ignition System i) Spark plugs ii) Magneto or electronic ignition system iii) Spark advance/retard system, if applicable 4) Exhaust manifold, if applicable 5) Evaporation System i) Fuel line ii) Fuel line fittings wc_tx000239gb.fm 14

17 PG 2/3 3. Safety Information 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 indicates a hazardous situation which, if not avoided, will result in death or serious injury. DANGER WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. WARNING CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION 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. 3.1 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. wc_si000145gb.fm 15

18 Safety Information PG 2/3 3.2 Operating Safety WARNING 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 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 and environmental hazards. Contact local authorities for assistance 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 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 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 NEVER stand on the machine DO NOT stand under the machine while it is being hoisted or moved DO NOT attach equipment to the machine when it is suspended ALWAYS read, understand, and follow procedures in the Operator s Manual before attempting to operate the equipment ALWAYS be sure operator is familiar with proper safety precautions and operation techniques before using machine. wc_si000145gb.fm 16

19 PG 2/3 Safety Information ALWAYS be sure the machine is on a firm, level surface and will not tip, roll, slide, or fall while operating ALWAYS close fuel valve on engines equipped with one when machine is not being operated ALWAYS store the equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children. 3.3 Operator Safety while using Internal Combustion Engines Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine owner s manual and the safety guidelines below. Failure to follow the warnings and safety guidelines could result in severe injury or 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 DO NOT spill fuel when refueling the engine DO NOT run the engine near open flames ALWAYS refill the fuel tank in a well-ventilated area ALWAYS replace the fuel tank cap after refueling. DANGER wc_si000145gb.fm 17

20 Safety Information PG 2/3 3.4 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 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 DO NOT test for spark on gasoline-powered engines if the engine is flooded or the smell of gasoline is present. A stray spark could ignite the fumes 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 keep the area around the muffler free of debris such as leaves, paper, cartons, etc. A hot muffler could ignite the debris and start a fire ALWAYS replace worn or damaged components with spare parts designed and recommended by Wacker Corporation ALWAYS disconnect the spark plug on machines equipped with gasoline engines, before servicing, to avoid accidental start-up. wc_si000145gb.fm 18

21 PG 2/3 3.5 Label Locations Safety Information M? C H &!! wc_si000145gb.fm 19

22 Safety Information PG 2/3 3.6 Safety Labels Wacker machines use international pictorial labels where needed. These labels are described below: Label Meaning 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. WARNING! Hot surface! 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! Pressurized contents. Do not open when hot! Impeller rotation. Guaranteed sound power level in db(a) wc_si000145gb.fm 20

23 PG 2/3 Label Meaning Safety Information 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. This machine may be covered by one or more patents. wc_si000145gb.fm 21

24 Technical Data PG 2/3 4. Technical Data 4.1 Engine Item Number: PG , PG , Engine Make Engine Wacker Engine Model WM 130 WM 170 Displacement cm 3 (in 3 ) 126 (7.7) 169 (10.3) Engine Speed rpm 3600 ± 100 Max. Operating Power kw (Hp) 3.2 (4.3) 4.2 (5.7) Rated Power kw (Hp) 2.2 (3.0) 3.0 (4.0) Spark Plug type NGK BR6HS (Champion RL86C) Electrode Gap mm (in.) ( ) Air Cleaner type Dual Element Engine Lubrication oil grade class SAE10W30, SE or higher Engine Oil Capacity ml (oz.) 600 (20) Valve Clearance (cold) mm (in.) ( ) Fuel type Regular unleaded gasoline Fuel Tank Capacity l (qts.) 2.7 (2.8) 3.6 (3.8) Fuel Consumption l (qts.)/hr. 1.3 (1.4) 1.8 (1.9) Running Time hr wc_td000145gb.fm 22

25 PG 2/3 4.2 Pump Technical Data Item Number: PG , PG , Pump Dimensions (L x W x H) mm (in.) 480 x 375 x 395 (19 x 15 x 15.5) 515 x 405 x 460 (20 x 16 x 18) Operating Weight kg (lbs.) 24 (53) 31 (69) *Max. Suction Lift m (ft.) 8 (26) Max. Discharge Head m (ft.) 30 (98) Suction / Discharge Dia. mm (in.) 50 (2) 75 (3) Maximum Solid Size mm (in.) 6.5 (0.25) Max. Flow Rate l/m (gpm) 600 (158) 970 (256) * Based on pump operating at sea level. Maximum suction lift will be less at higher altitudes. 4.3 Sound Specifications The required sound specification, Paragraph f of 89/392/EEC Machinery Directive, is: the sound pressure level at operator's location (L pa ): PG 2 = 84 db(a), PG 3 = 87 db(a). the guaranteed sound power level (L WA ): PG 2 = 103 db(a), PG 3 = 105 db(a). These sound values were determined according to ISO 3744 for the sound power level (L WA ) and ISO 6081 for the sound pressure level (L pa ) at the operator's location. wc_td000145gb.fm 23

26 Operation PG 2/3 5. Operation 5.1 Application This pump is intended for removing clean water and water containing some debris and solids. Refer to Technical Data for maximum solid size. 5.2 Recommended Fuel The engine requires regular grade unleaded gasoline. Use only fresh, clean gasoline. Gasoline containing water or dirt will damage fuel system. Consult engine Owner s Manual for complete fuel specifications. wc_tx000407gb.fm 24

27 PG 2/3 5.3 Before Starting Operation See Graphic: wc_gr Read safety instructions at the beginning of manual Place pump as near to water as possible, on a firm, flat, level surface To prime pump, remove prime plug (a) and fill pump case with water. If the pump case is not filled with water before starting, it will not begin pumping. DO NOT open priming plug, discharge plug, or loosen hose fittings if pump is hot! Water or vapor inside pump may be under pressure. WARNING Check for leaks between pump and engine. If water is leaking, the seal inside pump is worn or damaged. Continued operation may cause water damage to engine Check that hoses are securely attached to pump. Suction hose (b) must not have any air leaks. Tighten hose clamps (c) and couplings (d). Check that discharge hose (e) is not restricted. Lay hose out as straight as possible. Remove any twists or sharp bends from hose which may block the flow of water Make sure suction strainer (f) is clean and securely attached to end of hose. The strainer is designed to protect the pump by preventing large objects from being pulled into the pump. CAUTION: Strainer should be positioned so it will remain completely under water. Running the pump with the strainer above water for long periods can damage the pump Check fuel level, engine oil level, and condition of air cleaner. A >? B M? C H &! # wc_tx000407gb.fm 25

28 Operation PG 2/3 5.4 To Start See Graphic: wc_gr Open fuel valve by moving lever down (a1). Note: If engine is cold, move choke lever to close position (d2). If engine is hot, set choke to open position (d1) Turn engine switch to ON (b2) Open throttle by moving it slightly to left (c2) Pull starter rope (e). Note: If the oil level in the engine is low, the engine will not start. If this happens, add oil to engine Open choke as engine warms (d1) Open throttle fully to operate (c1). a2 b2 a1 b1 c1 c2 c3 d2 d1 e wc_gr To Stop See Graphic: wc_gr Reduce engine RPM to idle by moving throttle completely to right (c3) Turn engine switch to OFF (b1) Close fuel valve (a2). wc_tx000407gb.fm 26

29 PG 2/3 5.6 Operation Operation Pump should begin pumping water within a minute depending on length of suction hose and height of pump above water. Longer hoses will require more time. If pump does not prime, check for loose fittings or air leak in suction hose. Make sure strainer in water is not blocked. Run engine at full speed while operating pump NEVER pump corrosive chemicals or water containing toxic substances. These fluids could create serious health and environmental hazards. Contact local authorities for assistance. WARNING 5.7 Hoses and Clamps See Graphic: wc_gr Suction hoses (a) must be rigid enough not to collapse when pump is operating. Discharge hoses (b) are usually thin-walled collapsible hoses. Rigid hoses similar to those used as suction hoses may also be used as discharge hoses. Note: Suction and discharge hoses are available from Wacker. Contact your nearest dealer for more information. Two clamps (c) are recommended for connection of suction hoses to inlet coupling. Note: This connection is important. Even a small air leak on the suction side of pump will prevent the pump from priming. For other hose connections, one T-bolt or worm-gear type clamp is usually sufficient to hold hoses in place. In some cases, slight variances in hose diameters may make it necessary to add more clamps in order to maintain tight connections.? > = M? C H &! $ wc_tx000407gb.fm 27

30 Maintenance PG 2/3 6. Maintenance 6.1 Periodic Maintenance Schedule The chart below lists basic machine and engine maintenance. Refer to the engine manufacturer s Operator s Manual for additional information on engine maintenance. Daily before starting After first 20 hrs. Every 50 hrs. Every 100 hrs. Every 300 hrs. Check fuel level. Check engine oil level. Inspect air filter. Replace as needed. Check external hardware. Inspect hoses and housing for leaks. Clean air cleaner element. Change engine oil. Clean cooling system. Check and clean spark plug. Clean sediment cup. Check and adjust valve clearance. Check and adjust impeller clearance. wc_tx000408gb.fm 28

31 PG 2/3 6.2 Cleaning Pump Maintenance See Graphic: wc_gr After pumping water containing a large amount of dirt or debris, clean out inside of pump housing Remove drain plug (b) from pump housing and drain any water left in pump Loosen the four knobs holding the pump cover (a) and remove cover Clean out dirt and debris. Inspect impeller and volute insert for wear. WARNING The impeller may develop sharp edges. Use care when cleaning around impeller to avoid getting cut. = > M? C H &! % wc_tx000408gb.fm 29

32 Maintenance PG 2/3 6.3 Adjusting Impeller Clearance See Graphic: wc_gr If it is necessary to replace impeller or volute, be sure clearance between impeller and volute is adjusted correctly. The impeller (a) should be as close to the volute (b) as possible without rubbing against it. Clearance is adjusted by adding or removing shims (c) from behind impeller. To adjust the clearance do the following: Remove pump housing but do not remove impeller Measure the distance (d) of volute Measure the distance (e) of impeller Subtract the distance (e) from (d). (d) - (e) = (f) clearance The clearance between the volute and the impeller should be 0.3 mm (0.012 in.) to 0.7 mm (0.028 in.). Adjust the distance by removing the impeller and adding shims as needed. Each shim measures 0.3 mm (0.012 in.). As the impeller wears down, additional shims may be required to maintain the clearance between the impeller and the volute. Check the clearance whenever the mechanical seal (g), impeller, volute, or rear flange plate are replaced. A C B =? M? C H &! & wc_tx000408gb.fm 30

33 PG 2/3 6.4 Mechanical Seal Replacement Maintenance See Graphic: wc_gr To service the mechanical seal do the following: Remove the impeller (a) from the engine shaft by turning it countercockwise. Note: If the impeller is hard to remove, tap it with a plastic mallet. Do not lose any adjusting shims (b) Remove mechanical seal spring (c) and carbon face (d) from crankshaft Remove mechanical seal ceramic face (e) and L-ring (f) Clean engine shaft, remove any rust. Also clean contact surface of ceramic and carbon faces with a clean cloth. Do not lubricate seal faces Place ceramic face in L-ring and install in pump flange. Carefully place carbon face and seal spring on engine shaft Mount impeller to engine shaft. Turn impeller shaft clockwise to tighten. See Section Adjusting Impeller Clearance. wc_tx000408gb.fm 31

34 Maintenance PG 2/3 6.5 Spark Plug See Graphic: wc_gr WARNING Clean or replace spark plug as needed to ensure proper operation. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it is hot. Note: Refer to the Technical Data for the recommended spark plug type and the electrode gap setting Remove spark plug and inspect it Replace plug if the insulator is cracked or chipped Clean spark plug electrodes with a wire brush Set the electrode gap (a) Tighten spark plug securely. CAUTION: A loose spark plug can become very hot and may cause engine damage. wc_tx000408gb.fm 32

35 PG 2/3 6.6 Servicing Air Cleaner Maintenance See Graphic: wc_gr WARNING NEVER use gasoline or other types of low flash point solvents for cleaning the air cleaner. A fire or explosion could result. CAUTION: NEVER run engine without air cleaner. Severe engine damage will occur. The engine is equipped with a dual 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 Remove the air cleaner cover (a). Remove the filter assembly by pulling it straight up. Inspect both elements for holes or tears. Replace damaged elements Wash the foam element (b) in a solution of mild detergent and warm water. Rinse it thoroughly in clean water. Allow the element to dry thoroughly Tap the paper element (c) lightly to remove excess dirt or blow compressed air through the filter from the inside out. Replace the paper element if it appears heavily soiled. a b c wc_gr wc_tx000408gb.fm 33

36 Maintenance PG 2/3 6.7 Changing Engine Oil See Graphic: wc_gr Drain oil while engine is still warm. Note: In 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 Remove the oil drain plug (a) Allow the oil to drain Install the drain plug Fill the engine crankcase through the oil filler opening (b), to the upper mark on the dipstick (c). Do not thread in the dipstick to check the level. See Technical Data for oil quantity and type When the crankcase is full, reinstall the dipstick.? a > = M? C H & % wc_gr Cleaning Fuel Strainer See Graphic: wc_gr To remove water and dirt, close the fuel lever and remove the fuel strainer Inspect the fuel strainer (a) for water and dirt After removing any dirt and water, wash the fuel cup with a nonflammable solvent Reinstall securely to prevent leakage. wc_tx000408gb.fm 34

37 PG 2/3 6.9 Storage Maintenance If pump is being stored for more than 30 days: WARNING NEVER open priming plug, discharge plug, or cover when pump is hot Remove discharge plug from pump casing and drain out any water left in the housing after pump has cooled 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 Tape up suction and discharge ports to prevent anything from falling into pump Change engine oil and follow procedures described in engine manual for engine storage Cover pump and engine and store in a clean, dry area. wc_tx000408gb.fm 35

38 Maintenance PG 2/ 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. Suction hose damaged. Replace or repair hose. Air leak at suction port. Check that fittings are tight and 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 low. Adjust speed. Suction strainer partially plugged. Clean strainer. Impeller worn. Adjust clearance by adding shims or replace impeller. Volute insert worn or damaged. Adjust clearance or replace insert. 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 on coupling. Pressure may be too high for clamps being used. Add another clamp. Hose kinked or end blocked. Check hose. Impeller does not turn; pump is hard to start. Impeller jammed or blocked. Open pump cover and clean dirt and debris from inside of pump housing. Impeller and insert binding. Adjust clearance by removing shim from behind insert. wc_tx000408gb.fm 36

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51 EC DECLARATION OF CONFORMITY CE-KONFORMITÄTSERKLÄRUNG DECLARACIÓN DE CONFORMIDAD DE LA CE DÉCLARATION DE CONFORMITÉ C.E. WACKER NEUSON CORPORATION, N92 W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA AUTHORIZED REPRESENTATIVE IN THE EUROPEAN UNION BEVOLLMÄCHTIGTER VERTRETER FÜR DIE EUROPÄISCHE GEMEINSCHAFT REPRESENTANTE AUTORIZADO EN LA UNIÓN EUROPEA REPRÉSENTANT AGRÉÉ AUPRÈS DE L UNION EUROPÉENNE WACKER CONSTRUCTION EQUIPMENT AG Preußenstraße München hereby certifies that the construction equipment specified hereunder / bescheinigt, daß das Baugerät / certifica que la máquina de construcción / atteste que le matériel : 1. Category / Art / Categoría / Catégorie Water Pump Units Wasserpumpen Equipos de Bomba de Agua Groupe Motopompe à Eau 2. Type - Typ - Tipo - Type PG 2, PG 2A 3. Item number of equipment / Artikelnummer / Número de referencia de la máquina / Numéro de référence du matériel : , , Net installed power / absolute installierte Leistung / Potencia instalada neta / Puissance installée nette : PG 2 3,2 kw PG 2A 2,6 kw Has been sound tested per Directive 2000/14/EC / In Übereinstimmung mit Richtlinie 2000/14/EG bewertet worden ist / Ha sido ensayado en conformidad con la norma 2000/14/CE / A été mis à l épreuve conforme aux dispositions de la directive 2000/14/CEE : Conformity Assessment Procedure / Konformitätsbewertungsverfahren / Procedimiento para ensayar conformidad / Procédé pour l épreuve de conformité Annex V / Anhang V Anexo V / Annexe V Measured sound power level / Gemessener Schallleistungspegel / Nivel de potencia acústica determinado / Niveau de puissance acoustique fixé PG db(a) PG 2A 100 db(a) Guaranteed sound power level/ Garantierter Schallleistungspegel / Nivel de potencia acústica garantizado / Niveau de puissance acoustique garanti PG db(a) PG 2A 103 db(a) and has been produced in accordance with the following standards: und in Übereinstimmung mit folgenden Richtlinien hergestellt worden ist: y ha sido fabricado en conformidad con las siguientes normas: et a été produit conforme aux dispositions des directives européennes ci-après : 2000/14/EC 2002/88/EC 89/336/EEC 98/37/EEC William Lahner Vice President of Engineering Dan Domanski Manager, Product Engineering Date / Datum / Fecha / Date WACKER NEUSON CORPORATION 2008-CE-PG2_Q.fm

52

53 EC DECLARATION OF CONFORMITY CE-KONFORMITÄTSERKLÄRUNG DECLARACIÓN DE CONFORMIDAD DE LA CE DÉCLARATION DE CONFORMITÉ C.E. WACKER NEUSON CORPORATION, N92 W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA AUTHORIZED REPRESENTATIVE IN THE EUROPEAN UNION BEVOLLMÄCHTIGTER VERTRETER FÜR DIE EUROPÄISCHE GEMEINSCHAFT REPRESENTANTE AUTORIZADO EN LA UNIÓN EUROPEA REPRÉSENTANT AGRÉÉ AUPRÈS DE L UNION EUROPÉENNE WACKER CONSTRUCTION EQUIPMENT AG Preußenstraße München hereby certifies that the construction equipment specified hereunder / bescheinigt, daß das Baugerät / certifica que la máquina de construcción / atteste que le matériel : 1. Category / Art / Categoría / Catégorie Water Pump Units Wasserpumpen Equipos de Bomba de Agua Groupe Motopompe à Eau 2. Type - Typ - Tipo - Type PG 3, PG 3A 3. Item number of equipment / Artikelnummer / Número de referencia de la máquina / Numéro de référence du matériel : , Net installed power / absolute installierte Leistung / Potencia instalada neta / Puissance installée nette : PG 3 4,2 kw PG 3A 3,6 kw Has been sound tested per Directive 2000/14/EC / In Übereinstimmung mit Richtlinie 2000/14/EG bewertet worden ist / Ha sido ensayado en conformidad con la norma 2000/14/CE / A été mis à l épreuve conforme aux dispositions de la directive 2000/14/CEE : Conformity Assessment Procedure / Konformitätsbewertungsverfahren / Procedimiento para ensayar conformidad / Procédé pour l épreuve de conformité Annex V / Anhang V Anexo V / Annexe V Measured sound power level / Gemessener Schallleistungspegel / Nivel de potencia acústica determinado / Niveau de puissance acoustique fixé PG db(a) PG 3A 105 db(a) Guaranteed sound power level/ Garantierter Schallleistungspegel / Nivel de potencia acústica garantizado / Niveau de puissance acoustique garanti PG db(a) PG 3A 108 db(a) and has been produced in accordance with the following standards: und in Übereinstimmung mit folgenden Richtlinien hergestellt worden ist: y ha sido fabricado en conformidad con las siguientes normas: et a été produit conforme aux dispositions des directives européennes ci-après : 2000/14/EC 2002/88/EC 89/336/EEC 98/37/EEC William Lahner Vice President of Engineering Dan Domanski Manager, Product Engineering Date / Datum / Fecha / Date WACKER NEUSON CORPORATION 2008-CE-PG3_Q.fm

54 Wacker Construction Equipment AG Preußenstraße 41 D München Tel.: +49-(0) Fax: (0) Wacker Corporation P.O. Box 9007 Menomonee Falls, WI Tel. : (262) Fax: (262) Tel. : (800) Wacker Asia Pacific Operations Skyline Tower, Suite 2303, 23/F 39 Wang Kwong Road, Kowloon Bay, Hong Kong Tel Fax: