Operator’s Manual Pump PG 3A EN 5000184874 5 0 0 0 1 08 8 4 0511 8 7 4
Copyright notice © Copyright 2011 by Wacker Neuson Production Americas LLC All rights, including copying and distribution rights, are reserved. This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Production Americas LLC. Any type of reproduction or distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights.
PG 3A Foreword Foreword SAVE THESE INSTRUCTIONS—This manual contains important instructions for the machine models below. These instructions have been written expressly by Wacker Neuson Production Americas LLC and must be followed during installation, operation, and maintenance of the machines.
Foreword PG 3A Manufacturer’s This manual contains references to approved parts, attachments, and modificaapproval tions. The following definitions apply: Approved parts or attachments are those either manufactured or provided by Wacker Neuson. Approved modifications are those performed by an authorized Wacker Neuson service center according to written instructions published by Wacker Neuson. Unapproved parts, attachments, and modifications are those that do not meet the approved criteria.
EC Declaration of Conformity Manufacturer Wacker Neuson Production Americas LLC, N92W15000 Anthony Avenue, Menomonee Falls, Wisconsin USA Product Product PG 3A Product category Water Pump Units Product function To pump fluid Item number 0009055 Net installed power 3.
PG 3A 1 Foreword 3 EC Declaration of Conformity 5 Safety Information 9 1.1 1.2 1.3 1.4 1.5 2 Table of Contents Signal Words Used in this Manual ....................................................... 9 Machine Description and Intended Use ............................................. 10 Safety Guidelines for Operating the Machine ..................................... 11 Operator Safety while Using Internal Combustion Engines ............... 13 Service Safety ......................................
Table of Contents 5 PG 3A Maintenance 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 26 Maintaining the Emission Control System ...........................................26 Periodic Maintenance Schedule ..........................................................26 Cleaning the Pump ..............................................................................27 Adjusting the Impeller Clearance ........................................................28 Replacing the Mechanical Seal ..................
PG 2A / 3A 1 1.1 Safety Information Safety Information Signal Words Used in this Manual This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol. It is used to alert you to potential personal hazards. f Obey all safety messages that follow this symbol.
Safety Information 1.2 PG 2A / 3A Machine Description and Intended Use This machine is a centrifugal dewatering pump. The Wacker Neuson Dewatering Pump consists of a tubular steel frame surrounding a gasoline engine, a fuel tank, and an impeller pump with ports for water suction and discharge. The engine rotates the impeller during operation. Waste water is drawn into the pump through the suction port and expelled through the discharge port.
PG 2A / 3A Safety Information • Fuel and its fumes • Personal injury from improper lifting techniques • Projectile hazard from discharge • Crushing hazards from a tipping or falling pump To protect yourself and others, make sure you thoroughly read and understand the safety information presented in this manual before operating the machine. 1.3 Safety Guidelines for Operating the Machine WARNING Familiarity and proper training are required for the safe operation of the machine.
Safety Information PG 2A / 3A 1.3.4 Do not pump volatile, flammable, or low flash point fluids. These fluids could ignite or explode. 1.3.5 Do not pump corrosive chemicals or water containing toxic substances. These fluids could create serious health and environmental hazards. Contact local authorities for assistance. 1.3.6 Do not open the priming plug when the pump is hot. Do not loosen or remove inlet or discharge hose fittings when the pump is hot.
PG 2A / 3A 1.4 Safety Information Operator Safety while Using Internal Combustion Engines WARNING Internal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety standards could result in severe injury or death. f Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. DANGER Asphyxiation hazard. Using a pump indoors CAN KILL YOU IN MINUTES. Pump exhaust contains carbon monoxide.
Safety Information PG 2A / 3A When refueling the engine: 1.5 • Do not smoke. • Do not refuel a hot or running engine. • Do not refuel the engine near sparks or open flames. • Do not refuel if the machine is positioned in a truck fitted with a plastic bed liner. Static electricity can ignite the fuel or fuel vapors.
PG 2A / 3A 1.5.8 wc_si000069gb.fm Safety Information original in all types of specifications, such as physical dimensions, type, strength, and material. Disconnect the spark plug on machines equipped with gasoline engines, before servicing, to avoid accidental start-up.
Labels 2 2.1 PG 3A Labels Label Locations A B F C G, H D E wc_gr000833 16 wc_si000519gb.
PG 3A 2.2 Labels Label Meanings A STOP DANGER! Asphyxiation hazard. Engines emit carbon monoxide. Do not run the machine indoors or in an enclosed area. NEVER use inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and vents. Read the Operator’s Manual. No sparks, flames, or burning objects near the machine. Stop the engine before refueling.
Labels PG 3A E Impeller rotation. F Guaranteed sound power level in dB(A). G 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 nameplate 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.
PG 2A / 3A 3 Lifting and Transporting Lifting and Transporting Lifting the machine This pump is heavy enough to cause injury if proper lifting techniques are not used. Observe the following guidelines when lifting the pump. • Do not attempt to lift the pump unassisted. Use appropriate lifting equipment such as slings, chains, hooks, ramps, or jacks. • Make sure lifting equipment is attached securely and has enough weight-bearing capacity to lift or hold the pump safely.
Operation 4 4.1 PG 2A / 3A Operation Preparing the Machine for First Use Preparing for first use To prepare your machine for first use: 4.1.1 Make sure all loose packaging materials have been removed from the machine. 4.1.2 Check the machine and its components for damage. If there is visible damage, do not operate the machine! Contact your Wacker Neuson dealer immediately for assistance. 4.1.
PG 2A / 3A 4.2 Operation Recommended Fuel Type This engine/equipment requires regular unleaded gasoline. • Use only fresh (no older than three months old), clean gasoline. • Use a fuel stabilizer per the fuel stabilizer manufacturer’s instructions. Use of oxygenated fuels Some conventional gasolines are blended with alcohol. These gasolines are collectively referred to as oxygenated fuels. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.
Operation 4.3 PG 2A / 3A Before Starting See Graphic: wc_gr000835 4.3.1 Read safety instructions at the beginning of this Operator’s Manual. 4.3.2 Place pump as near to water as possible, on a firm, flat, level surface. 4.3.3 To prime pump, remove prime plug (a) and fill pump housing with water. If the pump housing is not filled with water before starting, it will not begin pumping.
PG 2A / 3A 4.4 Operation Starting See Graphic: wc_gr000014 4.4.1 Open fuel valve by moving lever to the right (a1). Note: If engine is cold, move choke lever to close position (b1). If engine is hot, set choke to open position (b2). 4.4.2 Turn engine switch to “ON” (e1). 4.4.3 Open throttle by moving it slightly to left (d1). 4.4.4 Pull starter rope (c). Note: If the oil level in the engine is low, the engine will not start. If this happens, add oil to engine.
Operation 4.6 PG 2A / 3A 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. 4.7 Hoses and Clamps See Graphic: wc_gr000836 Suction hoses (a) must be rigid enough not to collapse when pump is operating.
PG 2A / 3A 4.8 Operation Emergency Shutdown Procedure If a breakdown/accident occurs while the machine is operating, follow the procedure below. wc_tx000177gb.fm 4.8.1 Stop the engine. 4.8.2 Turn off the fuel supply. 4.8.3 Remove any obstructions. 4.8.4 Unkink the hoses. 4.8.5 Allow the machine to cool. 4.8.6 Contact the rental yard or machine owner.
Maintenance 5 5.1 PG 2A / 3A Maintenance Maintaining the Emission Control System Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a dealer/service center authorized by the engine manufacturer. See the supplied engine owner’s manual for the applicable emission warranty information. 5.2 Periodic Maintenance Schedule The table below lists basic machine maintenance.
PG 2A / 3A 5.3 Maintenance Cleaning the Pump See Graphic: wc_gr000837 After pumping water containing a large amount of dirt or debris, clean out inside of pump housing. 5.3.1 Remove drain plug (b) from pump housing and drain any water left in pump. 5.3.2 Loosen the four knobs holding the pump cover (a) and remove cover. 5.3.3 Clean out dirt and debris. Inspect impeller and volute insert for wear. The impeller may develop sharp edges. Use care when cleaning around impeller to avoid getting cut.
Maintenance 5.4 PG 2A / 3A Adjusting the Impeller Clearance See Graphic: wc_gr000838 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: 5.4.1 Remove pump housing but do not remove impeller. 5.4.
PG 2A / 3A 5.5 Maintenance Replacing the Mechanical Seal See Graphic: wc_gr000839 To service the mechanical seal do the following: 5.5.1 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). wc_tx000178gb.fm 5.5.2 Remove mechanical seal spring (c) and carbon face (d) from crankshaft. 5.5.3 Remove mechanical seal ceramic face (e) and L-ring (f). 5.5.
Maintenance 5.6 PG 2A / 3A Spark Plug Clean or replace spark plug as needed to ensure proper operation. Refer to the engine owner’s manual. Recommended Plug: (NGK) BPR 6ES The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it is hot. WARNING 5.6.1 Remove spark plug and inspect it. 5.6.2 Replace plug if the insulator is cracked or chipped. 5.6.3 Clean spark plug electrodes with a wire brush. 5.6.4 Set gap (a) to 0.7-0.
PG 2A / 3A 5.7 Maintenance Servicing the Air Cleaner See Graphic: wc_gr000840 Service air cleaner frequently to prevent carburetor malfunction. NOTICE: NEVER run engine without air cleaner. Severe engine damage will occur. NEVER use gasoline or other types of low flash point solvents for cleaning the air cleaner. A fire or explosion could result. WARNING To service: 5.7.1 Remove air cleaner cover (a). Inspect element (b) for holes or tears. Replace element if damaged. 5.7.
Maintenance 5.8 PG 2A / 3A Engine Oil See Graphic: wc_gr000022 WARNING Most used oil contains small amounts of materials that can cause cancer and other health problems if inhaled, ingested, or left in contact with skin for prolonged periods of time. f Take steps to avoid inhaling or ingesting used engine oil. f Wash skin thoroughly after exposure to used engine oil. 5.8.1 Drain the oil while the engine is still warm. 5.8.2 Remove the oil filler plug (a) and the drain plug (b) to drain the oil.
PG 2A / 3A 5.9 Maintenance Cleaning the Sediment Cup See Graphic: wc_gr000029 wc_tx000178gb.fm 5.9.1 Turn the fuel valve off. 5.9.2 Remove the sediment cup (a) and the O-ring (b). 5.9.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 5.9.4 Turn the fuel valve on and check for leaks.
Maintenance 5.10 PG 2A / 3A Carburetor Adjustment See Graphic: wc_gr000032 5.10.1 Start the engine and allow it to warm up to operating temperature. 5.10.2 Set the pilot screw (a) two turns out. See Note. 5.10.3 With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm. 5.10.4 After the pilot screw is adjusted, turn the throttle stop screw (b) to obtain the standard idle speed. See Technical Data.
PG 2A / 3A 5.12 Maintenance Long-Term Storage If pump is being stored for more than 30 days: Do not open priming plug, discharge plug, or cover when pump is hot. WARNING wc_tx000178gb.fm 5.12.1 After pump has cooled, remove discharge plug from pump housing and drain out any water left in the housing. 5.12.2 Remove pump cover and clean inside of pump housing. Coat inside of pump with a light film of oil to reduce corrosion. A spray can of oil works well for this. 5.12.
Troubleshooting 6 PG 2A/3A Troubleshooting Problem / Symptom Pump does not take in water. Reason / Remedy • 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.
PG 3A 7 Technical Data Technical Data 7.1 Engine Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item Number: PG 3A 0009055 Rev. 102 and lower, 0007659 PG 3A 0009055 Rev. 103 and higher Engine Engine make Honda Engine model Maximum rated power @ rated speed GX160K1WKT2 GX160K1WKT4 3.6 (4.8) @ 3600 rpm kW (Hp) Operating speed rpm 3600 ± 100 Spark plug type NGK BPR 6ES Electrode gap Air cleaner 0.7–0.8 (0.028–0.
Technical Data 7.2 PG 3A Machine Pump Weight kg (lb) 31 (69) *Max. suction lift m (ft) 7.5 (25) Max. total head m (ft) 30 (98) Suction / discharge dia. mm (in.) 75 (3) Maximum solid size mm (in.) 6.5 (0.25) Max. discharge 1000 (264) L/min (gpm) * Based on pump operating at sea level. Maximum suction lift will be less at higher altitudes. 7.3 Sound Measurements The required sound specification, Paragraph 1.7.4.
Emission Control Systems Information and Warranty 8 Emission Control Systems Information and Warranty The Emission Control Warranty and associated information is valid only for the U.S.A., its territories, and Canada. 8.1 Emission Control Systems Warranty Statement See the supplied engine owner’s manual for the applicable exhaust and evaporative emission warranty statement. wc_tx001753gb.
Emission Control Systems Information and Warranty 40 wc_tx001753gb.
Wacker Neuson SE, Preußenstraße 41, D-80809 München, Tel.: +49-(0)89-3 54 02-0 Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI 53051 Tel. : (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
