Operator’s Manual Diaphragm Pump PDI2A PDI3A PDT2A PDT3A EN 5000184784 5 0 0 0 1 03 8 4 0811 7 8 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.
PD 2A / PD 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 PD 2A / PD 3A 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 PDT 2A, PDT2, PDI 2A(i), PDT 3A, PDT 3, PDI 3A, PDI 3A(i) Product category Water Pump Units Product function To pump fluid Item number 0620769, 0620772, 0620773, 0620775, 0620776 Net installed power PDT 2A, PDI 2A(i), PDT 3A, PDI 3A, PDI 3A(i): 2.6 kW PDT 2, PDT 3: 3.
PD 2A / PD 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 Operating Safety ................................................................................ 11 Service Safety ....................................................................................
Table of Contents 5 PD 2A / PD 3A Maintenance 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 31 Maintaining the Emission Control System ...........................................31 Periodic Maintenance Schedule ..........................................................32 Servicing the Air Cleaner .....................................................................33 Greasing the Connecting Rod Bearing ................................................34 Changing the Engine Oil ................................
PD 2 / PD 3 / PD 2A / PD 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 PD 2 / PD 3 / PD 2A / PD 3A Machine Description and Intended Use This machine is a diaphragm pump. The Wacker Neuson Diaphragm Pump consists of a gasoline engine, a fuel tank, a handle, a set of wheels, and a diaphragm pump with ports for fluid suction and discharge. The engine raises and lowers the diaphragm via a connecting rod.
PD 2 / PD 3 / PD 2A / PD 3A 1.3 Safety Information Operating Safety Operator training Before operating the machine: Read and understand the operating instructions contained in all manuals delivered with the machine. Familiarize yourself with the location and proper use of all controls and safety devices. Contact Wacker Neuson for additional training if necessary. When operating this machine: Do not allow improperly trained people to operate the machine.
Safety Information Operating guidelines PD 2 / PD 3 / PD 2A / PD 3A When operating this machine: Ensure that the machine is on a firm, level surface and that it will not tip, roll, slide, or fall while operating. When operating this machine: Do not pump volatile, flammable, or low-flash-point fluids. Do not change hoses while the engine is running. Do not attempt to move the machine while the engine is running.
PD 2 / PD 3 / PD 2A / PD 3A 1.4 Safety Information Service Safety Service training Before servicing or maintaining the machine: Read and understand the instructions contained in all manuals delivered with the machine. Familiarize yourself with the location and proper use of all controls and safety devices. Only trained personnel should troubleshoot or repair problems occurring with the machine. Contact Wacker Neuson for additional training if necessary.
Safety Information Lifting and transporting PD 2 / PD 3 / PD 2A / PD 3A When replacing electrical components, use components that are identical in rating and performance as the original components. When replacement parts are required for this machine, use only Wacker Neuson replacement parts or those parts equivalent to the original in all types of specifications, such as physical dimensions, type, strength, and material.
PD 2 / PD 3 / PD 2A / PD 3A 1.5 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.
Labels Labels Label Locations K J C E F I G B D wc_gr007188 2.1 A 2 PD 2A / PD 3A 16 wc_si000392gb.
PD 2A / PD 3A 2.2 Labels Label Meanings A 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. B NOTICE Lifting point.
Labels PD 2A / PD 3A D WARNING! Pinch point! Do not operate without safety guards. Read and understand the Operator’s Manual. E CAUTION! Read and understand the supplied Operator’s Manual before operating this machine. Failure to do so increases the risk of injury to yourself and others. F WARNING! Hot surface 18 wc_si000392gb.
PD 2A / PD 3A Labels G Guaranteed sound power level in dB(A). I Notice Do not exceed 60 strokes per minute with the diaphragm pump. Read the Operator’s Manual. J Notice Use noncollapsible hose or pipe on suction side of pump. Read the Operator’s Manual. wc_si000392gb.
Labels PD 2A / PD 3A K WARNING! Never pump volatile, flammable, or lowflash-point fluids. These fluids could ignite or explode. Read the Operator’s Manual. 20 wc_si000392gb.
PD 2 / PD 3 / PD 2A / PD 3A 3 Lifting and Transporting Lifting and Transporting Requirements Transport vehicle capable of carrying at least 70 kg (150 lbs.) Use lifting equipment capable of lifting at least 70 kg (150 lbs.) WARNING Fire hazard. Spilled fuel can ignite and cause severe burns. f Lift and transport the machine in an upright position. Guidelines Follow the guidelines below when lifting and transporting this machine. Close the fuel valve.
Operation 4 4.1 PD 2A / PD 3A Operation Preparing the Machine for First Use Preparing for first use To prepare your machine for first use: 1. Make sure all loose packaging materials have been removed from the machine. 2. Check the machine and its components for damage. If there is visible damage, do not operate the machine! Contact your Wacker Neuson dealer immediately for assistance. 3.
PD 2A / PD 3A 4.3 Operation Recommended Fuel Type Use of oxygenated fuels 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. 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 4.4 PD 2A / PD 3A Refueling the Machine Requirements Procedure Machine shut down Engine cool Machine/fuel tank level with the ground Fresh, clean fuel supply Perform the procedure below to refuel the machine. WARNING Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause severe burns. f Keep all sources of ignition away from the machine while refueling. f Do not refuel if the machine is positioned in a truck fitted with a plastic bed liner.
PD 2A / PD 3A 4.5 Operation Before Installing the Pump Requirements Tasks API GL-5 rated gear oil Machine off Perform the following tasks before installing the pump. 1. Read the safety instructions at the beginning of this manual. 2. Place the pump on a firm, flat, level surface. 3. Check fuel level. Add fuel as needed. 4. Check engine oil level. Add engine oil as needed. 5. Check condition of air filter. Replace the air filter if needed. 6. Fill the pump’s gearbox with oil. a.
Operation 4.6 PD 2A / PD 3A Installing the Pump Requirements Completed before-installing-the-pump procedures Procedure Perform the procedure below to install the pump. NOTICE: Do not use collapsible hoses on the suction side of the pump. 1. Place the pump as near to the water to be pumped as possible. 2. Check that hose couplings/nipples (b) are installed and secure. 3. Make sure the suction strainer (e) is clean and securely attached to the end of the suction hose. 4.
PD 2A / PD 3A 4.7 Operation Starting Requirements Procedure Completed installation procedures Engine owner’s manual read and understood Perform the procedure below to start the machine. 1. Move the fuel valve lever (a) to the OPEN position (a1). 2. Move the choke lever (b) to the CLOSED position (b1). If the engine is warm, the choke lever may be left in the OPEN position (b2). 3. Move the throttle lever (c) approximately 1/3 of the way to the “MAX.” position. 4.
Operation 4.8 PD 2A / PD 3A Stopping Procedure Perform the procedure below to stop the machine. Note: To stop the engine in an emergency, move the engine switch to the OFF position. In all other circumstances, use the following procedure. 1. Move the throttle lever (c) to “MIN.” position. 2. Turn the engine switch (d) to the OFF position (d2). 3. Move the fuel valve lever (a) to the CLOSED position (a2). 4.9 Running the Pump Guidelines Follow the guidelines below when running the pump.
PD 2A / PD 3A 4.10 Operation Clearing Jams Overview Prerequisites Large solids or accumulated sand and sediment may become lodged in the pump housing. This debris prevents the plunger arm from making a full stroke, causing the pump to stall or the crank to slip on the output shaft. The debris must be cleared before resuming operation. If the pump has stalled Engine is stopped Machine is cool to the touch Follow the procedure below to clear a jam if the pump has stalled.
Operation 4.11 PD 2A / PD 3A Emergency Shutdown Procedure If a breakdown/accident occurs while the machine is operating, follow the procedure below. 1. Stop the engine. 2. Turn off the fuel. 3. Remove the obstruction. 4. Unkink the hoses. 5. Allow the machine to cool. 6. Contact the rental yard or machine owner. 30 wc_tx001331gb.
PD 2A / PD 3A 5 5.1 Maintenance 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. wc_tx001332gb.
Maintenance 5.2 PD 2A / PD 3A Periodic Maintenance Schedule The table below lists basic machine and engine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment. Refer to the engine owner’s manual for additional information. Interval* (hours of service) Task Daily before starting First month Monthly 6 months Yearly --- (20) (40) (100) (300) Check fuel level. 3 Check engine oil level.
PD 2A / PD 3A 5.3 Maintenance Servicing the Air Cleaner When Requirements Inspect the air cleaner elements daily. Clean the air cleaner elements as needed. Replace the air cleaner elements if they are damaged or cannot be cleaned. Machine shut down Mild detergent and warm water Clean engine oil WARNING Fire or explosion hazards. Gasoline or low-flash-point solvents are flammable and must not be used to clean the air cleaner or filter element.
Maintenance PD 2A / PD 3A c. Soak the foam element in clean engine oil until saturated. Squeeze out excess oil. 6. Reinstall the filter elements and air cleaner cover. Note: In the interests of environmental protection, dispose of waste oil and soiled rags in accordance with environmental protection legislation. 5.4 Greasing the Connecting Rod Bearing When Grease the connecting rod bearing every 40 hours of operation or monthly.
PD 2A / PD 3A 5.5 Maintenance Changing the Engine Oil When Requirements Change the engine oil after the first 20 hours of operation and then after every 100 hours of operation or 6 months, whichever comes first.
Maintenance 5.6 PD 2A / PD 3A Cleaning the Sediment Cup When Clean the engine sediment cup every 100 hours or 6 months. Requirements Procedure Machine shut down Nonflammable solvent Perform the procedure below to service the sediment cup. 1. Stop the engine. 2. Move the fuel valve to the OFF position. 3. Remove the sediment cup (a) and the O-ring (b). WARNING Fire hazard. Gasoline or low-flash-point solvents are flammable and may ignite if used to clean the machine.
PD 2A / PD 3A 5.7 Maintenance Spark Plug When Requirements Clean the spark plug every 100 hours of operation or every 6 months. Replace the spark plug as needed. Procedure Machine shut down Engine cool Perform the procedure below to clean the spark plug. WARNING Burn hazard. The engine and muffler become very hot while running. f Allow the engine to cool before performing this procedure. 1. Stop the engine and allow it to cool. 2. Remove the spark plug. 3. Inspect the spark plug.
Maintenance 5.8 PD 2A / PD 3A Changing the Gearbox Oil When Change the gearbox oil every 100 hours of operation or every 6 months. Requirements Procedure Machine shut down Engine warm API GL-5 rated gear oil Container for used oil Perform the procedure below to change the gearbox oil. WARNING Burn hazard. The engine and muffler become very while running. f Stop the engine before performing this procedure. 1. Stop the engine. 2.
PD 2A / PD 3A 5.9 Maintenance Cleaning the Pump Requirements Machine shut down Machine cool Background When pumping heavy sludges or water containing large amounts of dirt and solids, clean the pump often. Materials left in the pump can dry and harden which may lead to damage of the valves or the diaphragm. Procedure Perform the procedure below to clean the machine. WARNING Fire hazard. Gasoline or low-flash-point solvents are flammable and may ignite if used to clean the machine.
Maintenance 5.10 PD 2A / PD 3A Storage Requirements Procedure Machine shut down Machine cool Machine clean Perform the procedure below to store the machine for more than 30 days. WARNING Fire hazard. The machine may cause a fire if it is covered while it is hot. f Do not cover the machine while it is running or while it is hot. 1. Stop the engine. 2. Change the engine oil. 3. Cover the pump. 4. Store the pump in a clean, dry location. 40 wc_tx001332gb.
PD 2 / PD 3 / PD 2A / PD 3A 6 Troubleshooting Troubleshooting Problem Cause Remedy Engine does not start Engine oil level too low Add oil to engine. Pump housing filled with dirt and debris Clean pump. Air leak in suction line Repair or replace suction line. Defective flapper valve Replace the flapper valves. Clogged strainer Clean or replace the strainer. No liquid in suction line Fill the pump and suction line with water. Pump housing filled with dirt and debris Clean pump.
Troubleshooting PD 2 / PD 3 / PD 2A / PD 3A Problem Cause Remedy Water accumulates on top of the diaphragm Diaphragm has crack or hole. Replace the diaphragm. Screw loose holding diaphragm Tighten the screw. Discharge hose height over 25 feet of head Lower the discharge hose. Pump housing filled with dirt and debris Clean the pump. Pump stalls repeatedly or stops for no apparent reason 42 wc_tx001382gb.
PD 2A / PD 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. Engine PDI 2/PDT 2 PDI 3/PDT 3 Type — Air-cooled Manufacturer — Honda Model — GX 120K1QX Maximum rated power at rated speed Displacement Number of cylinders Oil capacity kW/rpm (hp/rpm) cm3 (in.3) — ml (oz.) 2.6/3600 (3.5/3600) 118 (7.
Technical Data 7.2 PD 2A / PD 3A Pump Machine PDI 2/PDT 2 PDI 3/PDT 3 50 (2) 75 (3) kg (lb) 59 (131) 63 (140) Maximum discharge head m (ft) 7.6 (38) 7.6 (38) Maximum flow rate L/min (gpm) 189 (50) 333 (88) Maximum suction lift m (ft) 6.1 (20) 6.1 (20) mm (in.) 38 (1.5) 41 (1.625) Suction and discharge hose diameter Operating weight Maximum solid size diameter 7.3 mm (in.) Sound Measurements The required sound specification, Paragraph 1.7.4.
PD 2A / PD 3A 7.4 Technical Data Dimensions PD2 590 (23) PD3 590 (23) PD2 1000 (40) PD3 1070 (42) PD2 580 (23) PD3 680 (27) PD2 590 (23) PD3 590 (23) PD2 460 (18) PD3 460 (18) PD2 1000 (40) PD3 1070 (42) wc_gr007189 wc_td000379gb.
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. 46 wc_tx001753gb.
Wacker Neuson Produktion GmbH & Co. KG, 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.
