Wacker Neuson PDI 3 Repair Manual

www.wackergroup.comPumpPDT 2PDI 2PDT 3PDI 3REPAIR MANUAL0163153en 00106060163153EN

Safety Information PD 2/3wc_si000176gb.fm 61.4 Label LocationsDO NOT OPERATE WITHOUT SAFETY GUARDS. READ AND UNDERSTAND INSTRUCTION BOOK.NICHT OHNE S

PD 2/3 Safety Informationwc_si000176gb.fm 71.5 Safety LabelsWacker machines use international pictorial labels where needed.These labels are described

Safety Information PD 2/3wc_si000176gb.fm 8CAUTION! Lifting pointGuaranteed sound power level in dB(A)Label Meaning

PD 2/3 Safety Informationwc_si000176gb.fm 9

Technical Data PDwc_td000178gb.fm 102. Technical Data2.1 Engine—Machines with Honda EnginesItem Number:PDT/PDI 2A0007610, 00076110007624, 0007625PDT/P

PD Technical Datawc_td000178gb.fm 112.2 Pump—Machines with Honda Engines2.3 Sound Measurements—Machines with Honda EnginesThe required sound specifica

Technical Data PDwc_td000178gb.fm 122.4 Dimensions—Machines with Honda Enginesmm (in.)w c _ g r 0 0 1 0 6 2P D T 2 A / 3 AP D I 2 A / 3 AP D T 2

PD Technical Datawc_td000178gb.fm 132.5 Engine—Machines with Wacker EnginesItem Number:PDI/PDT 20009489, 0009494PDI/PDT 30009491, 0009492, 0009495Engi

Technical Data PDwc_td000178gb.fm 142.6 Pump—Machines with Wacker Engines2.7 Sound Measurements—Machines with Wacker EnginesThe required sound specifi

PD 2A/3A Operationwc_tx000592gb.fm 153. Operation3.1 ApplicationThis pump is intended for removing clean water or water containing alarge amount of de

Operation PD 2A/3Awc_tx000592gb.fm 163.3 Priming PumpSee Graphic: wc_gr001064Diaphragm pumps are self priming and seldom need to have wateradded to t

PD 2A/3A Operationwc_tx000592gb.fm 173.5 To Start—Machines with Honda EnginesSee Graphic: wc_gr0000143.5.1 Open fuel valve by moving lever to the righ

Operation PD 2A/3Awc_tx000592gb.fm 183.7 To Start—Machines with Wacker EnginesSee Graphic: wc_gr0006553.7.1 Open fuel valve by moving lever down (a1).

PD 2A/3A Operationwc_tx000592gb.fm 193.9 OperationRun engine at full speed while operating pump.Pump should begin pumping water within a minute depend

Operation PD 2A/3Awc_tx000592gb.fm 203.11 Hoses and ClampsSee Graphic: wc_gr001065Suction HoseSuction hoses (a) must be rigid enough not to collapse w

PD 2A/3A Operationwc_tx000592gb.fm 21

Maintenance PDwc_tx000593gb.fm 224. Maintenance4.1 Periodic Maintenance ScheduleThe chart below lists basic machine and engine maintenance. Refer toth

PD Maintenancewc_tx000593gb.fm 234.2 Changing Engine Oil—Machines with Honda EnginesSee Graphic: wc_gr0000224.2.1 Drain the oil while the engine is st

Maintenance PDwc_tx000593gb.fm 244.3 Changing Engine Oil—Machines with Wacker EnginesSee Graphic: wc_gr0000874.3.1 Drain oil while engine is still war

PD Maintenancewc_tx000593gb.fm 254.5 Cleaning Sediment Cup—Machines with Honda EnginesSee Graphic: wc_gr0000294.5.1 Turn the fuel valve off. 4.5.2 Rem

PD Repair Forewordwc_tx000591gb.fm iOperating / Parts InformationYou must be familiar with the operation of this machine before youattempt to troubles

Maintenance PDwc_tx000593gb.fm 264.7 Servicing Air Cleaner—Machines with Honda EnginesSee Graphic: wc_gr000025The engine is equipped with a dual eleme

PD Maintenancewc_tx000593gb.fm 274.8 Servicing Air Cleaner—Machines with Wacker EnginesSee Graphic: wc_gr000656NEVER use gasoline or other types of lo

Maintenance PDwc_tx000593gb.fm 284.9 Spark PlugSee Graphic: wc_gr000028Clean or replace the spark plug as needed to ensure proper operation.Refer to t

PD Maintenancewc_tx000593gb.fm 294.10 Gear CaseSee Graphic: wc_gr003450Check the oil level in the gear case once a week or every 25 hours ofoperation.

Maintenance PDwc_tx000593gb.fm 304.11 Lubricating Connecting Rod BearingSee Graphic: wc_gr003451Grease connecting rod bearing once a week or every 25

PD Maintenancewc_tx000593gb.fm 314.13 StorageIf pump is being stored for more than 30 days: NEVER open priming plug, discharge plug, or cover when pum

Maintenance PDwc_tx000593gb.fm 324.14 TroubleshootingProblem / Symptom Reason / RemedyEngine does not start. • Engine problem. See engine manufacturer

PD Repair Disassembly/Assembly Procedureswc_tx000590gb.fm 335. Disassembly/Assembly Procedures5.1 ToolsBecause all possible problems encountered while

Disassembly/Assembly Procedures PD Repairwc_tx000590gb.fm 345.4 Replacing the Flapper ValveSee Graphic: wc_gr003452There are flapper valves located on

PD Repair Disassembly/Assembly Procedureswc_tx000590gb.fm 35wc_gr003452abchddeffggeh

Foreword PD Repairwc_tx000591gb.fm iiCALIFORNIAProposition 65 Warning: Engine exhaust, some of its constituents, and certain vehiclecomponents, conta

Disassembly/Assembly Procedures PD Repairwc_tx000590gb.fm 365.5 Replacing the DiaphragmSee Graphic: wc_gr003453Removal:5.5.1 Turn off the engine.5.5.2

PD Repair Disassembly/Assembly Procedureswc_tx000590gb.fm 37wc_gr003453acbdehhfghABCDe

Disassembly/Assembly Procedures PD Repairwc_tx000590gb.fm 385.6 Replacing the Connecting Rod and BearingSee Graphic: wc_gr003459This procedure require

PD Repair Disassembly/Assembly Procedureswc_tx000590gb.fm 39wc_gr003459aacecgedfbbd

Disassembly/Assembly Procedures PD Repairwc_tx000590gb.fm 405.7 Replacing the EngineSee Graphic: wc_gr003459Removal:5.7.1 Turn off the engine.5.7.2 Re

PD Repair Disassembly/Assembly Procedureswc_tx000590gb.fm 41wc_gr003460acfbedagg

Disassembly/Assembly Procedures PD Repairwc_tx000590gb.fm 425.8 Gearbox Exploded Viewwc_gr003462agcdfebjnklmhi

PD Repair Disassembly/Assembly Procedureswc_tx000590gb.fm 435.9 Gearbox ComponentsRef. Description Ref. DescriptionaScrew hSealb Screw i Needle bearin

Disassembly/Assembly Procedures PD Repairwc_tx000590gb.fm 445.10 Gearbox DisassemblySee Graphic: wc_gr003461 and wc_gr003462This procedure requires an

PD Repair Disassembly/Assembly Procedureswc_tx000590gb.fm 45wc_gr003461acdebbfhjklmin

PD 2/3 Table of Contentswc_br0163153001enTOC.fm 11. Safety Information 31.1 Operating Safety ...

Disassembly/Assembly Procedures PD Repairwc_tx000590gb.fm 465.11 Gearbox ReassemblySee Graphic: wc_gr003462 and wc_gr003463This procedure requires an

PD Repair Disassembly/Assembly Procedureswc_tx000590gb.fm 47wc_gr003463acdebfhkklmin

Disassembly/Assembly Procedures PD Repairwc_tx000590gb.fm 485.12 TestingSee Graphic: wc_gr003464 and wc_gr003465This procedure requires a vacuum gauge

PD Repair Disassembly/Assembly Procedureswc_tx000590gb.fm 49wc_gr003465wc_gr003464

Disassembly/Assembly Procedures PD Repairwc_tx000590gb.fm 50

Threadlockers and SealantsThreadlockers and SealantsThreadlocking adhesives and sealants are specified throughout thismanual by a notation of “S” plus

Threadlockers and SealantsThreadlockers and Sealants (continued)Threadlocking adhesives and sealants are specified throughout this manual by a notatio

Torque ValuesTorque ValuesMetric Fasteners (DIN)TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZESize Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric I

Torque ValuesTorque Values (continued)Inch Fasteners (SAE)Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric InchNo.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/

Table of Contents PD 2/3wc_br0163153001enTOC.fm 24.5 Cleaning Sediment Cup—Machines with Honda Engines ...254.6 Carburetor Adjustment—

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PD 2/3 Safety Informationwc_si000176gb.fm 31. Safety InformationThis manual contains DANGER, WARNING, CAUTION, and NOTEcallouts which must be followed

Safety Information PD 2/3wc_si000176gb.fm 41.1 Operating SafetyInternal combustion engines present special hazards during operationand fueling. Read a

PD 2/3 Safety Informationwc_si000176gb.fm 51.2 Operator Safety while using Internal Combustion EnginesPoorly maintained equipment can become a safety