Wacker Neuson PG 2 User manual

www.wackergroup.com
Pump
PG 2
OPERATOR’S MANUAL
0154616en 004
0105
0154616EN

PG 2 Table of Contents
wc_bo0154616003enTOC.fm 1
1. Foreword 3
2. Safety Information 4
2.1 Laws Pertaining to Spark Arresters ...................................................... 4
2.2 Operating Safety .................................................................................. 5
2.3 Operator Safety while using Internal Combustion Engines .................. 6
2.4 Service Safety ...................................................................................... 6
2.5 Label Locations .................................................................................... 7
2.6 Safety Labels ........................................................................................ 8
3. Technical Data 10
3.1 Technical Data ................................................................................... 10
3.2 Sound Specifications .......................................................................... 11
3.3 Dimensions ......................................................................................... 11
4. Operation 12
4.1 Application .......................................................................................... 12
4.2 Recommended Fuel ........................................................................... 12
4.3 Before Starting ................................................................................... 13
4.4 To Start ............................................................................................... 14
4.5 To Stop ............................................................................................... 14
4.6 Operation ............................................................................................ 15
4.7 Hoses and Clamps ............................................................................. 15

Table of Contents PG 2
wc_bo0154616003enTOC.fm 2
5. Maintenance 16
5.1 Periodic Maintenance Schedule ..........................................................16
5.2 Cleaning Pump ....................................................................................17
5.3 Adjusting Impeller Clearance ..............................................................18
5.4 Mechanical Seal Replacement ............................................................19
5.5 Spark Plug ...........................................................................................20
5.6 Air Cleaner ..........................................................................................21
5.7 Engine Oil ............................................................................................22
5.8 Cleaning Sediment Cup ......................................................................22
5.9 Carburetor Adjustment ........................................................................23
5.10 Adjusting Idle Speed ...........................................................................23
5.11 Storage ................................................................................................24
5.12 Troubleshooting ...................................................................................25

Foreword
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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 2004 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.
WARNING

Safety Information PG 2/3
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2. 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 an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may 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.
2.1 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.
DANGER
WARNING
CAUTION

PG 2/3 Safety Information
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2.2 Operating Safety
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.
2.2.1 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.
2.2.2 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.
2.2.3 NEVER use accessories or attachments that are not recommended by
Wacker. Damage to equipment and injury to the user may result.
2.2.4 NEVER pump volatile, flammable or low flash point fluids. These fluids
could ignite or explode.
2.2.5 NEVER pump corrosive chemicals or water containing toxic
substances. These fluids could create serious health and
environmental hazards. Contact local authorities for assistance.
2.2.6 NEVER open priming plug when pump is hot. Never loosen or remove
inlet or discharge hose fittings when pump is hot. Hot water inside
could be pressurized much like the radiator on an automobile. Allow
pump to cool to the touch before loosening plug and before loosening
or removing inlet or discharge hose fittings.
2.2.7 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.
2.2.8 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.
2.2.9 ALWAYS read, understand, and follow procedures in Operator's
Manual before attempting to operate equipment.
2.2.10 ALWAYS be sure operator is familiar with proper safety precautions
and operation techniques before using machine.
2.2.11 ALWAYS be sure machine is on a firm, level surface and will not tip,
roll, slide, or fall while operating.
2.2.12 ALWAYS close fuel valve on engines equipped with one when
machine is not being operated.
2.2.13 ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the reach of
children.
WARNING

Safety Information PG 2/3
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2.3 Operator Safety while using Internal Combustion Engines
Internal combustion engines present special hazards during operation
and fueling! Read and follow warning instructions in engine owner's
manual and safety guidelines below. Failure to follow warnings and
safety guidelines could result in severe injury or death.
2.3.1 DO NOT smoke while operating machine.
2.3.2 DO NOT smoke when refueling engine.
2.3.3 DO NOT refuel hot or running engine.
2.3.4 DO NOT refuel engine near open flame.
2.3.5 DO NOT spill fuel when refueling engine.
2.3.6 DO NOT run engine near open flames.
2.3.7 ALWAYS refill fuel tank in well-ventilated area.
2.3.8 ALWAYS replace fuel tank cap after refueling.
2.4 Service Safety
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.
2.4.1 DO NOT attempt to clean or service machine while it is running.
Rotating parts can cause severe injury.
2.4.2 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.
2.4.3 DO NOT test for spark on gasoline-powered engines, if engine is
flooded or the smell of gasoline is present. A stray spark could ignite
fumes.
2.4.4 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.
2.4.5 ALWAYS keep area around muffler free of debris such as leaves,
paper, cartons, etc. A hot muffler could ignite them, starting a fire.
2.4.6 ALWAYS replace worn or damaged components with spare parts
designed and recommended by Wacker.
2.4.7 ALWAYS disconnect spark plug on machines equipped with gasoline
engines, before servicing, to avoid accidental start-up.
DANGER
WARNING

PG 2/3 Safety Information
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2.5 Label Locations
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Safety Information PG 2/3
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2.6 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
machine. Shut off engine before refueling.
WARNING!
Hot surface!
CAUTION!
Read and understand the supplied operator's
manuals before operating this machine. Fail-
ure to do so increases the risk of injury to your-
self or others.
WARNING!
Pressurized contents. Do not open when hot!
Impeller rotation.
Guaranteed sound power level in dB(A).

PG 2/3 Safety Information
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A nameplate listing the Model Number, Item
Number, Revision, and Serial Number is
attached to each unit. Please record the infor-
mation found on this plate so it will be avail-
able should the nameplate become lost or
damaged. When ordering parts or requesting
service information, you will always be asked
to specify the model, item number, revision
number, and serial number of the unit.
This machine may be covered by one or more
patents.
Label Meaning

Technical Data PG 2
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3. Technical Data
3.1 Technical Data
PG 2
0007658, 0009054
Engine
Engine Make Honda
Engine Model GX 120 W1 B4
Rated Power kW (Hp) 3.0 (4.0)
Spark Plug type NGK BPR 6ES
Electrode Gap mm (in.) 0.7-0.8 (0.028-0.031)
Air Cleaner type Single element
Engine Lubrication oil grade
class SAE 10W30
SG or SF
Engine Oil Capacity ml (oz.) 600 (20)
Fuel type Regular unleaded gasoline
Fuel Tank Capacity l (qts.) 2.5 (2.6)
Valve Clearance (cold) mm (in.) Inlet:0.15 ( 0.006)
Outlet: 0.20 (0.008)
Pump
Weight kg (lbs.) 24 (53)
*Max. Suction Lift m (ft.) 7.5 (25)
Max. Total Head m (ft.) 30 (98)
Suction / Discharge Dia. mm (in.) 50 (2)
Maximum Solid Size mm (in.) 6.5 (0.25)
Max. Flow Rate m3/h (gpm) 36 (159)
* Based on pump operating at sea level. Maximum suction lift will be less at higher altitudes.

PG 2 Technical Data
wc_td000049gb.fm 11
3.2 Sound Specifications
The required sound specification, Paragraph 1.7.4.f of 89/392/EEC
Machinery Directive, is:
- the sound pressure level at operator’s location (LpA) = 84 dB(A)
- the guaranteed sound power level (LWA) = 103 dB(A)
These sound values were determined according to ISO 3744 for the
sound power level (LWA) and ISO 6081 for the sound pressure level
(LpA) at the operator’s location.
3.3 Dimensions
mm (in.)

Operation PG 2/3
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4. Operation
4.1 Application
This pump is intended for removing clean water and water containing
some debris and solids. Refer to “Technical Data” for maximum solid
size.
4.2 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.

PG 2/3 Operation
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4.3 Before Starting
See Graphic: wc_gr000835
4.3.1 Read safety instructions at the beginning of 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 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.
4.3.4 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.
4.3.5 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.
4.3.6 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.
4.3.7 Check fuel level, engine oil level, and condition of air cleaner.
WARNING
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Operation PG 2/3
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4.4 To Start
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. Some engines are equipped with an oil
alert light (f) that will come on while pulling the starter rope.
4.4.5 Open choke as engine warms (b2).
4.4.6 Open throttle fully to operate.
4.5 To Stop
See Graphic: wc_gr000014
4.5.1 Reduce engine RPM to idle by moving throttle completely to right (d2).
4.5.2 Turn engine switch to “OFF” (e2).
4.5.3 Close fuel valve by moving lever to the left (a2).

PG 2/3 Operation
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4.6 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.
4.7 Hoses and Clamps
See Graphic: wc_gr000836
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 asmallair leakon thesuction
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.
WARNING
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Maintenance PG 2/3
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5. Maintenance
5.1 Periodic Maintenance Schedule
Daily
before
start-
ing
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 and tighten 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. •

PG 2/3 Maintenance
wc_tx000178gb.fm 17
5.2 Cleaning Pump
See Graphic: wc_gr000837
After pumping water containing a large amount of dirt or debris, clean
out inside of pump housing.
5.2.1 Remove drain plug (a) from pump housing and drain any water left in
pump.
5.2.2 Loosen the four knobs holding the pump cover (b) and remove cover.
5.2.3 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 prevent getting cut.
WARNING
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Maintenance PG 2/3
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5.3 Adjusting 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:
5.3.1 Remove pump housing but do not remove impeller.
5.3.2 Measure the distance (d) of volute.
5.3.3 Measure the distance (e) of impeller.
5.3.4 Subtract the distance (e) from (d).
(d) - (e) = (f) clearance.
5.3.5 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.
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