Wacker Neuson PTK 4 User manual

Pump
PTS 4V
PTK 4
OPERATOR’S MANUAL
0154628en 005
0107
0154628EN

PTS 4V / PTK 4 Table of Contents
wc_bo0154628en_005TOC.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 ...................................................................................... 7
2.5 Label Locations ................................................................................. 8
2.6 Safety Labels ........................................................................................ 9
3. Technical Data 11
3.1 Engine ................................................................................................ 11
3.2 Pump .................................................................................................. 12
3.3 Sound Measurements ........................................................................ 13
3.4 Dimensions ......................................................................................... 13
4. Operation 14
4.1 Application .......................................................................................... 14
4.2 Recommended Fuel ........................................................................... 14
4.3 Before Starting ................................................................................... 14
4.4 To Start ............................................................................................... 16
4.5 To Stop ............................................................................................... 17
4.6 Operation ............................................................................................ 17
4.7 Pump Wrench ..................................................................................... 17
4.8 Accessories ........................................................................................ 18
4.9 Hoses and Clamps ............................................................................. 18

Table of Contents PTS 4V / PTK 4
wc_bo0154628en_005TOC.fm 2
5. Maintenance 19
5.1 Periodic Maintenance Schedule ..........................................................19
5.2 Engine Lubrication ...............................................................................20
5.3 Changing Oil Filter ...............................................................................21
5.4 Air Cleaner ..........................................................................................22
5.5 Spark Plug ...........................................................................................23
5.6 Fuel Filter ............................................................................................24
5.7 Carburetor Adjustment ........................................................................24
5.8 Mechanical Seal Lubrication ...............................................................25
5.9 Adjusting Impeller Clearance ..............................................................26
5.10 Cleaning Pump ....................................................................................27
5.11 Storage ................................................................................................28
5.12 Lifting ...................................................................................................28
5.13 Troubleshooting ...................................................................................29

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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 2007by 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 PTS 4V / PTK 4
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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 a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, could
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

PTS 4V / PTK 4 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 use accessories or attachments that are not recommended by
Wacker. Damage to equipment and injury to the user may result.
2.2.3 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.
2.2.4 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 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.
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 be sure operator is familiar with proper safety precautions
and operation techniques before using machine.
2.2.10 ALWAYS read, understand, and follow procedures in the Operator’s
Manual before attempting to operate the equipment.
2.2.11 ALWAYS be sure the 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.
WARNING

Safety Information PTS 4V / PTK 4
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2.2.13 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.
2.2.14 ALWAYS wear hearing protection when operating equipment.
2.3 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.
2.3.1 DO NOT run the machine indoors or in an enclosed area such as a
deep trench unless adequate ventilation, through such items as
exhaust fans or hoses, is provided. Exhaust gas from the engine
contains poisonous carbon monoxide gas; exposure to carbon
monoxide can cause loss of consciousness and may lead to death.
2.3.2 DO NOT smoke while operating the machine.
2.3.3 DO NOT smoke when refueling the engine.
2.3.4 DO NOT refuel a hot or running engine.
2.3.5 DO NOT refuel the engine near an open flame.
2.3.6 DO NOT spill fuel when refueling the engine.
2.3.7 DO NOT run the engine near open flames.
2.3.8 ALWAYS refill the fuel tank in a well-ventilated area.
2.3.9 ALWAYS replace the fuel tank cap after refueling.
DANGER

PTS 4V / PTK 4 Safety Information
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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 the 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 the engine is
flooded or the smell of gasoline is present. A stray spark could ignite
the 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 operate machine with all safety devices and guards in place
and in working order. DO NOT modify or defeat safety devices. DO
NOT operate machine if any safety devices or guards are missing or
inoperative.
2.4.6 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.
2.4.7 ALWAYS replace worn or damaged components with spare parts
designed and recommended by Wacker Corporation.
2.4.8 ALWAYS disconnect the spark plug on machines equipped with
gasoline engines, before servicing, to avoid accidental start-up.
2.4.9 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
2.4.10 ALWAYS handle impeller carefully. The impeller can develop sharp
edges which can cut.
WARNING

Safety Information PTS 4V / PTK 4
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2.5 Label Locations
wc_gr001479
PRECAUTION
PRECAUCION
VORSICHT
CAUTION

PTS 4V / PTK 4 Safety Information
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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 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!
Do not open if pump is hot. Hot water and/or
steam inside could be pressurized.
WARNING!
Never pump volatile, flammable or low flash point
fluids. These fluids could ignite or explode.
CAUTION!
Lifting point
PRECAUTION
PRECAUCION
VORSICHT
CAUTION

Safety Information PTS 4V / PTK 4
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Guaranteed sound power level in dB(A)
Key switch:
off
on
start
Throttle control lever:
Rabbit = Full or Fast
Turtle = Idle or Slow
A nameplate listing the model number, item num-
ber, revision number, and serial number is
attached to each unit. Please record the informa-
tion found on this plate so it will be available
should the nameplate become lost or damaged.
When ordering parts or requesting service infor-
mation, 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.
Label Meaning
R e v . S e r i a l N u m b e r
M E N O M O N E E F A L L S , W I U S A 5 3 0 5 1
h pk Wl b
d B ( A ) M a n u f . Y r .
M o d e l
k g
M A D E
I N U S A
I t e m N u m b e r
8 8 2 2 3

PTS 4V / PTK 4 Technical Data
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3. Technical Data
3.1 Engine
Item No. PTS 4V
0007683 Rev 115 & lower
0007691 Rev 116 & lower
0007692
PTS 4V
0007683 Rev 116 & higher
0007691 Rev 117 & higher
Engine
Engine Make Briggs and Stratton
Engine Model Vanguard 303447-
1256-E2
Vanguard 305447-
0144-E1
Rated Power kW (Hp) 12 (16)
Spark Plug Champion RC12YC
Electrode Gap mm (in.) 0.76 (0.030)
Engine Speed rpm 3600
Air Cleaner type Dual element
Battery V/CCA/
amp-hr./size
12 / 230 / 32 / 22NF
Engine Lubrication oil grade /
service class >5°C (40°F) SAE 10W30 / SG, SF, or SE
<5°C (40°F) SAE 30W / SG, SF, or SE
Engine Oil Capacity ml (oz.) 1400 (48)
Fuel type Regular unleaded gasoline
Fuel Tank Capacity l (gal.) 17 (4.5)

Technical Data PTS 4V / PTK 4
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3.2 Pump
Item number: PTS 4V
0007683, 0007691, 0007692
Pump
Weight kg (lbs.) 163 (360)
*Max. Suction Lift m (ft.) 7.5 (25)
Max. Total Head m (ft.) 32 (106)
Mechanical Seal Lubrication oil grade
ml (oz.)
SAE 30
150 (5)
Suction / Discharge Diameter mm (in.) 100 (4)
Max. Solid Size mm (in.) 50 (2)
*Based on pump operating at sea level. Maximum suction lift will be less at higher altitudes.

PTS 4V / PTK 4 Technical Data
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3.3 Sound Measurements
The required sound specifications per Appendix 1, Paragraph 1.7.4 of
the EC-Machine Regulations, is:
• the guaranteed sound power level (LWA) = 104 dB(A)
These sound values were determined according to ISO 3744 for the
sound power (LWA).
The sound measurements were obtained with the unit operating on
pavement at nominal speed.
3.4 Dimensions
mm (in.)
890 (35) 915 (36)
890
(35)
wc_gr001478

Operation PTS 4V / PTK 4
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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.
4.1.1 NEVER pump volatile, flammable or low flash point fluids. These fluids
could ignite or explode.
4.1.2 NEVER pump corrosive chemicals or water containing toxic
substances. These fluids could create serious health and
environmental hazards. Contact local authorities for assistance.
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.
4.3 Before Starting
See Graphic: wc_gr000013
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.
WARNING
WARNING
WARNING

PTS 4V / PTK 4 Operation
wc_tx000339gb.fm 15
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.

Operation PTS 4V / PTK 4
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4.4 To Start
See Graphic: wc_gr001480
Follow the instructions below and read starting and stopping
instuctions found in the engine owner’s manual.
4.4.1 Open the fuel valve (b1).
4.4.2 If the engine is cold, pull out the choke control (a1). If the engine is hot,
push in the choke control (a2).
4.4.3 Move the throttle control to the fast position (c1).
4.4.4 Turn the key switch to the start position (d3) and hold it until the engine
starts.
CAUTION: Do not crank engine longer than 15 seconds at a time.
Extended cranking can damage the starter motor.
4.4.5 To start the engine using manual start:
• Turn the key switch to the run position (d2).
• Rapidly pull the starter rope (e) to start the engine.
• Leave key in run position (d2) while engine is running.
Note: The engine is equipped with a low oil protection system, which
does not allow the engine to start if the oil level is low. This device will
not protect the engine if a low oil level occurs while running. The switch
opens on a pressure rise of 4 psi +/-1.5 psi.
4.4.6 Push the choke in as the engine warms (a2).
4.4.7 Keep the engine throttle in the fast position while operating pump.
wc_gr001480
d1 d2
d3
b2
b1
c1
c2
a1 a2

PTS 4V / PTK 4 Operation
wc_tx000339gb.fm 17
4.5 To Stop
See Graphic: wc_gr001480
4.5.1 Reduce engine RPM by moving the throttle completely to the idle
position (c2).
4.5.2 Turn the engine switch to the stop position (d1).
4.5.3 Close the fuel valve (b2).
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.
4.6.1 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 Pump Wrench
See Graphic: wc_gr001481
The wrench (a) supplied with the pump can be used to loosen and
tighten: hose couplings, knobs on pump cover, priming plug, and drain
plug on front cover.
Store wrench on pump frame.
WARNING
a
wc
g
r001481

Operation PTS 4V / PTK 4
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4.8 Accessories
Wacker offers a complete line of fittings, hoses, and clamps to properly
connect the pump to match various job conditions.
4.9 Hoses and Clamps
See Graphic: wc_gr000021
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.