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Trash Pumps

PT 6LTPT 6LS

REPAIR MANUAL

0163080en 002

0606

0 1 6 3 0 8 0 E N

PT6 Repair Foreword

Operating / Parts InformationYou must be familiar with the operation of this machine before youattempt to troubleshoot or repair it. Basic operating and maintenanceprocedures are described in the Operator’s Manual supplied with themachine. Keep a copy of the Operator’s Manual with the machine at alltimes. Use the separate Parts Book supplied with the machine to orderreplacement parts. If you are missing either of the documents, pleasecontact Wacker Corporation to order a replacement.

Damage caused by misuse or neglect of the unit should be brought tothe attention of the operator to prevent similar occurrences fromhappening in the future.

This manual provides information and procedures to safely repair andmaintain the above Wacker model(s). For your own safety andprotection from injury, carefully read, understand, and observe allinstructions described in this manual. THE INFORMATIONCONTAINED IN THIS MANUAL IS BASED ON MACHINESMANUFACTURED UP TO THE TIME OF PUBLICATION. WACKERCORPORATION RESERVES THE RIGHT TO CHANGE ANYPORTION OF THIS INFORMATION WITHOUT NOTICE.

This manual covers machines with Item Number:0007174, 0007175

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Foreword PT6 Repair

CALIFORNIA

Proposition 65 Warning:

Diesel engine exhaust, some of its constituents, and certain vehiclecomponents contain or emit chemicals known to the State of Californiato cause cancer and birth defects or other reproductive harm.

Laws Pertaining to Spark Arresters

Notice: State Health Safety Codes and Public Resources Codesspecify that in certain locations spark arresters be used on internalcombustion engines that use hydrocarbon fuels. A spark arrester is adevice designed to prevent accidental discharge of sparks or flamesfrom the engine exhaust. Spark arresters are qualified and rated bythe United States Forest Service for this purpose.

In order to comply with local laws regarding spark arresters, consultthe engine distributor or the local Health and Safety Administrator.

All rights, especially copying and distribution rights, are reserved.

Copyright 2006 by Wacker Corporation

No part of this publication may be reproduced in any form or by anymeans, electronic or mechanical, including photocopying, withoutexpress written permission from Wacker Corporation.

Any type of reproduction or distribution not authorized by WackerCorporation represents an infringement of valid copyrights, andviolators will be prosecuted. We expressly reserve the right to maketechnical modifications, even without due notice, which aim atimproving our machines or their safety standards.

WARNING

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PT6 Repair Table of Contents

1. Safety Information 4

1.1 State Regulations Concerning Trailers ................................................. 41.2 Operating Safety .................................................................................. 51.3 Operator Safety While Using Internal Combustion Engines ................. 61.4 Service Safety ...................................................................................... 61.5 Towing Safety ....................................................................................... 71.6 Reporting Trailer Safety Defects .......................................................... 81.7 Label Locations .................................................................................... 91.8 Safety Labels ...................................................................................... 10

2. Technical Data 12

2.1 Engine ................................................................................................ 122.2 Pump .................................................................................................. 132.3 Lubrication .......................................................................................... 132.4 Trailer ................................................................................................. 142.5 Dimensions ......................................................................................... 15

3. Operation 16

3.1 Operation and Service Locations ....................................................... 163.2 Application .......................................................................................... 183.3 Recommended Fuel ........................................................................... 183.4 Before Starting the Engine ................................................................. 183.5 Before Starting the Pump ................................................................... 183.6 To Start ............................................................................................... 203.7 To Stop ............................................................................................... 203.8 Automatic Shutdown System ............................................................. 213.9 Important Operation Note ................................................................... 213.10 Hoses ................................................................................................. 223.11 Hose Couplings .................................................................................. 223.12 Hose Clamps ...................................................................................... 223.13 Strainer ............................................................................................... 233.14 Discharge Port .................................................................................... 233.15 Covers ................................................................................................ 243.16 Hitching and Towing the Trailer .......................................................... 26

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Table of Contents PT6 Repair

4. Maintenance 28

4.1 Engine Fuel Delivery System Maintenance .........................................284.2 Storage ................................................................................................284.3 Periodic Maintenance Schedule ..........................................................294.4 Air Cleaner ..........................................................................................304.5 Fuel Filter ............................................................................................314.6 Priming the Fuel System .....................................................................314.7 Engine Lubrication ...............................................................................324.8 Engine Oil ............................................................................................334.9 Valve Clearances ................................................................................334.10 Fan Belt ...............................................................................................344.11 Pump Housing Mounting Bolts ............................................................354.12 Mechanical Seal Lubrication ...............................................................364.13 Bearing Housing Lubrication ...............................................................374.14 Impeller Clearance ..............................................................................384.15 Cleaning the Engine Cooling Fins .......................................................404.16 Battery .................................................................................................404.17 Lifting the Machine ..............................................................................414.18 Tires ....................................................................................................424.19 Wheels and Lug Nuts ..........................................................................424.20 Tongue Jack ........................................................................................424.21 Safety Chains ......................................................................................434.22 Lights ...................................................................................................444.23 Wiring Diagram — Trailer ....................................................................454.24 Wiring Diagram (0007174 > Rev 119; 0007175 > Rev 122) ...............464.25 Wiring Diagram Components ..............................................................474.26 Wiring Diagram (0007174 < Rev 120; 0007175 < Rev 123) ...............484.27 Wiring Diagram Components ..............................................................494.28 Basic Troubleshooting .........................................................................50

5. Theory and Performance 52

5.1 Evaluating the Pump’s Performance ...................................................525.2 Vacuum Test .......................................................................................54


PT6 Repair Table of Contents

6. Lombardini Engine Troubleshooting 56

6.1 Troubleshooting Flowcharts ............................................................... 566.2 Engine Does Not Crank—Flowchart 1A ............................................. 576.3 Checking Keyswitch and Wiring (0007174 > Rev 119;

0007175 > Rev 122) ........................................................................... 586.4 Checking Keyswitch and Wiring (0007174 < Rev 120;

0007175 < Rev 123) ........................................................................... 606.5 Replacing the Keyswitch .................................................................... 626.6 Engine Cranks But Does Not Start—Flowchart 1B ............................ 636.7 Checking the Throttle Solenoid .......................................................... 646.8 Checking the Auto Shutdown Circuit .................................................. 656.9 Checking Voltage to Glow Plug .......................................................... 676.10 Checking Glow Plug Relay ................................................................. 686.11 Replacing Glow Plug Relay ................................................................ 686.12 Checking Glow Plug ........................................................................... 696.13 Engine Shuts Down—Flowchart 1C ................................................... 706.14 Checking Oil Pressure and Coolant Temperature Switches .............. 716.15 General Engine Troubleshooting ........................................................ 72

7. Disassembly/Assembly Procedures 75

7.1 Tools ................................................................................................... 757.2 Ordering Parts .................................................................................... 757.3 Reference Numbers ( ) ....................................................................... 757.4 Weight Block ...................................................................................... 757.5 Replacing the Flapper Valve .............................................................. 767.6 Replacing the Impeller ........................................................................ 787.7 Replacing the Mechanical Seal .......................................................... 807.8 Removing the Pump and Bearing Housing ........................................ 827.9 Installing the Pump and Bearing Housing .......................................... 847.10 Replacing the Flex Coupling and Mounting Flange ............................ 867.11 Bearing Housing ................................................................................. 887.12 Bearing Housing Components ........................................................... 897.13 Bearing Housing Disassembly ........................................................... 907.14 Bearing Housing Assembly ................................................................ 927.15 Installing End Cap and Seal Housing ................................................. 94


Safety Information PT 6 /...

1. Safety Information

This manual contains DANGER, WARNING, CAUTION, and NOTEcallouts which must be followed to reduce the possibility of personalinjury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potentialpersonal injury hazards. Obey all safety messages that follow thissymbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, willresult in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, couldresult in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, couldresult in minor or moderate injury.

CAUTION: Used without the safety alert symbol, CAUTION indicatesa potentially hazardous situation which, if not avoided, may result inproperty damage.

Note: Contains additional information important to a procedure.

1.1 State Regulations Concerning Trailers

Trailer laws covering such things as brakes, lights, safety chains, etc.,will vary from state to state. Make certain that your trailer is incompliance with the regulations of the state in which the trailer will beused. If you are not sure what these regulations are, contact the statemotor vehicle department for information.

In some states, trailers must be registered and licensed by the StateDepartment of Transportation. Before towing, be sure to checklicensing requirements.

DANGER

WARNING

CAUTION

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PT 6 /... Safety Information

1.2 Operating Safety

Familiarity and proper training are required for the safe operation ofequipment. Equipment operated improperly or by untrained personnelcan be dangerous. Read the operating instructions contained in boththis manual and the engine manual and familiarize yourself with thelocation and proper use of all controls. Inexperienced operators shouldreceive instruction from someone familiar with the equipment beforebeing allowed to operate the machine.

1.2.1 NEVER allow anyone to operate this equipment without propertraining. People operating this equipment must be familiar with therisks and hazards associated with it.

1.2.2 NEVER touch the engine or muffler while the engine is on orimmediately after it has been turned off. These areas get hot and maycause burns.

1.2.3 NEVER use accessories or attachments that are not recommended byWacker. Damage to equipment and injury to the user may result.

1.2.4 NEVER leave machine running unattended.

1.2.5 NEVER operate this machine in applications for which it is notintended.

1.2.6 NEVER open the priming plug when the pump is hot. Never loosen orremove inlet or discharge hose fittings when the pump is hot. Hot waterinside could be pressurized much like the radiator on an automobile.Allow the pump to cool to the touch before loosening the plug andbefore loosening or removing the inlet or discharge hose fittings.

1.2.7 NEVER position the pump on a loose, uneven, or unstable surfacewhere it can tip, roll, slide or fall! The pump must be secure beforeoperating. Position the pump on a firm, flat surface; adjust the trailerjacks to be sure the pump is level and supported firmly.

1.2.8 NEVER open the pump housing cover while the pump is operating orstart the pump with the cover off. The rotating impeller inside the pumpcan cut or sever objects caught in it.

1.2.9 NEVER block or restrict flow from the inlet line or the discharge line.Remove kinks from the discharge line before starting the pump.Operation with a blocked inlet line or discharge line can cause waterinside the pump to overheat.

1.2.10 NEVER reach into or insert anything into the pump while the engine ison! The impeller inside the pump housing is turning at all times whilethe engine is running.

1.2.11 DO NOT allow anyone to stand in front of the discharge port whenstarting the engine or while priming the pump! The sudden out-rush ofwater could push or knock a person down.

WARNING

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1.2.12 ALWAYS make sure the hose connections on the pump are tight. A
loose connection could cause water to spray or result in a hose fallingoff the pump while it is in operation.

1.2.13 ALWAYS make sure the water stream from the pump discharge is notdirected in such a way so as to cause erosion to the surroundingground or damage or weakening of nearby structures!

1.3 Operator Safety While Using Internal Combustion Engines1.3.1 DO NOT run the machine indoors or in an enclosed area such as a

deep trench unless adequate ventilation, through such items asexhaust fans or hoses, is provided. Exhaust gas from the enginecontains poisonous carbon monoxide gas; exposure to carbonmonoxide can cause loss of consciousness and may lead to death.

1.3.2 DO NOT smoke while operating the machine.

1.3.3 DO NOT smoke when refueling the engine.

1.3.4 DO NOT refuel a hot or running engine.

1.3.5 DO NOT refuel the engine near an open flame.

1.3.6 ALWAYS refill the fuel tank in a well-ventilated area.

1.3.7 ALWAYS replace the fuel tank cap after refueling.

1.3.8 ALWAYS check the fuel lines and the fuel tank for leaks and cracksbefore starting the engine. Do not run the machine if fuel leaks arepresent or the fuel lines are loose.

1.3.9 ALWAYS keep the area around a hot exhaust pipe free of debris toreduce the chance of an accidental fire.

1.4 Service Safety

Poorly maintained equipment can become a safety hazard! In orderfor the equipment to operate safely and properly over a long period oftime, periodic maintenance and occasional repairs are necessary.

1.4.1 DO NOT attempt to clean or service the machine while it is running.Rotating parts can cause severe injury.

1.4.2 DO NOT use gasoline or other types of fuels or flammable solvents toclean parts, especially in enclosed areas. Fumes from fuels andsolvents can become explosive.

1.4.3 DO NOT attempt to clean or service the machine while it is running.

1.4.4 DO NOT operate the machine without an air cleaner.

1.4.5 ALWAYS replace worn or damaged components with spare partsdesigned and recommended by Wacker Corporation.

WARNING

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1.4.6 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operatinginstructions and warn of dangers and hazards.

1.4.7 ALWAYS replace the safety devices and guards after repairs andmaintenance.

1.4.8 ALWAYS check all external fasteners at regular intervals.

1.4.9 ALWAYS remain aware of moving parts and keep hands, feet, andloose clothing away from the moving parts of the equipment.

1.5 Towing Safety

Towing a large trailer requires special care. Both the trailer and vehiclemust be in good condition and securely fastened to each other toreduce the possibility of an accident.

1.5.1 ALWAYS check that the hitch and coupling on the vehicle are ratedequal to, or greater than, the trailer's “gross vehicle weight rating”(GVWR).

1.5.2 ALWAYS inspect the hitch and coupling for wear or damage. DO NOTtow the trailer using defective parts.

1.5.3 ALWAYS make sure the coupling is securely fastened to the vehicle.

1.5.4 ALWAYS check the tires on the trailer for tread wear, inflation, andcondition. Replace worn tires.

1.5.5 ALWAYS connect the safety chains.

1.5.6 ALWAYS connect the breakaway cable safety hook to the bumper orrear of the vehicle. DO NOT attach it to the hitch.

1.5.7 ALWAYS test the surge brakes on the trailer and the brakes on thevehicle that will be used for towing.

1.5.8 ALWAYS make sure directional and trailer lights are connected andworking properly.

1.5.9 ALWAYS check that the lug nuts holding the wheels are tight and thatnone are missing.

WARNING

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1.6 Reporting Trailer Safety Defects

If you believe your trailer has a defect which could cause a crash orcould cause injury or death, you should immediately inform theNational Highway Traffic Safety Administration (NHTSA) in addition tonotifying Wacker Corporation.

If NHTSA receives similar complaints, it may open an investigation;and if it finds that a safety defect exists in a group of vehicles, it mayorder a recall and remedy campaign. However, NHTSA cannotbecome involved in individual problems between you, your dealer, orWacker Corporation.

To contact NHTSA, you may either contact the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0129 in Washington DC area),www.nhtsa.com, or write to NHTSA, U.S. Department ofTransportation, 400 7th Street SW, (NSA-11), Washington, DC 20590.You can also obtain other information about motor vehicle safety fromthe Auto Safety Hotline.

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1.7 Label Locations

wc_gr001145

13

7

6

3

8 109

5

6

4

12

11

2

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1.8 Safety Labels

Ref. Label Meaning

1

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.

2

CAUTION! Use only clean, filtered diesel fuel.

3

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.

4

CAUTION! Lifting point

5

WARNING! Hot surface!

6

WARNING! Pressurized contents. Do not open when hot!

7

WARNING! Never pump volatile, flammable or low flash point fluids. These fluids could ignite or explode.

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8

9

10

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 plate so it will be available should the nameplate become lost or dam-aged. When ordering parts or request-ing service information, you will always be asked to specify the model number, item number, revision number, and serial number of the unit.

11

12

CAUTION!Engine overheat - Check fan belt.

This machine may be covered by one or more patents.

Ref. Label Meaning

INSTRUCTIONS DE REMORQUAGETOWING INSTRUCTIONS ABSCHLEPPINSTRUKTIONEN INSTRUCCIONES DE REMOLQUE1. READ OPERATOR'S MANUAL.2. USE HITCH RATED FRO TRAILER'S "GROSS VEHICLE WEIGHT RATING".3. SECURELY ATTACH TRAILER TO TOW VEHICLE.4. ATTACH SAFETY CHAINS USING CROSS PATTERN.5. ATTACH BREAKDOWN CHAIN TO VEHICLE.6. CHECK TRAILER LIGHTS.

1. BETRIEBSVORSCHRIFT LESEN.2. ANHANGEVORRICHTUNG VERWENDEN, DIE DER GESAMTBETRIEBSGEWICHTSKLASSE ENTSPRICHT.3. ANHANGER SICHER AM ZUGFAHRZEUG BEFESTIGEN.4. SICHERHEITSKETTEN KREUZWEISE ANBRINGEN.5. ABREISSKETTE AM FAHRZEUG ANBRINGEN.6. ANHANGERLEUCHTEN PRUFEN.

1. LEA EL MANUAL DEL OPERARIO.2. UTILICE UN ACOPLE CORRECTAMENTE CLASIFICADO PARA LA "CLASE DE PESO BUTO" DEL VEHICULO DEL REMOLQUE.3. ASEGURESE DE AMARRAR CORRECTAMENTE EL REMOLQUE AL VEHICULO DE REMOLQUE.4. FIJE EN CRUZ LAS CADENAS DE SEGURIDAD.5. FIJE EN EL VEHICULO DE REMOLQUE LA CADENA DE DESPRENDIMIENTO.6. CONTROLE LAS LUCES DEL REMOLQUE.

1. LIRE LA NOTICE D'EMPLOI.2. UTILISER UN GROCHET D'ATTELAGE CONFORME AU DEBIT NOMINAL DU POIDS BRUT DE VEHICULE DU TRACTEUR.3. ATTACHER LA REMORQUE FERMEMENT AU VEHICULE TRACTEUR.4. ATTACHER LES CHAINES DE SURETTE EN UTILISANT UNE METHODE CROISEE.5. ATTACHER LA CHAINE DE REMORQUAGE AU VEHICULE.6. VERIFIER LES LAMPES DE LA REMORQUE.

1148

94

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Technical Data PT 6 /...

2. Technical Data

2.1 Engine

Item No. PT 6LT0007175

PT 6LS0007174

Engine

Engine type Three cylinder, 4-cycle air cooled, diesel engine

Engine make Lombardini

Engine model 11LD625-3

Rated power kW (Hp) 22 (30)

Alternator Amp 14

Engine speed - full load rpm 2500 ± 100

Engine speed - idle rpm 1500 ± 100

Valve clearance (cold) intake: exhaust:

mm (in.) 0.15 (0.006)0.20 (0.007)

Air cleaner type Oil Bath(Do not use oil lighter than 20W)

Battery V / size 12V / 31

Fuel type No. 2 Diesel

Fuel tank capacity l (gal.) 98 (26)

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PT 6 /... Technical Data

2.2 Pump

2.3 Lubrication


PT 6LS0007174

Pump

Weight kg (lbs.) 1090 (2400) 850 (1870)

Max. suction lift m (ft.) 7.5 (25)

Max. total head m (ft.) 30.5 (100)

Max. discharge m³/h (gpm) 295 (1300)

Suction / discharge dia. mm (in.) 150 (6)

Max. solid size mm (in.) 50 (2)


PT 6LS0007174

Lubrication

Engine type / qty. SAE 15W40 CD Rated / 5.0 L (5 qts.)

Pump seal housing type / qty. SAE 15W40 / 800ml (27oz.)

Pump bearing housing type / qty. SAE 15W40 / 470ml (16oz.)

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Technical Data PT 6 /...

2.4 Trailer


Trailer

Power take-off type Direct Drive with Flex-Coupling

Trailer tounge weight kg (lbs) 75 (165)

Gross vehicle weight Rating kg (lbs) 1588 (3500)

Tire size 205 / 75D-14

Tire load Rating C

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PT 6 /... Technical Data

2.5 Dimensions

wc_gr001154

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Operation PT 6 /...

3. Operation

3.1 Operation and Service Locations

See Graphic: wc_gr003183

Ref. Description Ref. Description

1 Engine oil dipstick 14 Engine oil filter

2 Fuel filter 15 Battery box

3 Manual fuel pump lever 16 Trailer hitch

4 Engine oil drain plug 17 Jack stand

5 Engine throttle solenoid 18 Rear stabilizers

6 Control panel 19 Drain cover

7 Ignition switch 20 Front impeller cover

8 Hour meter 21 Suction port

9 Bearing/Seal housing 22 Priming cover

10 Lifting point 23 Discharge port

11 Engine oil fill cap 24 Fuel fill cap

12 Inspection cover 25 License plate holder

13 Air cleaner 26 Circuit breaker

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PT 6 /... Operation

wc_gr003183

18

17

15

16

7

8

9

6

26

23

22

21

20

19

25

12

11

13

10

14

24

1

2

45

3

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Operation PT 6 /...

3.2 Application

The PT6 is a self-priming, high performance trash pump designed tohandle water and solids up to 50.8 mm (2.0 in). It is built for thedemands of construction, mining, municipality, farm and marineapplications.

3.3 Recommended Fuel

The engine requires No. 2 diesel fuel. Use only fresh, clean fuel. Fuelcontaining water or dirt will damage the fuel system. Consult theengine owner’s manual for complete fuel specifications.

3.4 Before Starting the Engine

3.4.1 Read and understand the safety and operating instructions at thebeginning of this manual.

3.4.2 Check:

• The oil level in the engine

• The fuel level

• The condition of the air cleaner

• The tightness of the external fasteners

• The condition of the fuel lines

CAUTION: DO NOT run the engine without oil in the oil-bath aircleaner or severe engine damage will result.

3.5 Before Starting the Pump


3.5.1 Check the bearing/seal housing (f) for proper oil level. Also check theoil for water contamination. Do not operate the pump if contaminationis found.

3.5.2 Position the pump as near to the water as possible, on a firm, flatsurface. Keep the pump level.

3.5.3 Lower the rear stabilizers (a) until they contact the ground. Lock thestabilizers in position with the pins.

3.5.4 Crank down the jack stand (b) on the front of the trailer. Block bothwheels to keep the pump from rolling during operation.

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PT 6 /... Operation
3.5.5 If necessary, rotate the discharge elbow to direct water flow in the
desired direction.

3.5.6 Attach the suction hose to the suction port (d). Attach the dischargehoses to the discharge port (e). Check and tighten the clamps andcoupling to make sure the hoses are securely fastened.

A loose connection can create a serious safety hazard should it breakloose while the pump is running.

3.5.7 Attach the suction strainer to the suction hose to prevent large debrisfrom being pulled into the pump.

3.5.8 Prime the pump. To do so, open the cover (c) at the top of the pumpand fill the pump housing with water. The pump will not prime unlessthis is done.

WARNING

wc_gr001165

a

b

fc

d

e

g

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Operation PT 6 /...

3.6 To Start


3.6.1 Loosen the throttle lever knob (c) and set the engine throttle (d) to highspeed. Tighten the throttle lever knob.

3.6.2 Open the cover on the battery box (a) and turn and hold the ignition key(b) to the ON position until the glow plug light on the control panel goesout. Then, turn the ignition key to the START position. Release the keyafter the engine starts. It will spring back into the ON position.

Note: The engine will not start if the oil pressure is too low or thecylinder head temperature exceeds the preset value.

The pump should prime and begin pumping within a minute or two. Athigh suction lifts or low engine speeds, the pump will require a longerperiod of time to prime. If the pump does not prime, shut off the engineand refer to the section on troubleshooting.

CAUTION: DO NOT crank the starter for more than 15–20 seconds ata time; the starter motor can overheat and be damaged.

CAUTION: DO NOT run the pump dry for long periods of time or runthe pump without oil in the bearing/seal housing. The mechanical sealcould overheat and be damaged.

Adjusting Pump Flow:

Pump flow can be set by adjusting the speed of the engine.

3.6.1 To set the engine speed, loosen the throttle lever knob (c) and adjustthe throttle lever (d).

3.6.2 Tighten the throttle lever knob to hold the throttle lever in place whilethe pump is operating. When priming the pump, set the throttle lever atfull speed until the pump flow begins; then, adjust the throttle lever tothe desired speed.

3.7 To Stop


3.7.1 Turn ignition key (b) to OFF.

CAUTION: If temperatures are expected to fall below freezing duringthe night, be sure to drain the pump housing (e) while the pump is notin use.

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PT 6 /... Operation

3.8 Automatic Shutdown System

The engine is equipped with an automatic shutdown system to protectit from damage should a low oil pressure or a high cylinder temperaturecondition occur.

During a low-oil-pressure condition, the low-oil-pressure switch openscutting power to the throttle solenoid. During a high-cylinder-temperature condition, the engine temperature switch shorts toground. This trips the circuit breaker and cuts power to the throttlesolenoid. Whenever power is cut to the throttle solenoid, it de-energizes. When the throttle solenoid is de-energized, the enginestops.

If the engine stops unexpectedly and the circuit breaker trips, it is asign of a problem with the fan belt. Check the fan belt and replace it ifnecessary. Reset the circuit breaker before resuming use of the pump.

If the engine stops unexpectedly without the circuit breaker tripping,check the amount of oil in the engine crankcase. Fill the enginecrankcase with oil as needed.

3.9 Important Operation Note

CAUTION: DO NOT run the pump in less than 1.2 m (4.0 ft.) of water!At this level the water begins to form a funnel down to the bottom of thesuction line and strainer, allowing the pump to draw in air. The mixtureof air and water leads to a condition known as cavitation, which willquickly destroy the impeller and the water chamber inside the pumphousing

wc_gr001166

a

b

d

c

e

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Operation PT 6 /...

3.10 Hoses

Suction hoses must be rigid enough not to collapse. Make sure thesuction hose is in good condition. A hole or tear in the suction hoseabove the water line will prevent the pump from priming.

CAUTION: Always use a strainer on the end of the suction hose toprevent pulling in large debris which could clog the pump or jam theimpeller.

Discharge hoses are usually thin-walled collapsible hoses; however,rigid hoses like those used on the suction side can also be used.

Lay the discharge hose as straight as possible. Avoid sharp bends andturns.

Note: Both suction and discharge hoses are available through WackerCorporation.

3.11 Hose Couplings

A variety of couplings are available to attach the hoses to the suctionand discharge ports as well as to connect two hose lengths together.

3.12 Hose Clamps

Suction Hose to Inlet Port Coupling

At least two T-bolt clamps are recommended for connection of thesuction hose to the pump inlet. Index clamps at 90° intervals for bestseal. Add additional clamps if the pump has trouble priming.

Note: The smallest air leak on the suction side of the pump will preventthe pump from priming.

Other hose connections

Normally only one T-bolt or worm gear clamp is required to hold thehoses in place. In some cases, variances in hose diameters may makeit necessary to add extra clamps to maintain a reliable connection.

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PT 6 /... Operation

3.13 Strainer

CAUTION: DO NOT use a strainer with holes larger than the maximumsolid-size rating of the pump—50 mm (2 in.). DO NOT place thestrainer directly into mud or sand. Always keep the strainer suspendedin the liquid being pumped. Failure to follow the above directives maycause pump damage.

3.14 Discharge Port


The discharge port (a) can be rotated 360° to direct water flow in anydirection.

To rotate the elbow:

3.14.1 Remove the locknuts (b) which hold the port to the pump housing.

3.14.2 Lift the port off the studs and position it as desired. Always check thegasket and replace it if it is damaged.

3.14.3 Tighten the locknuts evenly. Torque them to 160 Nm (118 ft. lbs).

wc_gr001184

a

b

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Operation PT 6 /...

3.15 Covers


DO NOT open the covers or reach into the pump while the engine isrunning! The spinning impeller could cause a severe injury.

DO NOT run the pump with any of the covers open or missing.

Drain/Priming Cover:

Clean-out covers are located on the top (a) and bottom (b) of thepump. The top cover is also used to add water to the pump housing forpriming. To open a cover, loosen the knob and swing the cover to theside.

Grease the rubber gasket under each cover occasionally to prevent itfrom sticking to the metal and tearing.

Impeller Cover:

The impeller cover (c) can be removed to clean the pump, set theimpeller clearance, and inspect the pump interior.

To remove the impeller cover and elbow:

3.15.1 Turn the inner star wheel (d) in until it is seated tightly against theimpeller cover.

3.15.2 Turn the outer star wheel (e) in until the cover is pulled out of thehousing.

3.15.3 When the impeller cover is free of the housing, rotate the clamp (f)counterclockwise and pull the impeller cover from the housing.

To install the impeller:

3.15.4 Place the impeller cover assembly into the housing with the arrow onthe casting pointing up. Rotate the clamp (f) into position.

3.15.5 Turn the outer star wheel out until it is seated against the end of thethreaded shaft (g).

3.15.6 Turn the inner star wheel out to push the impeller cover into thehousing. Hand tighten the inner star only!

3.15.7 After the impeller cover is installed, turn in the outer wheel to push theclamp down over the impeller cover and secure it in place.

WARNING

wc_tx000261gb.fm 24

PT 6 /... Operation

wc_gr003210

3

1

2

e

g

31

2

d

a

b

c

f

wc_tx000261gb.fm 25

Operation PT 6 /...

3.16 Hitching and Towing the Trailer


Before hitching and towing the trailer, check the following:

• Check that the vehicle, towing hitch, and coupler have a rating equal to or greater than the trailer's Gross Vehicle Weight Rating (GVWR). See Technical Data for trailer weight.

• Check tread wear and inflation of the trailer’s tires. Make sure all the lug nuts are in place and tight.

• Make sure that the trailer coupler and towing vehicle’s hitch are compatible. The trailer is equipped with either a pintle-style cou-pler or a 2" or 2-5/16" ball coupler.

• Check the condition of the trailer’s coupler and the hitch on the towing vehicle. DO NOT tow the trailer if the coupler or the hitch are damaged.

• Check that the coupler and the hitch ball are clean; then, apply a film of grease to the coupler and the hitch ball. A film of grease will extend the coupler and ball life and eliminate squeaking.

• Check that all the pins and bolts on the tongue are secure.

To hitch the trailer:

3.16.1 Back your vehicle as close as possible to the trailer. It is easier andsafer to back the tow vehicle under the trailer than to pull the trailer tothe vehicle.

3.16.2 Check that the coupler locking device (h) is released.

3.16.3 Raise the trailer coupler using the tongue jack (d) to a height just abovethe ball on the hitch. Carefully position the vehicle so the ball on thehitch is under the coupler. Lower the jack until the coupler is all the waydown over the ball.

3.16.4 Check under the coupling to be sure that the ball clamp is below theball and not riding on top of it.

3.16.5 Clamp the coupler to the hitch ball. To be sure it is clamped andsecurely in place, raise up on the trailer tongue. If it comes loose fromthe ball, release the ball clamp and repeat step 3.

3.16.6 After the trailer is hitched to the towing vehicle, lock the rear stabilizers(k) and the tongue jack (d) in the UP positions.

3.16.7 Make sure the wiring harness (g) is connected to the vehicle and thatthe tail, stop, and turn lights (e) and side marker lights (f) work.

3.16.8 Connect the safety chains (c) in a crossing pattern under the trailertongue.

wc_tx000261gb.fm 26

PT 6 /... Operation

When towing, maintain extra space between the vehicles and avoidsoft shoulders, curbs, and sudden lane changes. If you have not pulledthe trailer before, practice turning, stopping, and backing up in an areaaway from traffic.

DO NOT exceed 55 mph when towing the trailer.

In most states, large trailers must be registered and licensed by theState Department of Transportation. Before towing, be sure to checklicensing requirements.

3.16.9 Always refer to the applicable Department of Transportationregulations before towing.

CAUTION

WARNING

wc_gr003185

h

dc

fg

k

e

wc_tx000261gb.fm 27

Maintenance PT 6 /...

4. Maintenance

4.1 Engine Fuel Delivery System Maintenance

Maintenance to the engine fuel delivery system should be performedby an experienced mechanic familiar with diesel engines. For detailedmaintenance procedures on the engine fuel system, refer to the enginemanual supplied with the machine at the time of shipment.

4.2 Storage

If storing the machine longer than 30 days the following steps arerecommended.

4.2.1 Flush the pump and hose lines by pumping clean water for a fewminutes. If the pump was used for pumping salt water, be sure to usefresh water when flushing it.

4.2.2 Change the engine oil.

4.2.3 Drain and clean the fuel tank. Replace the fuel filter.

4.2.4 Thoroughly clean the exterior of the pump and engine. Visually inspectthe machine for signs of damage or loose bolts.

4.2.5 Remove the covers and clean the pump interior. Wipe or spray allinterior surfaces with a rust-inhibiting oil.

4.2.6 Change the oil in the seal and bearing housings.

4.2.7 Replace the covers. Seal the suction and discharge openings withtape.

4.2.8 Remove the battery from the machine and store it in a clean dry area.Charge the battery once a month to maintain condition of theelectrolyte.

4.2.9 Store the machine indoors in a clean, dry area. If the machine must bestored outside, wrap it tightly.

wc_tx000567gb.fm 28

PT 6 /... Maintenance

4.3 Periodic Maintenance Schedule

The chart below lists basic engine maintenance. Refer to the enginemanufacturer’s Operation Manual for additional information on enginemaintenance.

* Change more often in dusty conditions. Refer to engine manufacturer’s manual.

Lombardini 11LD625-3 Engine Dailybefore

starting

Every125hrs.

Every250hrs.

Every500 hrs.

Check engine oil. Fill to correct level. •

Clean air cleaner. •

Check condition and tension on fan belt. •

Change oil in engine crankcase.* •

Change engine oil filter. •

Change fuel filter •

Clean engine cooling fins. •

Check valve clearance. •

Tighten fittings and clean injectors •

Replace fan belt. •

Machine Dailybefore

starting

Every100hrs.

Every250 hrs.

Every500hrs.

Check and tighten external hardware. •

Open pump housing cover and remove any debris from inside of pump housing.

•

Check oil level in seal housing. Fill to cor-rect level.

•

Check bearing/seal housing for oil or water leaks.

•

Check oil level in bearing housing. •

Drain water from water separator in fuel line. •

Change oil in seal housing. •

Change oil in bearing housing. •

Check coupling bolt tightness. •

wc_tx000567gb.fm 29


4.4 Air Cleaner


Inspect the air cleaner and change the oil in the oil bath daily beforestarting the engine. In dusty conditions, check the condition of the oilin the air cleaner several times during the day. Change the oil if itappears thick or gritty. Clean the air cleaner often.

Keep the oil bowl filled with clean oil up to level mark (a).

CAUTION: NEVER run the engine without oil in the air cleaner! Severeengine damage will result.

To clean the air cleaner:

4.4.1 Release the snap clips (b) and remove the oil bowl (c).

4.4.2 Remove the filter element (d) from the oil bowl. Be careful not todamage the rubber seal ring (e) on the element.

4.4.3 Rinse the filter element with diesel fuel or kerosene. DO NOT usegasoline. Allow the filter element to air dry completely.

4.4.4 Change the oil in the oil bowl. Fill the oil bowl to the level mark (a).Place the filter element in the oil bowl and install the oil bowl on air thecleaner.

Oil

wc_gr003175

a

c e

d

b

wc_tx000567gb.fm 30


4.5 Fuel Filter


Change the engine fuel filter every 250 hours of operation.

4.5.1 Remove the filter (a) from the engine block.

4.5.2 Install a new filter. If necessary, prime the fuel lines as described in thenext section.

4.6 Priming the Fuel System


If the fuel tank has been run completely dry, it will be necessary toprime the fuel system.

To prime fuel system:

4.6.1 Remove the small plug from the top of the water separator and prefillthe element with clean diesel fuel.

4.6.2 Loosen the bleed screw (a) on the fuel filter and pump the manual leveron the fuel pump (b) until fuel flows freely from the screw hole. Tightenthe bleed screw.

4.6.3 Loosen the bleed screw (c), starting with the injector closest to the fuelfilter, and manually pump until fuel flows freely from the screw hole.Tighten the bleed screw. Repeat for each injector.

wc_gr001188

a

wc_gr003175

ac c

c

b

wc_tx000567gb.fm 31


4.7 Engine Lubrication

See Graphic: wc_gr000057 & wc_gr001187

Check the engine oil level daily. Add oil as required.

To check oil:

Place the machine on a level surface, remove the dipstick and checkthat the oil level is at the top mark. Add oil through the oil filler cap (a)on top of engine, checking occasionally with dipstick; DO NOT overfill.

Suggested oil grades:

Use only diesel engine oil API service rating CD or equivalent.

ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATUREAmbient Temperature

(Multi-grade)

-25ºC(-13ºF)

-15ºC(5ºF)

-20ºC(-4ºF)

15ºC(59ºF)

30ºC(86ºF)

0ºC(32ºF)

SAE 10W-30

SAE 15W-40, 20W-40

SAE 5W-20

wc_gr000057

wc_gr001187

b ca

wc_tx000567gb.fm 32


4.8 Engine Oil


Change the oil and oil filter (b) every 250 hours. On new machines,change the oil after the first 50 hours of operation. Drain the oil whilethe engine is still warm.

4.8.1 Remove the oil drain plug (c) to the drain oil.

Note: In the interests of environmental protection, place plasticsheeting and a container under the machine to collect the liquid whichdrains off. Dispose of this liquid properly.

4.8.2 Install the drain plug.

4.8.3 Remove the oil filler cap (a) and fill the engine crankcase with therecommended oil.

Oil Capacity: 5 liters (5 qts.) SAE15W40, CD rated

4.8.4 Install the oil filler cap.

4.9 Valve Clearances


Check and adjust the valve clearance every 500 hours.

Set the clearance when the engine is cold.

4.9.1 Remove the rocker arm cover and check the gaskets for breakage.

4.9.2 Bring each cylinder piston to top dead center on the compressionstroke and set the clearance.

Valve clearance: 0.20 mm (0.008 in.).

4.9.3 Replace the rocker arm cover and tighten bolts to 19 Nm (14 ft.lbs.).

wc_gr000476

wc_tx000567gb.fm 33


4.10 Fan Belt


Check the tension on the fan belt every 125 hours. Replace the fan beltevery 500 hours.

4.10.1 Remove the belt guard (a) and check the fan belt (b) for cracks orsplitting.

4.10.2 To tighten the fan belt, add or remove spacers (c) located between thefan pulley halves (d). Spacers are 0.5, 1.0, 2.0 mm (0.017, 0.034,0.068 in.) thick.

4.10.3 To check fan belt tension, press the fan belt halfway between beltpulleys with a 10 kg (22 lb.) load or strong thumb pressure. The fan beltshould deflect 1 cm (3/8 in.).

wc_gr001190

a

b

dc

wc_tx000567gb.fm 34


4.11 Pump Housing Mounting Bolts


Tighten the mounting bolts (a) on the pump housing after the first 50hours of operation. Inspect the bolts periodically thereafter and tightenwhen required. Torque the bolts to 330 Nm (243 ft. lbs.).

wc_gr003178

a

wc_tx000567gb.fm 35


4.12 Mechanical Seal Lubrication


Check the oil in the seal housing daily before starting the pump. Checkits level and check it for signs of water contamination. If watercontamination is found, change the oil immediately. Otherwise,change the oil every 100 hours of pump operation.

Note: It is normal for some water to pass through the mechanical seal;however, if water contamination is heavy and oil feels watered down,inspect the mechanical seal for signs of wear or damage.

To check the oil level:

4.12.1 Remove the plastic fill plug (a) from the top of the bearing housing. Theoil level should touch the base of the plug opening. Add oil as required.

To change the oil:

4.12.2 Remove the drain plug (c) from the bottom of the bearing housing.

4.12.3 Replace the drain plug and add oil (approximately 800 ml (27 oz.)15W40) through the port (a) on top of the bearing housing until the oillevel is at the base of the fill plug opening.

wc_gr003179

cd

a

b

wc_tx000567gb.fm 36


4.13 Bearing Housing Lubrication


Check oil level in housing daily before starting. Add oil as required.Change oil every 300 hours.

To check oil level:

4.13.1 Remove plastic fill plug (b) from top of bearing housing. Oil levelshould be near center of drive shaft. Add oil as required.

To change oil:

4.13.1 Remove plug (d) from bottom of bearing housing.

4.13.2 Replace drain plug and add 470 ml (16 oz.) of 15W40 oil through port(b) on top of bearing housing. DO NOT overfill housing.

Inspect drained oil. If oil is dirty or feels watered down, inspect pumpand bearing housing seals.

wc_tx000567gb.fm 37


4.14 Impeller Clearance


Sand, dirt, and debris will cause the impeller to wear. If the pump’sperformance drops over time, check and adjust the clearance betweenthe impeller and the insert.

4.14.1 Shut down the machine.

DO NOT reach into or insert anything into the pump while the engineis running!

DO NOT run the pump with the impeller cover removed.

4.14.2 Open the bottom drain cover and drain the pump.

4.14.3 Remove the suction flange (a) and the flapper gasket (b) from the frontof the pump.

Impeller edges can become extremely sharp; use care when workingon the pump to reduce the risk of being cut.

4.14.4 Clean the impeller (d) with a 50-50 mixture of bleach and water beforeworking on it.

4.14.5 Reach inside the pump through the suction port, and use a feelergauge (c) to check the gap between the impeller and the insert (e). Thepump will operate most efficiently when the gap is maintained between0.15–0.75 mm (0.005–.025 in.). Larger gaps are allowable but mayreduce pump output slightly.

4.14.6 If necessary, add shims (f) between the insert and the impeller cover(g) to decrease the gap between the impeller and the insert. The insertis attached to the back side of the impeller cover. To add shims:

• Remove the impeller cover.

• Remove the screws that secure the insert to the impeller cover.

• Add shims as required and recheck the clearance gap.

• After the proper shimming has been determined, use a high-strength threadlocking compound on the screws and secure the shims and insert to the impeller cover. Torque the screws to 26 Nm (19 ft.lbs.).

4.14.7 Reinstall the suction flange and the flapper gasket.

WARNING

CAUTION

wc_tx000567gb.fm 38


wc_gr003206

a

bg

c

d

d

e

e f g

g

e

f

g

0.15–0.75 mm(0.005–0.025 in.)

wc_tx000567gb.fm 39


4.15 Cleaning the Engine Cooling Fins


The engine is air-cooled and depends on the cylinder cooling fins todissipate heat. In dusty conditions the cooling fins may becomeclogged or covered with dust, reducing engine cooling.

Remove the engine cover and inspect the engine cooling fins every100 hours.

Remove dirt build-up using a brush and diesel fuel or kerosene. Drythe engine using compressed air. Replace the inspection cover beforestarting the engine.

4.16 Battery


The battery (a) supplied on this machine is a heavy-duty, lead acidbattery, rated at 12V, 160 Ah, BCI group 31. Check the level of theelectrolyte in the battery periodically and add distilled water as requiredto keep the electrolyte at the correct level.

Keep the battery terminals clean and tighten them as required.

In cold weather, diesel engines must crank at a fairly high speed.Maintain your battery at full charge and use a replacement battery withthe highest cold-cranking amperage available to improve your coldweather starting capabilities.

wc_gr003177

a

wc_tx000567gb.fm 40


4.17 Lifting the Machine


Attach a sling or chain to the lifting eye (a) using a suitable hook orshackle. Each lifting device must have capacity of at least 1090 Kg(2400 lbs.).

Only use steel ropes or chains for hoisting. The rope or chain musthave the suitable specified lifting capacity of 1090 Kg (2400 lbs.). Donot use improvised ropes or chains.

Never use any other part of the PT6 Pump to lift the machine, assevere damage may occur.

Do not stand under or get onto the machine while it is being hoisted ormoved.

WARNING

CAUTION

WARNING

wc_gr003180

a

wc_tx000567gb.fm 41


4.18 Tires

Keep the tires properly inflated and make sure they have the properload rating. Under-inflated tires may cause a blowout which couldresult in fishtailing or loss of control of the towing vehicle.

Always maintain full air pressure as indicated by the tire manufactureron the tire's sidewalls. Check air pressure when the tires are cold,before you move the trailer. When the trailer tires become worn ordamaged, replace them promptly with the same type, size, and loadcapacity as the original tires.

For convenience and safety, it is recommended that you carry a sparewheel and tire.

4.19 Wheels and Lug Nuts

Loose or missing lug nuts can cause you to lose a wheel! Keep all lugnuts tight.

Before each trip, check for loose or missing lug nuts. When replacinglug nuts, make sure the replacement nut matches the original nutexactly. While the threads of the nut may match, the nut may be a sizethat does not hold the wheel securely against the hub even when fullytightened. Torque nuts evenly in increments to 115 Nm (85 ft.lbs.).

Note: During normal use, the lug nuts will seat during the first onehundred miles resulting in a drop in torque. Each nut should bechecked at that time and torqued to the proper value.

4.20 Tongue Jack


All trailers are equipped with a tongue jack (d). Use the tongue jack tolift and lower the trailer coupling on or off the tow vehicle hitch.

WARNING

WARNING

wc_tx000567gb.fm 42


4.21 Safety Chains


Failure to properly attach the safety chains between your trailer andthe tow vehicle can result in a runaway trailer; should the coupler andhitch separate while towing.

Safety chains (c) on your trailer provide added protection that it will notbecome separated from the towing vehicle. Make sure the chains arecorrectly attached between the towing vehicle and the trailer beforeeach trip.

Chains should be attached in a crossing pattern under the trailertongue. The chains will prevent the trailer tongue from dropping to theground if the trailer separates from the hitch. Rig the chains as tight aspossible with just enough slack to permit tight turns.

If a chain must be replaced, do not substitute a lighter weight chain.This trailer must be equipped with two chains, each with a minimumbreaking strength of no less than the Gross Vehicle Weight Rating(GVWR) of the trailer. All chain attachments, including hooks, must beat least as strong as the chain. Replace damaged chains. DO NOTweld or attempt to repair damaged chains.

WARNING

wc_gr003181

cd

wc_tx000567gb.fm 43


4.22 Lights


Check and make certain that all trailer lights are working before towingthe trailer.

State and federal regulations require that all types of trailers beequipped with tail, stop and turn lights (e) and side marker lights (f).

A special wiring harness (g) for connecting the trailer lights to thelighting system of the tow vehicle is supplied with the trailer.

WARNING

wc_gr003182

e

fg

wc_tx000567gb.fm 44


4.23 Wiring Diagram — Trailer

Wire Colors

B Black R Red Y Yellow Or Orange

G Green T Tan Br Brown Pr Purple

L Blue V Violet Cl Clear Sh Shield

P Pink W White Gr Gray LL Light blue

wc_tx000567gb.fm 45


4.24 Wiring Diagram (0007174 > Rev 119; 0007175 > Rev 122)

+ –

+ –

wc_gr003163

RR

B

RWB L

WBr

WBr

LBr

B

BRL

B

W

Br

Y/R

Br

L

GrW/B

Y/G

B

B

Y

W

B

R

Y

BrL

L

Br

P

G/W

G

LR

OrR R

G

W/RV/B

W/RG

Or

V

W

W

Y

Y

Y

Y Y R

B

B

R

L

L

Y

Y

P/B

BL

V/B

G/Y

B

P/B

P/B

5030

15/54 86 85

30

87

1

3

4

5

6

7 825

26

9

10111213

22

21

14

23 23

15

16

17

18

24

19

20

2

wc_tx000567gb.fm 46


4.25 Wiring Diagram Components

(0007174 > Rev 119; 0007175 > Rev 122)

Ref. Component Ref. Component

1 Cylinder head temperature switch

14 Oil temperature sensor

2 Engine harness 15 Engine Control Unit (ECU)

3 Extension harness 16 Battery

4 Glow plug 17 Starter solenoid

5 Throttle solenoid 18 Voltage regulator

6 Hour meter 19 Low oil pressure switch - N.O.

7 Control panel 20 Low oil pressure switch - N.C.

8 Keyswitch 21 Diagnostic port

9 Glow plug relay 22 Cam RPM sensor

10 15A Fuse 23 Control solenoids

11 20A Circuit breaker 24 Engine alternator

12 Pump sensor 25 80A Fuse

13 Engine RPM sensor 26 Control panel harness

Wire Colors





wc_tx000567gb.fm 47


4.26 Wiring Diagram (0007174 < Rev 120; 0007175 < Rev 123)

+ –

+ –

wc_gr003173

W

Or Br

G

B

L

Y/G

B

B

Y

W

R

Y

L

Br

G

V

W

W

Y

Y

Y

Y Y R

B

B

R

L

L

L

G/Y

B

5030

15/54

1

3

5

6

7 8

4

1011

13

14

9

12

6

15

2

R

wc_tx000567gb.fm 48


4.27 Wiring Diagram Components

(0007174 < Rev 120; 0007175 < Rev 123)


1 Coolant temperature sensor 9 Voltage regulator

2 Engine harness 10 15A Fuse

3 Extension harness 11 20A Circuit breaker

4 Control panel harness 12 Engine alternator

5 Throttle solenoid 13 Battery

6 Hour meter 14 Starter solenoid

7 Control panel 15 Oil pressure failure sensor

8 Keyswitch - ---

Wire Colors





wc_tx000567gb.fm 49


4.28 Basic Troubleshooting

Problem / Symptom Reason / Remedy

Engine does not start. • Fuel tank empty.• Wrong type of fuel.• Old fuel. Drain tank, change fuel filter, and fill with

fresh fuel.• Fuel system not primed.• Battery connections loose or corroded. Battery dead.

Electrolyte low.• Engine oil level low.• Engine hot.• Ignition switch defective.• Throttle solenoid defective.• Electrical connections loose or broken.• Engine faulty.

Engine is hard to start. • Dirt or debris inside pump housing blocking move-ment of impeller.

• Battery charge low.• Engine faulty.

Engine starts but pump does not take in water.

• Pump housing not filled with water.• Strainer on suction hose plugged.• Suction hose damaged. Air leak above water line.• Air leak at suction port.• Pump too high above water line. • Engine speed too low.• Debris collecting in pump housing.

Pump takes in water but little or no discharge.

• Suction strainer partially plugged.• Impeller worn. Shim insert.• Discharge hose kinked or blocked.• Engine speed too low.

Engines stops by itself. • No fuel.• Engine oil pressure low.• Engine too hot.

wc_tx000567gb.fm 50

Notes
wc_tx000567gb.fm 51

Theory and Performance PT6 Repair

5. Theory and Performance

5.1 Evaluating the Pump’s Performance


Certain factors outside the pump will influence the pump’s output andits ability to lift water. These factors can be critical if the pump mustoperate near its maximum lift and head.

Before servicing the pump, review its current application and theconditions under which it is operating. Determine the total head on thejob site and refer to the performance chart to determine the maximumpump capacity.

• Suction Lift (A)Suction lift is the height of the pump inlet above the water to be pumped. As the height of the pump above the water to be pumped increases, the pump’s capacity decreases. When oper-ating the pump, locate it as close to the water to be pumped as possible. The maximum suction lift of a centrifugal pump is 7.5 m (25 ft.).

• Discharge Head (B)Discharge head is the height of the discharge hose above the water to be pumped.

• Total Head (C)Total head is the total vertical distance the pump must lift the water. Total head is the sum of the suction lift plus the discharge head. The pump’s capacity decreases as the total head increases. As the pump approaches its maximum head, its pump-ing capacity will fall off dramatically.

• Frictional LossesThe friction created by the liquid as it flows through a hose, pipe, strainer, or fitting creates a resistance that the pump must over-come. These losses increase with the length of the hose, number of fittings, and the amount of the flow (gpm). Frictional losses occur in both suction and discharge lines. In long hoses they can accumulate to significantly reduce the pump’s output.

wc_tx000568gb.fm 52

PT6 Repair Theory and Performance

Note: Factors such as altitude and water temperature can alsoadversely affect pump capacity.

wc_gr003207

A C

B

wc_tx000568gb.fm 53

Theory and Performance PT6 Repair

5.2 Vacuum Test


The vacuum created at the inlet port of the pump determines the heightof water a pump can lift at the inlet port. If the pump does not prime ortakes a long time to prime, it probably is due to an air leak in the inletside of the pump. The following test only checks for air leaks in thepump itself. More often, vacuum losses are due to poor hoseconnections at the inlet port, or air leaks in the inlet line.

To check the vacuum:

5.2.1 Insert a vacuum gauge in the gauge port (a) (1/4 in. NPT) and fill thepump case with water.

5.2.2 Start the engine and allow it to warm up to operating temperature.Check the engine speed with and adjust it if necessary to a no-loadspeed of 2600±100 rpm.

5.2.3 Turn off the engine.

5.2.4 Cap or seal the inlet port so it is air tight.

5.2.5 Refill the pump case with water.

5.2.6 Start the engine and read the vacuum gauge. The gauge readingshould climb slowly and then hold steady.

• If the gauge reads 20–24 inches of mercury (Hg) (68–82 kPa), the vacuum is excellent. If the gauge reads 16–19 inches Hg (55–67 kPa), the vacuum is adequate.

• If the gauge reads less than 16 inches Hg (55 kPa), the vacuum is low. Check the nipple in inlet port for air leaks. Also check the screws securing the inlet port for the proper torque.

5.2.7 If the vacuum gauge reading is acceptable, turn off the engine andobserve the gauge for 30 seconds. The vacuum should hold steady. Ifthe vacuum drops, check the flapper valve gasket for damage.

wc gr003209

c

ab

wc_tx000568gb.fm 54

PT6 Repair Theory and Performance
Notes
wc_tx000568gb.fm 55

Lombardini Engine Troubleshooting PT6 Repair

6. Lombardini Engine Troubleshooting

6.1 Troubleshooting Flowcharts

The troubleshooting flowcharts are designed to take you through theprocess of determining the source of a problem with engine starting ormachine operation. Many of the tests involve live voltages andtherefore should only be attempted by qualified personnel. Detailedprocedures for carrying out the tests are included in this manual. Allhighlighted text within the flowcharts have matching sections in thismanual.

wc_tx000566gb.fm 56

PT6 Repair Lombardini Engine Troubleshooting

6.2 Engine Does Not Crank—Flowchart 1A

Check battery voltage.

Is the black wire

connected?

Yes

No

wc_gr003165

Check for battery voltage betweenterminal 30 of keyswitch and ground.

Reconnect black wire.

Clean and tighten connections.

Check/repair wiring from terminal 30through 80A fuse and

wiring harnesses to battery.

Are connections clean

and tight?

Yes

No

Recharge or replace battery.

Does battery measure

11.0–13.0V?

No

Yes

Check for battery voltage betweenterminal 50 and ground when keyis placed in the START position.

Engine Does Not Crank

Is batteryvoltage measuredbetween 30 and

ground?

Yes

No

Replace keyswitch.

Is batteryvoltage measuredbetween 50 and

ground?

Yes

No

Check for battery voltage between black wire at starter solenoid and ground whenkey is in START position.

Repair/replace black wire.

Consult Lombardini

engine repair manual.

Is batteryvoltage measured

between black wire and ground?

Yes

No

Checking Keyswitch and Wiring

Check connection of black wire at starter solenoid.

Check wire connections at keyswitch.

wc_tx000566gb.fm 57


6.3 Checking Keyswitch and Wiring (0007174 > Rev 119; 0007175 >Rev 122)


Electric shock hazard. Only qualified personnel should conduct thesetests.

6.3.1 When troubleshooting Lombardini engines that do not crank, firstcheck that the B (black) wire (a) is connected to the starter solenoid.This wire provides voltage to the coil of the solenoid, if it is notconnected, the solenoid will not function.

6.3.2 Remove the screws securing the control panel bracket (b) to the frameand lift the control panel and its bracket from the machine.

6.3.3 Remove the back cover (c) of the control panel box and check that thethe wiring to the keyswitch (d) is clean and tight. Check that theappropriate wires are connected to the proper terminals of thekeyswitch.

6.3.4 Check for 12V (battery voltage approximately 12) between terminal 30of the keyswitch and ground. If no voltage is measured, repair thewiring from terminal 30 through the 80A fuse (e) and wiring harnessesback to battery. If voltage is measured, continue.

6.3.5 Place the keyswitch in the START position and check for 12V (batteryvoltage approximately 12) between terminal 50 of the keyswitch andground. If no voltage is measured, replace the keyswitch. If voltage ismeasured, continue.

6.3.6 Place the keyswitch in the START position and check for 12V (batteryvoltage approximately 12) between the B (black) wire (a) and groundat the starter solenoid. If no voltage is measured, repair the wiringbetween terminal 50 of the keyswitch and the starter solenoid. Ifvoltage is measured and the engine still will not crank, there is aproblem with the starter motor. See the Lombardini engine repairmanual for further information.

WARNING

wc_tx000566gb.fm 58


wc_gr003166

30

50

B

L

R

Br

15/54

c

e

a

b

d

V 1000200

202200m

F V

A

V- COM

wc_tx000566gb.fm 59


6.4 Checking Keyswitch and Wiring (0007174 < Rev 120; 0007175 <Rev 123)


Electric shock hazard. Only qualified personnel should conduct thesetests.

6.4.1 When troubleshooting Lombardini engines that do not crank, firstcheck that the B (black) wire (a) is connected to the starter solenoid.This wire provides voltage to the coil of the solenoid, if it is notconnected, the solenoid will not function.

6.4.2 Remove the screws securing the control panel bracket (b) to the frameand lift the control panel and its bracket from the machine.

6.4.3 Remove the back cover of the control panel (c) and check that the thewiring to the keyswitch (d) is clean and tight. Check that theappropriate wires are connected to the proper terminals of thekeyswitch.

6.4.4 Check for 12V (battery voltage approximately 12) between terminal 30of the keyswitch and ground. If no voltage is measured, repair thewiring from terminal 30 through the wiring harnesses and back tobattery. If voltage is measured, continue.

6.4.5 Place the keyswitch in the START position and check for 12V (batteryvoltage approximately 12) between terminal 50 of the keyswitch andground. If no voltage is measured, replace the keyswitch. If voltage ismeasured, continue.

6.4.6 Place the keyswitch in the START position and check for 12V (batteryvoltage approximately 12) between the B (black) wire (a) and groundat the starter solenoid. If no voltage is measured, repair the wiringbetween terminal 50 of the keyswitch and the starter solenoid. Ifvoltage is measured and the engine still won’t crank, there is a problemwith the starter motor. See the Lombardini engine repair manual forfurther information.

WARNING

wc_tx000566gb.fm 60


wc_gr003193

30

50

B

L

R

Br

15/54

ab

V 1000200

202200m

F V

A

V- COM

wc_tx000566gb.fm 61


6.5 Replacing the Keyswitch


Disassembly:

6.5.1 Shut down the engine and disconnect the battery.

6.5.2 Remove the six screws securing the control panel cover to the controlpanel.

6.5.3 Make note of the wire connections on the keyswitch and remove thewires (a) from the keyswitch.

6.5.4 Unscrew the locking ring (b) and remove the keyswitch from the panel.

Reassembly:

6.5.5 Insert the replacement keyswitch into the control panel and secure itwith the locking ring (b).

6.5.6 Attach the wires (a) to the appropriate terminals of the keyswitch.

6.5.7 Secure the control panel cover to the control panel with the six screws.

wc_gr003167

ba

30

50

B

L

R

Br

15/54

wc_tx000566gb.fm 62


6.6 Engine Cranks But Does Not Start—Flowchart 1B

Check position of circuit breaker; reset it if tripped.

Check battery condition.

Replace battery.

Repair/Replace components and/or

wiring.

Replace throttle solenoid.

Does battery provide

correct voltage and CCA?

No Yes

Yes

Make sure that the machine has fresh fuel and that the fuel filter and fuel hoses are in good condition. Also make sure that the engine isfilled with the proper amount of oil.

Engine Cranks But Does Not Start

Checking Throttle Solenoid

Check if throttle solenoid isfunctioning properly.

Checking Auto Shutdown Circuit

Check the components and wiringof the auto shutdown circuit.

Checking glow plug relay

Check glow plug relay.*

Checking glow plugs

Check glow plugs.*

wc_gr003190

Is throttlesolenoid functioning

properly?

Yes

No

Doglow plugs operate

correctly?Yes

No

Are the componentsand wiring

OK?

No

Doesglow plug relay operate

correctly?Yes

No

Replace glow plug.

*(0007174 > Rev 119; 0007175 > Rev 122)

Replace glow plug relay.

Consult Lombardini


wc_tx000566gb.fm 63


6.7 Checking the Throttle Solenoid


The throttle solenoid must be energized in order for the engine to start.To check if the throttle solenoid is functioning, carry out the followingprocedure:

6.7.1 Place the keyswitch in the START position and check the position ofthe throttle solenoid while the engine is cranking.

• If the throttle solenoid energizes (pulls in) the throttle solenoid is functioning.

• If the throttle solenoid does not energize, continue.

6.7.2 Check that the black wire (a) is secure and in good condition from thenegative terminal of the throttle solenoid to ground.

6.7.3 Disconnect the yellow wire (b) from the positive terminal of the throttlesolenoid. Place the keyswitch in the START position and check thevoltage between the yellow wire and ground. There should be 12V(battery voltage approximately 12) measured.

• If 12V is measured, the throttle solenoid should function. If it does not, it has failed; replace the throttle solenoid.

• If 12V is not measured, check the auto shutdown circuit.

wc_gr003191

b

a

wc_tx000566gb.fm 64


6.8 Checking the Auto Shutdown Circuit

See Graphic wc_gr003192

The auto shutdown circuit consists of the circuit breaker, thetemperature switch, the oil pressure switch, and the wiring between thethree components. Voltage is supplied to the throttle solenoid throughthe auto shutdown circuit. To check the auto shutdown circuit, do thefollowing:

6.8.1 Check that the wiring is clean and tightly connected to the temperatureswitch (a) and to the oil pressure switch (b). Try starting the engine. Ifthe throttle solenoid does not energize, continue.

6.8.2 Disconnect the white wire from the temperature switch. Place thekeyswitch in the ON position and measure the voltage between thewhite wire and ground. There should be 12V (battery voltageapproximately 12) measured.

• If 12V is not measured, check the continuity of the white wire from the temperature switch to the harness connector (c).

• If 12V is measured, continue.

6.8.3 Check the continuity of the temperature switch to ground. There shouldbe no continuity.

• If there is continuity between the temperature switch and ground, the switch has failed; replace it.

• If there is no continuity between the temperature switch and ground, continue.

6.8.4 Disconnect the yellow wire (d) from the oil pressure switch. Place thekeyswitch in the ON position and measure the voltage between theyellow wire and ground. There should be 12V (battery voltageapproximately 12) measured.

• If 12V is not measured, check the continuity of the wiring between the yellow wire of the oil pressure switch and the white wire of the temperature switch. Repair the wiring as needed.

• If 12V is measured, continue.

6.8.5 With the keyswitch in the ON position, touch the yellow wire (d) tooutgoing yellow wire on the opposite side of the oil pressure switch (e).The throttle solenoid should energize.

• If the throttle solenoid does not energize, check the continuity of the yellow wire from the oil pressure switch to the throttle sole-noid.

• If the throttle solenoid energizes, continue.

6.8.6 Check the engine oil pressure with an independent gauge.

• If the engine oil pressure checks OK, the oil pressure switch has failed; replace it.

wc_tx000566gb.fm 65

• If the engine oil pressure is not OK, refer to the Lombardini

a

wc_gr003192

e

b

d

c

wc_tx000566gb.fm 66


6.9 Checking Voltage to Glow Plug


To check the voltage to the glow plug, disconnect the B (black) wire (c),place the keyswitch in the START position, and measure the voltagebetween the black wire and ground. There should be 12V (batteryvoltage approximately 12) measured.

• If 12V is not measured, check the continuity of the wiring; repair or replace the wiring as needed.

• If 12V is measured, check the function of the glow plug.

wc_gr003189

c

wc_tx000566gb.fm 67


6.10 Checking Glow Plug Relay


6.10.1 Remove the screws securing the engine control panel. Leave all wiringconnected to the control panel.

6.10.2 Rotate the control panel to gain access to the rear of the control panel.Remove the enclosure cover to access the glow plug relay.

6.10.3 Place the keyswitch in the START position. A working relay will “click”when the keyswitch is in the START position.Check the continuity across the blue (L) and black (B) wires when thekeyswitch is in the START position. If there is no continuity, the relayis faulty; replace it.

6.11 Replacing Glow Plug Relay


6.11.1 Make note of the wire positions and disconnect all wires from the glowplug relay.

6.11.2 Bend back the tabs (a) securing the glow plug relay (b) and pull theglow plug relay from the enclosure.

wc_gr002475

ab

87

8530

86

B

L

G/YG/Y

Br

wc_tx000566gb.fm 68


6.12 Checking Glow Plug


6.12.1 Remove the glow plug from the engine.

Burn hazard. Glow plugs can reach temperatures up to 1200°F(649°C). Do not touch the element of the glow plug. Be extremelycareful when testing the glow plug.

6.12.2 Using 10-gauge wire, apply 12VDC to the glow plug—positive on theupper portion and ground the base. If the glow plug does not heat(glow) within five seconds, replace the glow plug.

WARNING

–

+

wc_gr003188

wc_tx000566gb.fm 69


6.13 Engine Shuts Down—Flowchart 1C

Check engine oil level.

wc_gr003085

Fill machine with oil.

Is machine oillevel correct?

Yes

No

Engine Shuts Down

Connect oil pressure switch

and/or repair wiring.

Is oil pressure

switch connectedcorrectly?

Yes

No

Check engine coolant level.

Fill engine withcorrect amount and

type of coolant.

Is engine coolantlevel correct?

No

Yes

Connect coolanttemperature switch and/or repair wiring.

Is coolant temperature

switch connectedcorrectly?

Yes

No

Refer to the Lombardini repair manual.

Call Wacker Service.

Checking oil pressure andcoolant temperature switches

Check wiring of oil pressureswitch.

Check wiring of coolant temperature switch.

wc_tx000566gb.fm 70


6.14 Checking Oil Pressure and Coolant Temperature Switches


6.14.1 If the engine starts but shuts down after approximately 10 seconds,check the following.

6.14.2 Check the engine oil level and add oil if necessary. Also check thecoolant temperature. If the coolant temperature is high, allow theengine to cool. Flush and fill the radiator with the correct coolant.

6.14.3 Check the oil pressure switch (a) and coolant temperature switch (b)wiring. If the wiring of either switch is shorted to ground, the engine willshut down. Be sure the switches are functioning—check each for continuity. Theoil pressure switch is a normally closed (NC) switch that should havecontinuity when the engine is off. If the switch has no continuity whenthe engine is off, the switch is faulty; replace it. The high coolant temperature switch is a normally open (NO) switch.This switch should have no continuity when the engine is off. If thisswitch has continuity when the engine is off, it has shorted and is faulty;replace it.

ab

wc_gr003194

wc_tx000566gb.fm 71


6.15 General Engine Troubleshooting

Possible Cause Symptom

Eng

ine

will

not

cra

nk

Eng

ine

does

not

sta

rt

Eng

ine

star

ts, b

ut s

tops

Poo

r ac

cele

ratio

n

Uns

tead

y rp

m

Bla

ck s

mok

e

Whi

te s

mok

e

Blu

e sm

oke

Low

oil

pres

sure

Oil

leve

l ris

ing

Exc

essi

ve o

il co

nsum

ptio

n

Wet

exh

aust

Ove

rhea

ting

Eng

ine

knoc

ks

Low fuel level • • •

Fuel supply/return lines clogged

• • • •

Clogged fuel tank vent • •

Fuel pump faulty • • •

Fuel contaminated with air • • • •

Unit injector(s) faulty/worn • • • • • • •

Unit injector settings incorrect • • • • • • •

Injection pump rack sticking • • •

Oil level too high • • • • • • •

Improper oil viscosity • • •

Oil diluted by fuel • • • • •

Oil pressure relief valve faulty •

Oil pick-up tube clogged •

Oil pump air contaminated at pick-up tube

•

Glow plugs faulty • •

Glow plug controller faulty •

Glow plug relay inoperable •

Starter defective •

wc_tx000566gb.fm 72


Battery voltage too low •

Battery/battery cable connections corroded

•

Key switch defective •

Air filter clogged • • • • • • •

Excessive idle/light load operation

• • • •

Incomplete engine run-in • • •

Engine overloaded • • • • •

Excessive secondary load • • •

Valve lash insufficient/excessive

• • • •

Injection timing out of spec - advanced

• • • • •

Injection timing out of spec - retarded

• • •

Governor linkage adjustment incorrect

• • • •

Governor spring fatigued or defective

• • •

Idle rpm too low • •

Piston rings worn or stuck • • • • •

Piston worn or damaged • • • • • • •

Cylinders worn or damaged • • • • • • •

Valve/valve guides worn • • • • •


Eng

ine

will

not

cra

nk

Eng

ine

does

not

sta

rt

Eng

ine

star

ts, b

ut s

tops

Poo

r ac

cele

ratio

n

Uns

tead

y rp

m

Bla

ck s

mok

e

Whi

te s

mok

e

Blu

e sm

oke

Low

oil

pres

sure

Oil

leve

l ris

ing

Exc

essi

ve o

il co

nsum

ptio

n

Wet

exh

aust

Ove

rhea

ting

Eng

ine

knoc

ks

wc_tx000566gb.fm 73


Valves sticking • • • • • • •

Bearings (main/rod) worn • • •

Governor/governor linkage malfunctioning

• • • • •

Cylinder head gasket damaged

• • •

Thermostat stuck or malfunctioning

•

Engine seized •

Radiator clogged (external or internal)

•

Coolant pump faulty •

Turbocharger faulty • • • • • • •


Eng

ine

will

not

cra

nk

Eng

ine

does

not

sta

rt

Eng

ine

star

ts, b

ut s

tops

Poo

r ac

cele

ratio

n

Uns

tead

y rp

m

Bla

ck s

mok

e

Whi

te s

mok

e

Blu

e sm

oke

Low

oil

pres

sure

Oil

leve

l ris

ing

Exc

essi

ve o

il co

nsum

ptio

n

Wet

exh

aust

Ove

rhea

ting

Eng

ine

knoc

ks

wc_tx000566gb.fm 74

PT6 Repair Disassembly/Assembly Procedures

7. Disassembly/Assembly Procedures

7.1 Tools

Because all possible problems encountered while repairing themachine cannot be anticipated, it is up to the mechanic to use commonsense and good judgement in tool selection.

The use of any special tools is recommended only for those operationswhere the use of conventional tools proves inadequate.

Before substituting another tool or procedure, you should be satisfiedthat neither personal injury nor damage to the component will result.

7.2 Ordering Parts

The repair procedures contained in this manual do not include partnumbers. For parts replacement information, refer to the Parts Bookoriginally supplied with the machine.

If the original Parts Book has been lost, a replacement may be orderedfrom Wacker Corporation. When ordering a replacement Parts Book,please list the model number, item number, revision level, and serialnumber of the machine. Parts Books are also available on the WackerCorporation Web site. See www.wackergroup.com. Enter the site as avisitor.

7.3 Reference Numbers ( )

Repair procedures contain reference numbers enclosed inparentheses ( ). These numbers refer to the item numbers shown onthe assembly drawings and other detailed drawings. They are includedto aid the mechanic in identifying parts and assembling components.

7.4 Weight Block


The weight block symbol gives an approximate weight measurementto aid the mechanic when lifting/hoisting larger components.

250 kg(550 lbs.)

wc_gr000843

wc_tx000557gb.fm 75

Disassembly/Assembly Procedures PT6 Repair

7.5 Replacing the Flapper Valve


The flapper valve is located at the pump inlet. During pump operation,this valve is open allowing a path for water to flow into the pump case.When the pump stops, the valve closes and prevents water in thesuction hose from draining out.

A leak around the outside of the flapper gasket will cause the pump tolose its prime and may make it difficult or impossible to prime at startup.

Removal:

7.5.1 Remove the locknuts (a) and washers that secure the inlet port (f) tothe pump and remove the inlet port.

7.5.2 Remove the rubber flapper valve (b).

7.5.3 Remove the locknuts (c) that secure the plates (d and e) to the rubberflapper and remove the plates.

Installation:

7.5.4 Secure the plates (d and e) to the rubber flapper with locknuts (c) andscrews.

CAUTION: Do not over-tighten the locknuts. Over-tightening will crushthe rubber flapper and may prevent it from sealing properly.

7.5.5 Install the rubber flapper valve (b) with the large plate (e) toward theinside of the pump.

7.5.6 Secure the inlet port (f) to the pump with washers and locknuts (a).Torque the locknuts to 160 Nm (118 ft.lbs.).

wc_tx000557gb.fm 76


wc_gr003195

a

a

bd

be

c

c d

wc_tx000557gb.fm 77


7.6 Replacing the Impeller


Removal:

7.6.1 Shut down the machine and disconnect the battery.

DO NOT reach into or insert anything into the pump while the engineis running!

DO NOT run the pump with the impeller cover removed.

7.6.2 Drain the seal housing cavity.

7.6.3 Remove the impeller cover (a) to expose the impeller (b).

Impeller edges can become extremely sharp; use care when workingon the pump to reduce the risk of being cut.

7.6.4 Clean the impeller with a 50-50 mixture of bleach and water beforeworking on it.

7.6.5 The impeller is threaded onto the drive shaft with right hand threads.To keep the drive shaft from turning while removing the impeller, holdthe drive shaft by the flats (located near the flex coupling).

7.6.6 Carefully pry the rotating half of the mechanical (c) seal from the backside of the impeller.

Installation:

7.6.7 Install the rotating half of the mechanical seal (c) onto the back side ofthe impeller (b). Refer to section Replacing the Mechanical Seal.

7.6.8 Thread the impeller onto the drive shaft. To keep the drive shaft fromturning, hold it by the flats near the flex coupling.

7.6.9 Check the gap between the impeller and the insert (d). Add or removeshims (e) as necessary to obtain a gap of 0.15–0.75 mm (0.005–0.025in.).

7.6.10 When the correct gap is obtained, apply an anti-seize compound to thethreads of the drive shaft; then, thread the impeller on.

7.6.11 Install the impeller cover (a).

WARNING

CAUTION

wc_tx000557gb.fm 78


wc_gr003204

a

a

a

e

e d

d e

b

0.15–0.75 mm(0.005–0.025 in.)

b

c

a

wc_tx000557gb.fm 79


7.7 Replacing the Mechanical Seal


Proper installation of the mechanical seal is crucial. It is extremelyimportant that the seal faces remain clean and that the O-ring andrubber boot are seated properly. Improper installation may cause sealfailure. During installation and handling of the mechanical seal, avoidscratching or contaminating the seal faces with oil or dirt.

Removal:

7.7.1 Drain the oil from the seal housing cavity.

7.7.2 Remove the impeller. See section Replacing the Impeller. By removingthe impeller you will remove the rotating portion of the mechanical seal.

7.7.3 Remove the stationary portion (a) of the mechanical seal and O-ring (i)from the seal housing.

7.7.4 The stationary portion of the mechanical seal is held in place by a pin(b) in the seal housing. If this pin is loose or damaged, it will requirereplacement. In order to do so, the seal housing must be removed fromthe pump. To remove the seal housing, remove the four screws thatsecure the seal housing (c) to the bearing housing. Insert two M10screws (d) into the threaded holes and use the M10 screws as pushersto push the seal housing from the bearing housing. Remove the setscrew and drive the pin from the seal housing. Refer to sectionInstalling End Cap and Seal Housing.

Installation:

7.7.5 If the seal housing (c) was removed, install it into the bearing housing.

7.7.6 Install the stationary portion (a) of the mechanical seal and the O-ring(i) into the seal housing. Match the notch in the mechanical seal withthe pin in the seal housing (b).

7.7.7 Thoroughly lubricate the impeller stem and the inside of themechanical seal (e) with soapy water. Start the installation of themechanical seal by hand; then, press it onto the impeller (f). Do notpress on the face of the mechanical seal. Instead, use a piece of plasticpipe (g) to support the mechanical seal while pressing. Do not pressthe mechanical seal too deeply or the seal ring may pop out of therubber boot.

7.7.8 Use a feeler gauge and check the gap around the bottom of theimpeller. The ideal gap is 0.02 mm (0.008 in.). If a larger gap exists,repeat the pressing procedure.

7.7.9 Clean (h) the mating surfaces of the mechanical seal with alcohol.

7.7.10 Install the impeller and impeller cover.

wc_tx000557gb.fm 80

7.7.11 Fill the seal housing with oil. See sections Mechanical Seal Lubrication
and Bearing Housing Lubrication.

wc_gr003205

75 mm(3 in.)

a

a

i

h

c

b

d

e

f

g

g

f

e

wc_tx000557gb.fm 81


7.8 Removing the Pump and Bearing Housing


It is only necessary to remove the pump and bearing housing whenreplacing the coupling flange plate, flex coupling, drive shaft, bearings,or the pump itself. It is not necessary to remove the pump and bearinghousing to replace the mechanical seal, impeller, or volute.

7.8.1 Remove the screws (a) that secure the protective guards and removethe protective guards. This will expose the drive coupling.

7.8.2 Remove the screws (b) that secure the drive-coupling flange plate tothe engine’s flywheel.

7.8.3 Scribe or mark a line (c) next to each leg of the pump housing on theframe of the trailer. This will aid in reassembly of the pump.

7.8.4 Remove the four screws (d) and washers that secure the pumpassembly to the frame. Take note of any shims (e) which may be underthe legs.

7.8.5 This step requires an appropriate crane or other lifting device and two4x4’s or similar blocks of wood.

The discharge elbow (f) may be used for placement of a lifting sling. Ifthe discharge elbow is facing the engine, a more-balanced load willresult. If the discharge elbow is facing away from the engine, a less-balanced load will result. Make sure the discharge elbow is securelyfastened to the pump housing before lifting. Wrap the lifting slingaround the discharge elbow and lift the pump off the trailer slowly andwith caution. Place the pump on the 4x4’s on the ground.

7.8.6 Remove the six locknuts (g) that secure the bearing housing to thepump. Loosen the three nuts holding the three pusher bolts (h) to thehousing. Use the three pusher bolts to push the bearing housing (i)free of the pump.

wc_tx000557gb.fm 82


wc_gr003196

a b

d

f

c

g

h

i

e

250 kg(550 lbs.)

wc_tx000557gb.fm 83


7.9 Installing the Pump and Bearing Housing


This procedure requires a dial indicator capable of being mounted tothe drive shaft.

Note: The bearing housing assembly may be mounted to the pumpwith or without the impeller installed.

7.9.1 Position the bearing housing into the pump. Secure it to the pumpusing six locknuts.

7.9.2 Install the flex coupling and mounting flange to the drive shaft. Seesection Replacing the Flex Coupling and Mounting Flange.

7.9.3 This step requires an appropriate crane or other lifting device.

The discharge elbow may be used for placement of a lifting sling. If thedischarge elbow is facing the engine, a more balanced load will result.If the discharge elbow is facing away from the engine, a less balancedload will result. Make sure the discharge elbow is securely fastened tothe pump housing before lifting. Wrap the lifting sling around thedischarge elbow and lift the pump off the trailer slowly and with caution.Place the pump on the frame.

7.9.4 The axial and angular alignment of the pump to the engine will need tobe checked using a dial indicator. To do so:

• Be certain the engine is installed correctly and that the engine mounting bolts are torqued to the correct specification.

• Position the pump so that the mounting flange (x) just touches the inside of the engine flywheel (y).

• Position a dial indicator so that it measures the angular alignment (squareness) of the drive shaft to the engine. This is done by clamping a dial indicator to the drive shaft and monitoring the dis-tance to the face of the bell housing as the drive shaft is rotated. First check the top (A1); then, rotate the drive shaft and check the bottom (A2). The maximum allowable derivation (amount out of square) is 0.5 mm (0.020 in.).

Reposition the dial indicator so that it measures the axial align-ment (concentricity) of the drive shaft to the engine. This is done by clamping a dial indicator to the drive shaft and monitoring the distance to the inside shoulder of the bell housing as the drive shaft is rotated. First check the top (B1); then, rotate the drive shaft and check the bottom (B2). The maximum allowable value is 0.5 mm (0.020 in.).

Shim the pump as needed to obtain the proper alignment.

wc_tx000557gb.fm 84

• In the same manner, check the axial alignment and the square-
ness of the drive shaft to the engine at the left (A3, B3) and the right (A4, B4) sides of the pump. Move the pump in very small increments to obtain the correct alignment.

• When the pump is in the correct position, secure the pump to the frame with four screws, washers, and beveled shims. Torque the screws to 330 Nm (240 ft.lbs.).

• Secure the mounting flange to the engine flywheel with eight screws. Torque the screws to 19 Nm (14 ft.lbs.).

wc_gr003197

A

B

0.5 mm (0.02 in.)

0.5 mm (0.02 in.)

A1

B1

B2

A2

A3

A4

B3

B4

xy

wc_tx000557gb.fm 85


7.10 Replacing the Flex Coupling and Mounting Flange


Removal:

7.10.1 Remove the screws (a) that secure the flex coupling to the couplinghub (b) and remove the flex coupling.

7.10.2 Remove the screws (c) that secure the flex coupling to the mountingflange and remove the mounting flange.

7.10.3 Loosen the setscrew (d) that secures the coupling hub to the driveshaft and remove the coupling hub and key (e) from the drive shaft.

Installation:

7.10.4 Place the key into the keyway of the drive shaft.

7.10.5 Position the coupling hub on the drive shaft so that it is approximately3 mm (0.12 in.) from the end of the key (f). There should be no keyshowing on the engine side of the coupling hub (g).

7.10.6 Apply a thin layer of grease to the under side (h) of the three screwsthat secure the flex coupling to the coupling hub. Also apply Loctite 242or equivalent to the threaded holes of the coupling hub. Do not applythe Loctite to the screw threads. The Loctite could rub off on the insideof the flex coupling and interact with the rubber causing it to fail. Securethe flex coupling to the coupling hub. Torque the screws to 85 Nm (62ft.lbs.). Secure the mounting flange to the flex coupling in the samemanner.

CAUTION: When installing the flex coupler, keep it as straight aspossible. Do not allow it to twist. Failure of the flex coupling may occur.

wc_tx000557gb.fm 86


wc_gr003198

d

b

c d

f

h

g

a

wc_tx000557gb.fm 87


7.11 Bearing Housing

12

2526

9

2829

13

26

25

14

17

2716

15

11

10

3 23

24

12

4

5

78

19

6

20

2423 19

17 16 2715 14

wc_gr003202

13

1129

108

7

65421

12

3

2120

20

28

wc_tx000557gb.fm 88


7.12 Bearing Housing Components



1 Socket head cap screw 16 Washer

2 O-ring 17 Shaft seal

3 Locking washer 18 Seal housing drain plug

4 Gasket 19 Roller plug

5 Bearing housing fill plug 20 Bearing plug drain plug

6 Vent 21 Sealing washer

7 Mechanical seal housing plug 22 Bearing housing

8 Retaining ring 23 Tapered roller bearing

9 Seal housing 24 Ring nut

10 O-ring 25 Cap

11 O-ring 26 Shaft seal

12 Drive shaft 27 Socket head cap screw

13 Impeller 28 Setscrew

14 Mechanical seal (rotating half) 29 Roll pin

15 Mechanical seal (stationary half) - ---

wc_tx000557gb.fm 89


7.13 Bearing Housing Disassembly


There are two bearings within the bearing housing. One is a taperedroller bearing and the other is a standard roller bearing. To avoidconfusion, the tapered roller bearing will be referred to as the “taperedbearing”. The standard roller bearing will be referred to as the “rollerbearing”.

7.13.1 Remove the pump and bearing housing from the frame. See sectionRemoving the Pump and Bearing Housing.

7.13.2 Remove the flex coupling and mounting plate. See section Replacingthe Flex Coupling and Mounting Flange.

7.13.3 Drain the oil from the bearing housing.

7.13.4 Remove the impeller. It is threaded on with right hand threads. Holdthe drive shaft from turning by the flats near the engine end. Refer tosection Replacing the Impeller.

7.13.5 If the mechanical seal is to be replaced, carefully pry it off the impeller.If it is not to be replaced, leave it attached to the impeller. Refer tosection Replacing the Mechanical Seal.

7.13.6 Pull the stationary half of the mechanical seal from the seal housing.

7.13.7 Remove the four screws (a) that secure the seal housing (b) to thebearing housing. Insert two M10 screws (c) into the threaded holesand use the M10 screws as pushers to push the seal housing from thebearing housing.

7.13.8 On the opposite end of the bearing housing, remove the four screwsthat secure the housing cover (d) and remove the housing cover. Thisaction will expose the ring nut (e) and locking washer that secure thetapered bearing.

7.13.9 Bend up the locking tab on the locking washer (f). Remove the ring nutand the locking washer from the shaft (g).

7.13.10 Place the bearing housing in an Arbor press engine-side up. Press onthe drive shaft until it breaks free from the tapered bearing. Once itbreaks free it will drop from the bearing housing—be ready catch it soit does not fall.

7.13.11 Remove the retaining ring (h) which holds the roller bearing.

7.13.12 Use a puller to pull the inner race (i) of the roller bearing from the driveshaft.

7.13.13 Press out the roller bearing (k) and the outer race of the taperedbearing (j) from the bearing housing.

wc_tx000557gb.fm 90


wc_gr003199

a

c

ff

hi

g

j k

ee

b

b

d

k

j

wc_tx000557gb.fm 91


7.14 Bearing Housing Assembly


There are two bearings within the bearing housing. One is a taperedroller bearing and the other is a standard roller bearing. To avoidconfusion, the tapered roller bearing will be referred to as the “taperedbearing”. The standard roller bearing will be referred to as the “rollerbearing”.

7.14.1 Press the outer race of the tapered bearing (k) and the roller bearing(j) into the bearing housing.

7.14.2 Press the inner race of the roller bearing (i) onto the drive shaft. Secureit with the retaining ring (h).

7.14.3 Position the bearing housing so that the impeller side is facing upward.Support it from underneath so that the drive shaft may be installed.Place the drive shaft into the bearing housing and guide it into the rollerbearing. DO NOT use force when installing the shaft into the rollerbearing.

7.14.4 Press the tapered bearing (l) onto the drive shaft. Press the race sothat the drive shaft starts to bind. Then, using a dead blow or plastichammer (m), rap the end of the drive shaft to release the tension. Thedrive shaft should now turn with ease.

7.14.5 Install the locking washer (f) onto the drive shaft. If necessary, bendthe inside tang (n) so the locking washer can slide in the groove of thedrive shaft.

7.14.6 Install the ring nut (e) with the tapered side toward the locking washer.Tighten the ring nut so that once again the drive shaft starts to bind.Notice how there are several notches in the ring nut into which tangsof the locking washer could fit. Find the tang-notch combination that isclosest to fitting together. Back off the ring nut so that this combinationfits. Before bending the tang to lock the ring nut, again, using a deadblow or a plastic hammer, rap the end of the drive shaft to release thetension. The drive shaft should now turn with ease with no noticeableend play. (It will have a free-rolling torque.) Bend the tang to lock thering nut.

7.14.7 Install the end cap and the seal housing. See section Installing EndCap and Seal Housing.

wc_tx000557gb.fm 92


wc_gr003200

ff

n

hi

l

h

i

g

j k

e

m

e

j

k

wc_tx000557gb.fm 93


7.15 Installing End Cap and Seal Housing

See Grapic: wc_gr003203

7.15.1 Prepare the seal housing (a) for installation by replacing the seals (b)and O-rings (c). When installing the seals, lubricate them with soapywater. Install the seals so that both seals face the same direction(towards the inside of the seal housing). When installing the O-rings,lubricant them with oil.

7.15.2 Inspect the roll pin (d) which protrudes into the seal housing cavity. Ifthe roll pin is loose or appears damaged, replace it. To do so, removethe set screw (e) and drive the roll pin out. Be careful not to damagethe seal housing when replacing the pin. Drive a new roll pin into thehole so that it protrudes 5 mm (1/16 in.) into the cavity. Use Loctite 569or equivalent on the set screw and install it into the threaded hole. Sealoff the set screw with a silicone sealant.

7.15.3 Clean out any old thread locking compound from the threaded holes inthe bearing housing. Apply fresh Loctite 242 or equivalent to thethreaded holes.

7.15.4 Using the new sealing washers, secure the seal housing to the bearinghousing with four screws (f). Torque the screws to 20 Nm (14 ft.lbs.).

7.15.5 Prepare the housing cover (g) by installing two new seals (h) and anew O-ring (i) into it. When installing the seals and O-rings, lubricatethem with oil. Install the new seals so that they are back to back (j).

7.15.6 Apply Loctite 242 or equivalent on four screws and secure the housingcover to the bearing housing. Torque the screws to 20 Nm (14 ft.lbs.).

7.15.7 Fill the bearing housing with oil.

7.15.8 Install the mechanical seal. See section Replacing the MechanicalSeal.

7.15.9 Install the impeller. It is threaded on with right hand threads. Keep thedrive shaft from turning by holding it by the flats near the engine end.See section Replacing the Impeller.

7.15.10 Install the bearing housing to the pump and the pump to the engine.See section Installing the Pump and Bearing Housing.

wc_tx000557gb.fm 94


wc_gr003203

5 mm(3/16 in.)

j

g

i

g

h

a

f

d

e

b

b

c

wc_tx000557gb.fm 95


wc_tx000557gb.fm 96

Threadlockers and Sealants


Threadlocking adhesives and sealants are specified throughout thismanual by a notation of “S” plus a number (S#) and should be usedwhere indicated. Threadlocking compounds normally break down attemperatures above 175°C (350°F). If a screw or bolt is hard toremove, heat it using a small propane torch to break down the sealant.When applying sealants, follow instructions on container. The sealantslisted are recommended for use on Wacker equipment.

TYPE( ) = Europe COLOR USAGE

PART NO. –SIZE

Loctite 222Hernon 420Omnifit 1150 (50M)

Purple Low strength, for locking threads smaller than 6 mm (1/4”).Hand tool removable.Temp. range: -54 to 149°C (-65 to 300°F)

73287 - 10 ml


Blue Medium strength, for locking threads larger than 6 mm (1/4”).Hand tool removable.Temp. range: -54 to 149°C (-65 to 300°F)

29311 - .5 ml17380 - 50 ml

Loctite 271/277Hernon 427Omnifit 1550 (220M)

Red High strength, for all threads up to 25 mm (1”).Heat parts before disassembly.Temp. range: -54 to 149°C (-65 to 300°F)

29312 - .5 ml26685 - 10 ml73285 - 50 ml

Loctite 290Hernon 431Omnifit 1710 (230LL)

Green Medium to high strength, for locking preassembled threads and for sealing weld porosity (wicking).Gaps up to 0.13 mm (0.005”)Temp. range: -54 to 149°C (-65 to 300°F)

28824 - .5 ml25316 - 10 ml

Loctite 609Hernon 822Omnifit 1730 (230L)

Green Medium strength retaining compound for slip or press fit of shafts, bearings, gears, pulleys, etc.Gaps up to 0.13 mm (0.005”) Temp. range: -54 to 149°C (-65 to 300°F)

29314 - .5 ml


Brown Hydraulic sealantTemp. range: -54 to 149°C (-65 to 300°F)

79356 - 50 ml

Loctite 592Hernon 920Omnifit 790

White Pipe sealant with Teflon for moderate pressures.Temp. range: -54 to 149°C (-65 to 300°F)

26695 - 6 ml73289 - 50 ml

Loctite 515Hernon 910Omnifit 10

Purple Form-in-place gasket for flexible joints.Fills gaps up to 1.3 mm (0.05”)Temp. range: -54 to 149°C (-65 to 300°F)

70735 - 50 ml


Threadlockers and Sealants (continued)

Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker equipment.

TYPE( ) = Europe COLOR USAGE

PART NO. –SIZE

Loctite 496Hernon 110Omnifit Sicomet 7000

Clear Instant adhesive for bonding rubber, metal and plastics; general purpose.For gaps up to 0.15 mm (0.006”)Read caution instructions before using.Temp. range: -54 to 82°C (-65 to 180°F)

52676 - 1oz.

Loctite Primer THernon Primer 10Omnifit VC Activator

AerosolSpray

Fast curing primer for threadlocking, retaining and sealing compounds. Must be used with stainless steel hardware. Recommended for use with gasket sealants.

2006124-6 oz.

Torque Values

Torque Values

Metric Fasteners (DIN)

TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE

Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch

M3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 –

M4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 –

M5 6.0 *53 8.5 6 10 7 8 5/16 4 –

M6 10 7 14 10 17 13 10 – 5 –

M8 25 18 35 26 41 30 13 1/2 6 –

M10 49 36 69 51 83 61 17 11/16 8 –

M12 86 63 120 88 145 107 19 3/4 10 –

M14 135 99 190 140 230 169 22 7/8 12 –

M16 210 155 295 217 355 262 24 15/16 14 –

M18 290 214 405 298 485 357 27 1-1/16 14 –

M20 410 302 580 427 690 508 30 1-1/4 17 –

1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

8.8 10.9 12.9

Torque Values

Torque Values (continued)

Inch Fasteners (SAE)

Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch

No.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32

No.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64

No.8 2.5 *22 3.5 *31 4.7 *42 9 11/32 – 9/64

No.10 3.6 *32 5.1 *45 6.8 *60 – 3/8 – 5/32

1/4 8.1 6 12 9 16 12 – 7/16 – 3/32

5/16 18 13 26 19 33 24 13 1/2 – 1/4

3/8 31 23 45 33 58 43 – 9/16 – 5/16

7/16 50 37 71 52 94 69 16 5/8 – 3/8

1/2 77 57 109 80 142 105 19 3/4 – 3/8

9/16 111 82 156 115 214 158 – 13/16 – –

5/8 152 112 216 159 265 195 24 15/16 – 1/2

3/4 271 200 383 282 479 353 – 1-1/8 – 5/8

1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21

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