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0107
Pump
PT 6 /...
OPERATOR’S MANUAL
0 1 5 4 6 2 9 E N
PT 6 /... Table of Contents
1. Foreword 3
2. Safety Information 4
3. Technical Data 13
4. Operation 16
wc_bo0154629en_006TOC.fm 1
Table of Contents PT 6 /...
5. Maintenance 28
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CALIFORNIA
Proposition 65 Warning:
Diesel engine exhaust, some of its constituents, and certain vehicle
WARNING
components contain or emit chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
1. Foreword
This manual provides information and procedures to safely operate
and maintain this Wacker model. For your own safety and protection
from injury, carefully read, understand and observe the safety
instructions described in this manual.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Corporation.
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Safety Information PT 6 /...
2. Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE and
NOTE callouts which must be followed to reduce the possibility of
personal injury, damage to the equipment, or improper service.
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PT 6 /... Safety Information
2.2 Operating Safety
Familiarity and proper training are required for the safe operation of
equipment. Equipment operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both
WARNING this manual and the engine manual and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the equipment before
being allowed to operate the machine.
2.2.1 NEVER allow anyone to operate this equipment without proper
training. People operating this equipment must be familiar with the
risks and hazards associated with it.
2.2.2 NEVER touch the engine or muffler while the engine is on or
immediately after it has been turned off. These areas get hot and may
cause burns.
2.2.3 NEVER use accessories or attachments that are not recommended by
Wacker. Damage to equipment and injury to the user may result.
2.2.4 NEVER leave machine running unattended.
2.2.5 NEVER operate this machine in applications for which it is not
intended.
2.2.6 NEVER open the priming plug when the pump is hot. Never loosen or
remove inlet or discharge hose fittings when the pump is hot. Hot water
inside could be pressurized much like the radiator on an automobile.
Allow the pump to cool to the touch before loosening the plug and
before loosening or removing the inlet or discharge hose fittings.
2.2.7 NEVER position the pump on a loose, uneven, or unstable surface
where it can tip, roll, slide or fall! The pump must be secure before
operating. Position the pump on a firm, flat surface; adjust the trailer
jacks to be sure the pump is level and supported firmly.
2.2.8 NEVER open the pump housing cover while the pump is operating or
start the pump with the cover off. The rotating impeller inside the pump
can cut or sever objects caught in it.
2.2.9 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 water
inside the pump to overheat.
2.2.10 NEVER reach into or insert anything into the pump while the engine is
on! The impeller inside the pump housing is turning at all times while
the engine is running.
2.2.11 DO NOT allow anyone to stand in front of the discharge port when
starting the engine or while priming the pump! The sudden out-rush of
water could push or knock a person down.
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Safety Information PT 6 /...
2.2.12 ALWAYS make sure the hose connections on the pump are tight. A
loose connection could cause water to spray or result in a hose falling
off the pump while it is in operation.
2.2.13 ALWAYS make sure the water stream from the pump discharge is not
directed in such a way so as to cause erosion to the surrounding
ground or damage or weakening of nearby structures!
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PT 6 /... Safety Information
2.4.6 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
2.4.7 ALWAYS replace the safety devices and guards after repairs and
maintenance.
2.4.8 ALWAYS check all external fasteners at regular intervals.
2.4.9 ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from the moving parts of the equipment.
Towing a large trailer requires special care. Both the trailer and vehicle
must be in good condition and securely fastened to each other to
reduce the possibility of an accident.
WARNING
2.5.1 ALWAYS check that the hitch and coupling on the vehicle are rated
equal to, or greater than, the trailer's “gross vehicle weight rating”
(GVWR).
2.5.2 ALWAYS inspect the hitch and coupling for wear or damage. DO NOT
tow the trailer using defective parts.
2.5.3 ALWAYS make sure the coupling is securely fastened to the vehicle.
2.5.4 ALWAYS check the tires on the trailer for tread wear, inflation, and
condition. Replace worn tires.
2.5.5 ALWAYS connect the safety chains.
2.5.6 ALWAYS connect the breakaway cable safety hook to the bumper or
rear of the vehicle. DO NOT attach it to the hitch.
2.5.7 ALWAYS test the surge brakes on the trailer and the brakes on the
vehicle that will be used for towing.
2.5.8 ALWAYS make sure directional and trailer lights are connected and
working properly.
2.5.9 ALWAYS check that the lug nuts holding the wheels are tight and that
none are missing.
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Safety Information PT 6 /...
2.6 Reporting Trailer Safety Defects
If you believe your trailer has a defect which could cause a crash or
could cause injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to
notifying 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 may
order a recall and remedy campaign. However, NHTSA cannot
become involved in individual problems between you, your dealer, or
Wacker 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 of
Transportation, 400 7th Street SW, (NSA-11), Washington, DC 20590.
You can also obtain other information about motor vehicle safety from
the Auto Safety Hotline.
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PT 6 /... Safety Information
2.7 Label Locations
3 1 2
7
6
11
6
12
5
3
9
8 10
wc_gr001145
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Safety Information PT 6 /...
2.8 Safety Labels
CAUTION!
Use only clean, filtered diesel fuel.
2
CAUTION!
Read and understand the supplied
Operator’s Manuals before operating
3
this machine. Failure to do so increases
the risk of injury to yourself or others.
CAUTION!
Lifting point.
4
WARNING!
Hot surface!
5
WARNING!
Pressurized contents. Do not open
6 when hot!
WARNING!
Never pump volatile, flammable or low
7 flash point fluids. These fluids could
ignite or explode.
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PT 6 /... Safety Information
Ref. Label Meaning
TOWING INSTRUCTIONS ABSCHLEPPINSTRUKTIONEN INSTRUCCIONES DE REMOLQUE INSTRUCTIONS DE REMORQUAGE
1. READ OPERATOR'S MANUAL. 1. BETRIEBSVORSCHRIFT LESEN. 1. LEA EL MANUAL DEL OPERARIO. 1. LIRE LA NOTICE D'EMPLOI.
2. USE HITCH RATED FRO TRAILER'S 2. ANHANGEVORRICHTUNG VERWENDEN, 2. UTILICE UN ACOPLE CORRECTAMENTE 2. UTILISER UN GROCHET D'ATTELAGE CONFORME AU
"GROSS VEHICLE WEIGHT RATING". DIE DER GESAMTBETRIEBSGEWICHTSKLASSE CLASIFICADO PARA LA "CLASE DE PESO BUTO" DEBIT NOMINAL DU POIDS BRUT DE VEHICULE DU
3. SECURELY ATTACH TRAILER TO TOW ENTSPRICHT. DEL VEHICULO DEL REMOLQUE. TRACTEUR.
VEHICLE. 3. ANHANGER SICHER AM ZUGFAHRZEUG 3. ASEGURESE DE AMARRAR CORRECTAMENTE 3. ATTACHER LA REMORQUE FERMEMENT AU VEHICULE
4. ATTACH SAFETY CHAINS USING CROSS BEFESTIGEN. EL REMOLQUE AL VEHICULO DE REMOLQUE. TRACTEUR.
PATTERN. 4. SICHERHEITSKETTEN KREUZWEISE ANBRINGEN. 4. FIJE EN CRUZ LAS CADENAS DE SEGURIDAD. 4. ATTACHER LES CHAINES DE SURETTE EN UTILISANT
114894
5. ATTACH BREAKDOWN CHAIN TO VEHICLE. 5. ABREISSKETTE AM FAHRZEUG ANBRINGEN. 5. FIJE EN EL VEHICULO DE REMOLQUE LA CADENA UNE METHODE CROISEE.
6. CHECK TRAILER LIGHTS. 6. ANHANGERLEUCHTEN PRUFEN. DE DESPRENDIMIENTO. 5. ATTACHER LA CHAINE DE REMORQUAGE AU VEHICULE.
6. CONTROLE LAS LUCES DEL REMOLQUE. 6. VERIFIER LES LAMPES DE LA REMORQUE.
CAUTION!
Service oil bath air filter daily before
starting engine. Severe engine damage
will occur if oil bath filter is low or empty.
11
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Safety Information PT 6 /...
Ref. Label Meaning
CAUTION!
Engine overheat - Check fan belt.
12
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PT 6 /... Technical Data
3. Technical Data
3.1 Engine
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: mm (in.) 0.15 (0.006)
exhaust: 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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Technical Data PT 6 /...
3.2 Pump
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)
3.3 Lubrication
3.4 Trailer
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PT 6 /... Technical Data
3.5 Dimensions
wc_gr001154
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Operation PT 6 /...
4. Operation
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PT 6 /... Operation
1
6 3
7
26
8
2
23
11 5 4
12
21
14
20
24
19 10
22
25 9 13
18
15
16
17
wc_gr003183
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Operation PT 6 /...
4.2 Application
The engine requires No. 2 diesel fuel. Use only fresh, clean fuel. Fuel
containing water or dirt will damage the fuel system. Consult the
engine owner’s manual for complete fuel specifications.
4.4.1 Read and understand the safety and operating instructions at the
beginning of this manual.
4.4.2 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
NOTICE: DO NOT run the engine without oil in the oil-bath air cleaner
or severe engine damage will result.
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PT 6 /... Operation
4.5.5 If necessary, rotate the discharge elbow to direct water flow in the
desired direction.
4.5.6 Attach the suction hose to the suction port (d). Attach the discharge
hoses to the discharge port (e). Check and tighten the clamps and
coupling to make sure the hoses are securely fastened.
4.5.7 Attach the suction strainer to the suction hose to prevent large debris
from being pulled into the pump.
4.5.8 Prime the pump. To do so, open the cover (c) at the top of the pump
and fill the pump housing with water. The pump will not prime unless
this is done.
c
f g
b
wc_gr001165
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Operation PT 6 /...
4.6 To Start
NOTICE: DO NOT crank the starter for more than 15–20 seconds at a
time; the starter motor can overheat and be damaged.
NOTICE: DO NOT run the pump dry for long periods of time or run the
pump without oil in the bearing/seal housing. The mechanical seal
could overheat and be damaged.
4.7 To Stop
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PT 6 /... Operation
c
b e
wc_gr001166
NOTICE: 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 the
suction line and strainer, allowing the pump to draw in air. The mixture
of air and water leads to a condition known as cavitation, which will
quickly destroy the impeller and the water chamber inside the pump
housing
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Operation PT 6 /...
4.10 Hoses
Suction hoses must be rigid enough not to collapse. Make sure the
suction hose is in good condition. A hole or tear in the suction hose
above the water line will prevent the pump from priming.
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PT 6 /... Operation
4.13 Strainer
NOTICE: DO NOT use a strainer with holes larger than the maximum
solid-size rating of the pump—50 mm (2 in.). DO NOT place the
strainer directly into mud or sand. Always keep the strainer suspended
in the liquid being pumped. Failure to follow the above directives may
cause pump damage.
wc_gr001184
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Operation PT 6 /...
4.15 Covers
Drain/Priming Cover:
Clean-out covers are located on the top (a) and bottom (b) of the
pump. The top cover is also used to add water to the pump housing for
priming. To open a cover, loosen the knob and swing the cover to the
side.
Grease the rubber gasket under each cover occasionally to prevent it
from sticking to the metal and tearing.
Impeller Cover:
The impeller cover (c) can be removed to clean the pump, set the
impeller clearance, and inspect the pump interior.
To remove the impeller cover and elbow:
4.15.1 Turn the inner star wheel (d) in until it is seated tightly against the
impeller cover.
4.15.2 Turn the outer star wheel (e) in until the cover is pulled out of the
housing.
4.15.3 When the impeller cover is free of the housing, rotate the clamp (f)
counterclockwise and pull the impeller cover from the housing.
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PT 6 /... Operation
d e
1 1
3
3
f
2
2
g
wc_gr003210
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Operation PT 6 /...
4.16 Hitching and Towing the Trailer
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PT 6 /... Operation
When towing, maintain extra space between the vehicles and avoid
soft shoulders, curbs, and sudden lane changes. If you have not pulled
CAUTION the trailer before, practice turning, stopping, and backing up in an area
away from traffic.
DO NOT exceed 55 mph when towing the trailer.
In most states, large trailers must be registered and licensed by the
State Department of Transportation. Before towing, be sure to check
licensing requirements.
h
f
g
c d
wc_gr003185
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Maintenance PT 6 /...
5. Maintenance
5.2 Storage
If storing the machine longer than 30 days the following steps are
recommended.
5.2.1 Flush the pump and hose lines by pumping clean water for a few
minutes. If the pump was used for pumping salt water, be sure to use
fresh water when flushing it.
5.2.2 Change the engine oil.
5.2.3 Drain and clean the fuel tank. Replace the fuel filter.
5.2.4 Thoroughly clean the exterior of the pump and engine. Visually inspect
the machine for signs of damage or loose bolts.
5.2.5 Remove the covers and clean the pump interior. Wipe or spray all
interior surfaces with a rust-inhibiting oil.
5.2.6 Change the oil in the seal and bearing housings.
5.2.7 Replace the covers. Seal the suction and discharge openings with
tape.
5.2.8 Remove the battery from the machine and store it in a clean dry area.
Charge the battery once a month to maintain condition of the
electrolyte.
5.2.9 Store the machine indoors in a clean, dry area. If the machine must be
stored outside, wrap it tightly.
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PT 6 /... Maintenance
5.3 Periodic Maintenance Schedule
The chart below lists basic engine maintenance. Refer to the engine
manufacturer’s Operation Manual for additional information on engine
maintenance.
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Maintenance PT 6 /...
5.4 Air Cleaner
NOTICE: NEVER run the engine without oil in the air cleaner! Severe
engine damage will result.
Oi
l c e
b
a
wc_gr003175
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PT 6 /... Maintenance
5.5 Fuel Filter
c
c c
a
b
wc_gr001188
wc_gr003175
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Maintenance PT 6 /...
5.7 Engine Lubrication
SAE 10W-30
SAE 5W-20
wc_gr000057
b c
a
wc_gr001187
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PT 6 /... Maintenance
5.8 Engine Oil
wc_gr000476
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Maintenance PT 6 /...
5.10 Fan Belt
a
c
d
wc_gr001190
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PT 6 /... Maintenance
5.11 Pump Housing Mounting Bolts
wc_gr003178
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Maintenance PT 6 /...
5.12 Mechanical Seal Lubrication
b d
c
wc_gr003179
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PT 6 /... Maintenance
5.13 Bearing Housing Lubrication
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Maintenance PT 6 /...
5.14 Impeller Clearance
5.14.2 Open the bottom drain cover and drain the pump.
5.14.3 Remove the suction flange (a) and the flapper gasket (b) from the front
of the pump.
Impeller edges can become extremely sharp; use care when working
on the pump to reduce the risk of being cut.
CAUTION
5.14.4 Clean the impeller (d) with a 50-50 mixture of bleach and water before
working on it.
5.14.5 Reach inside the pump through the suction port, and use a feeler
gauge (c) to check the gap between the impeller and the insert (e). The
pump will operate most efficiently when the gap is maintained between
0.15–0.75 mm (0.005–.025 in.). Larger gaps are allowable but may
reduce pump output slightly.
5.14.6 If necessary, add shims (f) between the insert and the impeller cover
(g) to decrease the gap between the impeller and the insert. The insert
is 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.).
5.14.7 Reinstall the suction flange and the flapper gasket.
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PT 6 /... Maintenance
b
g
d g
e d g
e f
f
0.15–0.75 mm
(0.005–0.025 in.)
wc_gr003206
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Maintenance PT 6 /...
5.15 Cleaning the Engine Cooling Fins
wc_gr003177
5.16 Battery
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PT 6 /... Maintenance
5.17 Lifting the Machine
Only use steel ropes or chains for hoisting. The rope or chain must
have the suitable specified lifting capacity of 1090 Kg (2400 lbs.). Do
WARNING not use improvised ropes or chains.
Never use any other part of the PT6 Pump to lift the machine, as
severe damage may occur.
CAUTION
Do not stand under or get onto the machine while it is being hoisted or
moved.
WARNING
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Maintenance PT 6 /...
5.18 Tires
Keep the tires properly inflated and make sure they have the proper
load rating. Under-inflated tires may cause a blowout which could
WARNING
result in fishtailing or loss of control of the towing vehicle.
Always maintain full air pressure as indicated by the tire manufacturer
on the tire's sidewalls. Check air pressure when the tires are cold,
before you move the trailer. When the trailer tires become worn or
damaged, replace them promptly with the same type, size, and load
capacity as the original tires.
For convenience and safety, it is recommended that you carry a spare
wheel and tire.
Loose or missing lug nuts can cause you to lose a wheel! Keep all lug
nuts tight.
WARNING
Before each trip, check for loose or missing lug nuts. When replacing
lug nuts, make sure the replacement nut matches the original nut
exactly. While the threads of the nut may match, the nut may be a size
that does not hold the wheel securely against the hub even when fully
tightened. Torque nuts evenly in increments to 115 Nm (85 ft.lbs.).
Note: During normal use, the lug nuts will seat during the first one
hundred miles resulting in a drop in torque. Each nut should be
checked at that time and torqued to the proper value.
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PT 6 /... Maintenance
5.21 Safety Chains
d
c
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Maintenance PT 6 /...
5.22 Lights
WARNING
State and federal regulations require that all types of trailers be
equipped with tail, stop and turn lights (e) and side marker lights (f).
A special wiring harness (g) for connecting the trailer lights to the
lighting system of the tow vehicle is supplied with the trailer.
g f
wc_gr003182
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PT 6 /... Maintenance
5.23 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
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Maintenance PT 6 /...
5.24 Wiring Diagram (0007174 > Rev 119; 0007175 > Rev 122)
1
W
W
Y Y
G/Y 3
G
20 W/R
V/B
B
P/B
2
L B
19 4
Y
L
Or
V
L 5
17
18
Y Y R
B
Y
24 6 + –
W
B B
Y
R
Y/G
B
+ –
26
16 G B L
Y Br
W/R W/B
W Y/R
V/B Gr
G
Y
Or 23 23
R R G/W Br
R P/B
L
R B
R P/B
B B R
15/54 86 87 85
L
Br
L 14 R B 50
30 25
W 12 7 8 9 30
Br 13 P
15 RW
11 10 L
BL 21 Br Br
L
W
Br 22 wc_gr003163
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PT 6 /... Maintenance
5.25 Wiring Diagram Components
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
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Maintenance PT 6 /...
5.26 Wiring Diagram (0007174 < Rev 120; 0007175 < Rev 123)
1
W
W
Y
G/Y 3
G
15 B
2
L
6
Y
L
L 5
14
9
Y Y R
B
Y
6 + –
W
B
12 B
Y
R
4
B
+ – R
13 W
L
Or Br B
G
Y Y/G
R
15/54
50
11
30
7 8 10
Br
wc_gr003173
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PT 6 /... Maintenance
5.27 Wiring Diagram Components
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
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Maintenance PT 6 /...
5.28 Basic Troubleshooting
wc_tx000567gb.fm 50
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 90
Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957
Wacker 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