INSTALLATION & SERVICED04-991-2400A

W0069A

Models: D-04, G-04

WANNER ENGINEERING, INC.1204 Chestnut Avenue, Minneapolis, MN 55403 TEL: (612) 332-5681 FAX: (612) 332-6937 TOLL-FREE FAX [US only]: (800) 332-6812

www.hydra-cell.com email: sales@wannereng.com

� D04-991-�400A

Max Pressure �,500psi(170bar)

Capacity @ Max Pressure rpm gpm I/min D/G-04-X 1750 �.9 11.0 D/G-04-E 1750 �.1 7.8 D/G-04-S 1750 1.6 6.1

Delivery @ Rated Pressure revs/gal

500psi 1500psi �500psi D/G-04-X 565 583 603 D/G-04-E 761 795 833 D/G-04-S 9�1 97� 1,093

revs/liter

35bar 100bar 170bar D/G-04-X 149 154 159 D/G-04-E �01 �11 ��4 D/G-04-S �44 �57 �87

Max Inlet Pressure 500psi(35bar)

Max Temperature �50°F(1�1°C)–consultfactoryfor temperaturesabove160°F(71°C)

Inlet Port D-04:1/�inchNPT G-04:1/�inchBSPT

Discharge Port D-04:1/�inchNPT G-04:1/�inchBSPT

Shaft Diameter 7/8inch(��.��mm)

Shaft Rotation Bi-directional

Bearings Ballbearings

Oil Capacity 1.1USquarts(1.05liters)

Weight 37lbs(16.8kg)

Calculating Required Horsepower (kW)*

+6xrpm

63,000= electricmotorHP*

D/G-04 Specifications

+6xrpm

84,4�8= electricmotorkW*

*rpmequalspumpshaftrpm.HP/kWisrequiredapplicationpower.Usecautionwhensizingmotorswithvariablespeeddrives.

D/G-04 Contents PageSpecifications..........................................................................�

Dimensions.............................................................................4

Installation...............................................................................5

Maintenance............................................................................9

Service(FluidEnd)...............................................................10

Service(HydraulicEnd)........................................................14

Troubleshooting.....................................................................17

Warranty................................................................................19

gpmxpsi

1,460– ( )psi–500�0

lpmxbar

511– ( )bar–354

3 D04-991-�400A

RPM

0

NPSH

r (fe

et o

f wat

er)

1750

1

2

3

4

5

6

7

8

9

10

11

12

0 200 400 600 800 1000 1200 1400 1600 1800

D/G-04-XD/G-04-ED/G-04-S

NPSH

r (m

eter

s of

wat

er)

1.0

2.0

3.0

2.5

3.5

0 .5

1.5

W0080

0

RPM0 200 400 600 800 1000 1200 1400 1600 1800

1750

500 PSI (35 bar)1500 PSI (100 bar)2500 PSI (170 bar)

12.5

0

11.25

10

8.75

7.5

6.25

5.0

3.75

2.5

1.25

3.33

3.00

2.66

2.33

2.00

1.66

1.33

1.00

0.66

0.33

Gal

lons

per

Min

ute

Lite

rs p

er M

inut

e

D/G-04-X

D/G-04-E

D/G-04-S

W0081

RPM

0

Lift

(feet

of w

ater

)

0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

200 400 600 800 1000 1200 1400 1600 1800

1750

D/G-04-XD/G-04-ED/G-04-S

Lift

(cm

of w

ater

)

20

40

60

80

100

120

140

160

180

200

220

240

W0079

Performance Net Positive Suction Head – NPSHr

Dry Lift

D/G-04 Specifications

4 D04-991-�400A

D/G-04 DimensionsD/G-04 Models with Metallic Pumping HeadBrass

304StainlessSteel

316StainlessSteel

7.01(178)

10.38(263.7)

Outlet D-04: 1/2" NPTG-04: 1/2" BSPT

D-04: 1/2" NPTG-04: 1/2" BSPTInlet

9.93(252.2)

2.25(57.2)

8.71(221.2)

2.25(57.2)

2.75(69.9)

2.75(69.9)

3.35(85.1)

0.75(19.1)

0.75(19.1)

4.25(108)

0.189(4.8)

1.71(43.4)

6.55(166)

5.00(127)

3.52(89.4)

4.97(126)

4.250(107.9)

0.875(22.23)

1.73(43.9)

Good Key

W0078A

5 D04-991-�400A

D/G-04 InstallationNOTE: The numbers in parentheses are the Reference Numbers on the illustrations in the Parts Manual.

LocationLocatethepumpasclosetothesupplysourceaspossible.

Installitinalightedcleanspacewhereitwillbeeasytoinspectandmaintain.Allowroomforcheckingtheoillevel,changingtheoil,andremovingthepumphead(manifold,valveplateandrelateditems).

MountingThe pump shaft can rotate in either direction.To preventvibration,securelyattachthepumptoarigidbase.

On a belt-drive system, align the sheaves accurately; pooralignmentwasteshorsepowerandshortensthebeltandbearinglife.Makesurethebeltsareproperlytightened,asspecifiedbythebeltmanufacturer.

Onadirect-drivesystem,aligntheshaftsaccurately.Unlessotherwisespecifiedby thecouplingmanufacturer,maximumparallel misalignment should not exceed .015” and angularmisalignmentshouldbeheldto1degreemaximum.Carefulalignmentextendslifeofthecoupling,pump,shafts,andsupportbearings.Consultcouplingmanufacturerforexactalignmenttolerances.

Onaclose-coupledsystem,coatthemotorshaftliberallywithanti-seize.

Important PrecautionsAdequate Fluid Supply. To avoid cavitation andprematurepumpfailure,besurethatthepumpwillhaveanadequatefluidsupplyandthattheinletlinewillnotbeobstructed.See“InletPiping”.

Positive Displacement.Thisisapositive-displacementpump.Toavoidseveresystemdamageifthedischargelineeverbecomesblocked,installareliefvalvedownstreamfromthepump.See“DischargePiping”.

Safety Guards. Install adequate safety guards overall pulleys, belts, and couplings. Follow all codes andregulations regarding installation and operation of thepumpingsystem.

Shut-Off Valves.Neverinstallshut-offvalvesbetweenthe pump and discharge pressure regulator, or in theregulatorbypassline.

Freezing Conditions.Protect thepump from freezing.SeealsotheMaintenanceSection.

ConsulttheFactoryforthefollowingsituations:

• Extremetemperatureapplicationsabove160°F(71°C)orbelow40°F(4°C)

• Pressurefeedingofpumps• Viscousorabrasivefluidapplications• Chemicalcompatibilityproblems• Hotambienttemperaturesabove110°F(43°C)• Conditionswherepumpoilmayexceed�00°F(93°C)

becauseofacombinationofhotambienttemperatures,hotfluidtemperature,andfullhorsepowerload—anoilcoolermayberequired

W0074A

6 D04-991-�400A

D/G-04 Installation

Inlet CalculationsAcceleration HeadCalculating the Acceleration Head

Usethefollowingformulatocalculateaccelerationheadlosses.SubtractthisfigurefromtheNPSHa,andcomparetheresulttotheNPSHroftheHydra-Cellpump.

Ha=(LxVxNxC)÷(KxG)

where:

Ha=Accelerationhead(ftofliquid)L=Actuallengthofsuctionline(ft)—notequivalentlengthV=Velocityofliquidinsuctionline(ft/sec)[V=GPMx(0.408

÷pipeID�)]N=RPMofcrankshaftC=Constantdeterminedbytypeofpump—use0.066forthe

D-04andG-04Hydra-CellpumpsK=Constant to compensate for compressibility of the fluid

—use:1.4forde-aeratedorhotwater;1.5formostliquids;�.5forhydrocarbonswithhighcompressibility

G=Gravitationalconstant(3�.�ft/sec�)

Friction LossesCalculating Friction Losses in Suction Piping

When following the above recommendations (under “inletPiping”) for minimum hose/pipe I.D. and maximum length,frictionallossesinthesuctionpipingarenegligible(i.e.,Hf=0)ifyouarepumpingawater-likefluid.

When pumping more-viscous fluids such as lubricating oils,sealants,adhesives,syrups,varnishes,etc.,frictional lossesinthesuctionpipingmaybecomesignificant.AsHfincreases,theavailableNPSH(NPSHa)willdecrease,andcavitationwilloccur.

Ingeneral,frictionallossesincreasewithincreasingviscosity,increasingsuction-linelength,increasingpumpflowrate,anddecreasing suction-line diameter. Changes in suction-linediameterhavethegreatestimpactonfrictionallosses:a�5%increase in suction-line diameter cuts losses by more thantwotimes,anda50%increasecutslossesbyafactoroffivetimes.

Consultthefactorybeforepumpingviscousfluids.

Inlet Piping (Suction Feed)CAUTION: When pumping at temperatures above 160° F (71° C), use a pressure-feed system.

Installdraincocksatanylowpointsofthesuctionline,topermitdraininginfreezingconditions.

Provideforpermanentortemporaryinstallationofavacuumgaugetomonitortheinletsuction.Tomaintainmaximumflow,vacuumatthepumpinletshouldnotexceed7in.Hgat3gpmand70°F(180mmHgat11.4 liters/minand�1°C).Do not supply more than one pump from the same inlet line.

Supply TankUseasupplytankthatislargeenoughtoprovidetimeforanytrappedairinthefluidtoescape.Thetanksizeshouldbeatleasttwicethemaximumpumpflowrate.

Isolatethepumpandmotorstandfromthesupplytank,andsupportthemseparately.

Install a separate inlet line from the supply tank to eachpump.

Installtheinletandbypasslinessotheyemptyintothesupplytankbelowthelowestwaterlevel,ontheoppositesideofthebafflefromthepumpsuctionline.

Ifalinestrainerisusedinthesysteminstallitintheinletlinetothesupplytank.

To reduce aeration and turbulence, install a completelysubmergedbaffleplatetoseparatetheincomingandoutgoingliquids.

Installavortexbreakerinthesupplytank,overtheoutletporttothepump.

Placeacoveroverthesupplytank,topreventforeignobjectsfromfallingintoit.

Hose Size and RoutingUse the shortest, most-direct route from the supply tank tothepump.Ifelbowsareneeded,45°arerecommended.Anyrestrictionsintheinletpipingmaycausepumpoutputtodrop.Do not install any 90° elbows in the pump inlet.

• Use flexiblenoncollapsiblehosebetweenthepumpandrigidpipingorsupplytank.Thiswillabsorbvibration,andallowforexpansionorcontraction.

• Use the largest practical hose. The smallest permissiblesizeis5/8in.(16mm)I.D.

• Allvalves, fittings,andunionsmustalsohave5/8-in. (16mm)minimumI.D.Donotexceed5feetofhoseandpipingbetweenandsupplytankandthepumpinlet.

• Supportthepumpandpipingindependently.• Makesurealljointsaresealedandtight,topreventthepump

fromdrawingairintotheinlet.• Donotusealinestrainerorfilterinthesuctionlineunless

regularmaintenanceisassured.Ifused,itshouldhaveafree-flowareaofatleastthreetimesthefree-flowareaoftheinlet.

Inlet Piping (Pressure Feed)Provideforpermanentortemporaryinstallationofavacuum/pressure gauge to monitor the inlet vacuum or pressure.Pressureatthepumpinletshouldnotexceed500psi(34bar);ifitcouldgethigher,installaninletpressureregulator.

Donotsupplymorethanonepumpfromthesameinletline.

7 D04-991-�400A

D/G-04 InstallationDischarge PipingNOTE: Consult the Factory before manifolding two or more pumps together.

NOTE: Single-acting pumps create a pulsing flow. Using pulsation dampening devices in the discharge line can reduce or eliminate this.

Hose and RoutingUsetheshortest,most-directrouteforthedischargeline.

Selectpipeorhosewithaworking pressure ratingofatleast1.5timesthemaximumsystempressure.EXAMPLE:Selecta3000psiW.P.ratedhoseforsystemstobeoperatedat�000psi-gaugepressure.

Useabout6ft(1.8m)offlexiblehosebetweenthepumpandrigidpiping.

Supportthepumpandpipingindependently.

Pressure RegulationInstall a pressure regulator or unloader in the discharge line.Bypasspressuremustnotexceedthepressurelimitofthepump.

Size the regulator so that, when fully open, it will be largeenough to relieve the full capacityof thepumpwithoutoverpressurizingthesystem.

Locatethevalveasclosetothepumpaspossibleandaheadofanyothervalves.

Adjustthepressureregulatingvalvetonomorethan10%overthemaximumworkingpressureofthesystem.Donotexceedthemanufacturer’spressureratingforthepumporregulator.

Routethebypasslinetothesupplytank,ortothesuctionlineas far as possible from the pump (to reduce the chance ofturbulenceandcavitation).

Ifthepumpmayberunforalongtimewiththedischargeclosedandfluidbypassing,installathermalprotectorinthebypassline(topreventseveretemperaturebuildupinthebypassedfluid).

CAUTION: Never install shutoff valves in the bypass line or between the pump and pressure regulator or relief valve.

Provideforpermanentortemporaryinstallationofapressuregaugetomonitorthedischargepressureatthepump.

Foradditionalsystemprotection,installa“pop-off”safetyreliefvalve in the discharge line, downstream from the pressureregulator.

Minimizing Acceleration Head and Frictional Losses

Tominimizetheaccelerationheadandfrictionallosses:

• Keepinletlineslessthan3ft(1m)long• Useatleast5/8in.(16mm)I.D.inlethose• Usesofthose(low-pressurehose,noncollapsing)forthe

inletlines• Minimizefittings(elbows,valves,tees,etc.)• Use a suction stabilizer on the inlet.

Net Positive Suction HeadNPSHamustbeequal toorgreater thanNPSHr. Ifnot, thepressureinthepumpinletwillbelowerthanthevaporpressureofthefluid—andcavitationwilloccur.

Calculating the NPSHa

UsethefollowingformulatocalculatetheNPSHa:

NPSHa=Pt+Hz-Hf-Ha-Pvp

where:

Pt=Atmosphericpressure

Hz=Verticaldistancefromsurfaceliquidtopumpcenterline(ifliquidisbelowpumpcenterline,theHzisnegative)

Hf=Frictionlossesinsuctionpiping

Ha=Accelerationheadatpumpsuction

Pvp = Absolute vapor pressure of l iquid at pumpingtemperature

NOTES:

• In good practice, NPSHa should be � ft greater thanNPSHr

• AllvaluesmustbeexpressedinfeetofliquidAtmospheric Pressure at Various Altitudes

Altitude Pressure Altitude Pressure (ft) (ft of H2O) (ft) (ft of H2O) 0 33.9 1500 3�.1 500 33.3 �000 31.5 1000 3�.8 5000 �8.�

8 D04-991-�400A

Before Initial Start-UpBeforeyoustartthepump,besurethat:

• Allshutoffvalvesareopen,andthepumphasanadequatesupplyoffluid.

• Allconnectionsaretight.• Theoillevelis1/4inch(6mm)abovethecastsurfaceinthe

upperoilreservoir.• Thereliefvalveonthepumpoutletisadjustedsothepump

startsunderminimumpressure.• All pulleys and belts are properly aligned, and belts are

tensionedaccordingtospecification.• Allpulleysandbeltshaveadequatesafetyguards.

Initial Start-Up Procedure1. Turnonpowertothepumpmotor.�. Checktheinletpressureorvacuum.Tomaintainmaximum

flow,inletvacuummustnotexceed7in.Hgat70°F(180mmHgat�1°C).Inletpressuremustnotexceed500psi(34bar).

3. Listen for any erratic noise, and look for unsteady flow.If thepumpdoesnot clear, refer to theTrouble-shootingSection.

4. Ifthesystemhasanairlockandthepumpfailstoprime: a. Turnoffthepower. b. Removethepressuregaugeorplugfromtheteefitting

atthepumpoutlet(refertotheillustrationonpage3). NOTE: Fluid may come out of this port when the plug

is removed. Provide an adequate catch basin for fluid spillage, if required. Fluid will come out of this port when the pump is started, so we recommend that you attach adequate plumbing from this port so fluid will not be sprayed or lost. Use high-pressure-rated hose and fittings from this port. Take all safety precautions to assure safe handling of the fluid being pumped.

c. Jogthesystemonandoffuntilthefluidcomingfromthisportisair-free.

d. Turnoffthepower. e. Removetheplumbingthatwastemporarilyinstalled,

andreinstallthepressuregaugeorplug.5. Adjust the discharge pressure regulator to the desired

operating and bypass pressures. Do not exceed themaximumpressureratingofthepump.

6. After the pressure regulator is adjusted, set the “pop-off” safety relief valveat 100psi (7bar) higher than thedesiredoperatingpressure.Toverifythissetting,adjustthedischargepressureregulatorupwarduntil thereliefvalveopens. Follow the recommendations in the above NOTE(step4b)forhandlingthefluidthatwillcomefromthereliefvalve.

7. Resetthedischargepressureregulatortothedesiredsystempressure.

8. Provideareturnlinefromthereliefvalvetothesupplytank,similartothebypasslinefromthepressureregulator.

D/G-04 Installation

9 D04-991-�400A

D/G-04 MaintenanceNOTE: The numbers in parentheses are the Ref. Nos. on the illustrations in the Parts Manual.

DailyCheck theoil leveland theconditionof theoil.Theoil levelshouldbe1/4in.(6mm)abovethecastsurfaceintheupperoilreservoir.

Use the appropriate Hydra-Oil for the application (contactWannerEngineeringifindoubt).

CAUTION: If you are losing oil but don’t see any external leakage, or if the oil becomes discolored and contaminated, one of the diaphragms (17) may be damaged. Refer to the Fluid-End Service Section. Do not operate the pump with a damaged diaphragm.

CAUTION: Do not leave contaminated oil in the pump housing or leave the housing empty. Remove contaminated oil as soon as discovered, and replace it with clean oil.

PeriodicallyChange the oil after the first 100 hours of operation, thenchange according to the guidelines below. When changing,removethedrainplug(60)atthebottomofthepumpsoalloilandaccumulatedsedimentwilldrainout.

Hours Between Oil Changes @ Various Process Fluid Temperatures <90°F <139°F <180°F Pressure RPM (32°C) (60°C) (82°C)

<1500psi(100bar) <1�00 6,000 4,000 �,000 <1800 3,000 �,000 1,500

<�500psi(170bar) <1�00 3,000 �,000 1,500 <1800 1,500 — 1,000

NOTE: Minimum oil viscosity for proper hydraulic end lubrication is 16-20 cST (80-100 SSU).

NOTE: Use of an oil cooler is recommended when process fluid and/or hydraulic end oil exceeds 180°F (82°C).

CAUTION: Do not turn the drive shaft while the oil reservoir is empty.

Checktheinletpressureorvacuumperiodicallywithagauge.Ifvacuumat thepump inletexceeds7 in.Hg (180mmHg),checktheinletpipingsystemforblockages.Ifthepumpinletislocatedabovethesupplytank,checkthefluidsupplylevelandreplenishiftoolow.

CAUTION: Protect the pump from freezing. Refer also to the “Shutdown Procedure”.

Shutdown Procedure During Freezing TemperaturesTake all safety precautions to assure safe handling of the fluid being pumped. Provide adequate catch basins for fluid drainage and use appropriate plumbing from drain ports, etc., when flushing the pump and system with a compatible antifreeze.

1. Adjustthedischargepressureregulatingvalvesothepumprunsunderminimumpressure.Stopthepump.

�. Drainsupplytank;openanydraincocksinsystempipingandcollectdrainage.Drainasmuchfluidfromthepumpmanifoldand plumbing attached directly to the pump manifold bylooseningfittingsorremovingplugsorgauges.

3. Closedraincocksinsystempipingandtightenorreplaceanyfittings,gaugesorplugs.

4. Fillsupplytankwithenoughantifreezetofillsystempipingandpump.

NOTE: Disconnect the system return line from the supply tank and connect it to a separate reservoir.

5. Startthepumpandallowittorununtilthesystemisfilledwithantifreeze.NOTE: If the system has an air lock and the pump fails to prime, follow step 4 of the Initial Start-up Procedure to clear the air.

6. Whenmostlyantifreezeisflowingfromthesystemreturnline,stopthepump.Connectthesystemreturnlinebacktothesupplytankandcirculatetheantifreezeforashortperiod.

7. It is also good practice to change the oil in the hydraulicendbeforestorageforanextendedperiod.Thiswillremoveany accumulated condensation and sediment from theoil reservoir. Drain and refill the hydraulic end with theappropriateHydra-Oilandoperatethepumpforashortperiodtoassuresmoothperformance.

10 D04-991-�400A

W0072A

D/G-04 Service (Fluid End)

Bolt Torque Specifications Ref. No. D-04 G-041 50ft-lbs 70Nm17 10in-lbs 110Ncm

W0070

W0071

11 D04-991-�400A

D/G-04 Service (Fluid End)NOTE: The number in parentheses are the Reference numbers on the illustration at right and in the Parts Manual.

Thissectionexplainshowtodisassembleandinspectalleasilyserviceable parts of the pump. Repair procedures for thehydraulicend(oilreservoir)ofthepumpareincludedinalatersectionofthemanual.

CAUTION: Do not disassemble the hydraulic end unlessyouareaskilledmechanic.Forassistance,contactWannerEngineering(TEL61�-33�-5681orFAX61�-33�-6937)orthedistributorinyourarea.

CAUTION: The two capscrews (16) that screw through thediaphragmplateinthepumphousingholdthediaphragmplateoverthehydraulicendofthepump.Donotremovethemexceptwhenrepairingthehydraulicend.

Tools and Supplies•Straightedge(atleast6in.long)•Greaseorpetroleumjelly•Torquewrench,ratedtoatleast50ft-lbs(70N-m)•Emerycloth•1/�-in.drivesocketwrench•5/16-in.(8-mm)open-endwrench•5-mmhexAllenwrench•8-mmhexbitsocket(1/�inchdrive)•WannerD-04/G-04ToolKit,whichincludesthefollowing: •Seatpuller •Plungerholder •Plungerguidelifter •Shaftrotator

Service Procedures

1. Remove Manifold (3) and Valve Plate (12) a.Remove all eight capscrews (1) around the manifold.

Usean8-mmhexAllenwrench. b.Removethemanifold(3). c. Inspect the manifold for warping or wear around the

inletandoutletports.Ifwearisexcessive,replacethemanifold.

Tocheckifthemanifoldiswarped,placeastraightedgeacrossit.Awarpedmanifoldshouldbereplaced.

d.Removethetwosocket-headcapscrews(14)thatholdthevalveplatetothepumphousing.Usea5-mmhexAllenwrench.

e. Inspect the valve plate in the same manner as themanifold,forexcessivewearand/orwarping.Replaceifnecessary.

W0076

2. Inspect Valves (5-11) Thethreeinletandthreeoutletvalveassembliesareidentical

(but face in opposite directions). Inspect each valve asfollows:

a.Checkthespringretainer(10),andreplaceifworn. b.Checkthevalvespring(8).Ifshorterthananewspring,

replaceit(donotstretchausedspring). c. Checkthevalve(7).Ifwornexcessively,replaceit. d.Removethevalveseat(6),O-ring(5),anddampening

washer(11)(Seenotebelow).AseatpullerisincludedintheWannerToolKit.Inspectallpartsforwear.Inallinstances,O-ring(5)shouldbereplaced.Replacethevalveseatand/ordampeningwasherifnecessary.

NOTE: On newer pump models, the dampening washer (11) is not used because the valve seat (6) is thicker. When replacing the valve seat on an older pump model which has dampening washers, do not reinstall the dampening washers as the new valve seat is thicker than the original.

e.Reinstallthevalveassemblies: •Cleanthevalveportsandshoulderswithemerycloth,

and lubricate them with lubricating gel or petroleumjelly.

•InstalltheO-ring(5)onthevalveseat(6). • Inlet (3 lower valves in the illustration below).Insert

thespringretainer(10)intothevalveplate,theninsertthespring,valve,Tetraseal,valveseat,anddampeningwasher (8,7,9,6,11). A flat O-ring (Tetra seal, 9) goesbetweentheretainerandseat.

• Outlet (3 upper valves in the illustration below).Insert the dampening washer, valve seat, Tetra seal,valve,andspring,thentheretainer.InstalltheflatO-ring(Tetraseal,9)betweentheretainerandseat.

1� D04-991-�400A

D/G-04 Service (Fluid End)3. Inspect and Replace Diaphragms (17) a.Liftadiaphragmbyoneedge,andturnthepumpshaft

untilthediaphragmmovesupto“topdeadcenter”.Thiswillexposemachinedcross-holesintheplungershaftbehindthediaphragm.

b. Inserttheplungerholdertoolthroughoneofthemachinedcross-holes, tohold thediaphragmup. (Don’t removethetooluntilthenewdiaphragmisinstalledinstep“f”below.)

c. Unscrewthediaphragm.Usea5/16-in.(8-mm)open-endwrench,andturncounterclockwise.

d. Inspectthediaphragmcarefully.Adamageddiaphragmgenerally indicates a pumping system problem andreplacingonly thediaphragmwill not solve the largerproblem.Inspectthediaphragmforthefollowing:

•Small puncture.Usuallycausedbyasharp foreignobjectinthefluid,orbyaniceparticle.

• Diaphragm pulled away from the metal insert.Usually caused by excessive inlet vacuum, or byoverpressurizationofthepumpinlet.

•Outer diaphragm bead extruded.Usuallycausedbyoverpressurizationofthepump.

• Diaphragm becoming stiff and losing flexibility.Usuallycausedbypumpingafluidthatisincompatiblewiththediaphragmmaterial.

• Cut diaphragm convolute. Usually caused byexcessiveinletvacuum.

CAUTION: If a diaphragm has ruptured and foreign material or water has entered the oil reservoir, do not operate the pump. Check all diaphragms, then flush the reservoir completely (as outlined below) and refill it with fresh oil. Never let the pump stand with foreign material or water in the reservoir, or with the reservoir empty.

e.Cleanawayanyspilledoil. f. Installagoodornewdiaphragmandtightento10in.-lbs

(110N-cm). g.Repeattheaboveinspectionprocedure(andreplacement,

ifnecessary)withtheothertwodiaphragms.

4. Flush Contaminant from Hydraulic End (only if a diaphragm has ruptured) a.With the valve plate and manifold still removed (see

above), remove theoildraincap(60)allowalloilandcontaminanttodrainout.

b.Fillthereservoirwithkeroseneorsolvent,manuallyturnthe pump shaft to circulate the kerosene, and drain.Disposeofthiscontaminatedfluidproperly.

c. Repeattheflushingprocedure(step“b”above). d.Fillthereservoirwithfreshoil,manuallyturnthepump

shafttocirculatetheoil,anddrainagain. e.Refill the reservoir. If the oil appears milky, there is

still contaminant in the reservoir. Repeat the flushingprocedureuntiltheoilappearsclean.

5. Prime the Hydraulic Cells a.With the pump horizontal, fill the reservoir with the

appropriateHydra-oilfortheapplication. b.All air in the oil within the hydraulic cell (behind the

diaphragms) must be forced out by turning the shaft—andthuspumpingthepiston.Useaglovewhenturningtheshaftbyhand.

Turn the shaft until a bubble-free flow of oil comesfrombehindall thediaphragms.Watch theoil level inthereservoir:ifitgetstoolowduringpriming,airwillbedrawnintothepiston(insidethehydraulicend).Thiswillcausethepumptorunrough,andyouwillhavetostartoveragainwithprimingthehydrauliccells.

c. AftertheHydra-Cellsarefullyprimed,ensurethattheoillevelis1/4in.(6mm)abovethecastsurfaceintheupperoilreservoir.

d.Wipe excess oil f rom the diaphragm plate anddiaphragms.

13 D04-991-�400A

D/G-04 Service (Fluid End)6. Reinstall Valve Plate (12) and Manifold (3) a.Reinstallthevalveplate(1�),withthevalveassemblies

installedasoutlinedabove,onto thediaphragmplate(18)andalignmentpins(�9).

Tighten the two socket-head capscrews evenly andsnuglytocompresstheouterdiaphragmbeadsandholdthevalveplateinplace.

b.Reinstall theO-rings(4)onthefrontsideof thevalveplate.Usepetroleumjellyorlubricatinggeltoholdtheminplace.

c. Reinstallthemanifoldontothevalveplate. d. Insertall capscrews (1),withwashers (�),around the

edgeof themanifold,andalternately tightenoppositeboltsuntilallaresecure.Torqueto50ft-lbs(70N-m).

e.Recheckallboltsfortightnessandpropertorque.

14 D04-991-�400A

D/G-04 Service (Hydraulic End)

W0073A

15 D04-991-�400A

D/G-04 Service (Hydraulic End)NOTE: The numbers in parentheses are the Ref. Nos. on the illustrations in the Parts Manual.

This section explains how to disassemble and inspect thehydraulicend(oilreservoir)ofthepump.

CAUTION: Do not disassemble the hydraulic end unless you are a skilled mechanic. For assistance, contact Wanner Engineering (TEL 612-332-5681 or FAX 612-332-6937) or the distributor in your area.

Dependingontherepairyouareattempting,youmayormaynothavetoremovethemotorfromadirect-drivepump/motorunit.

Internal piston components (�1-�7) can be serviced withoutremovingthemotororcrankshaft.Themotorandcrankshaftmust be removed to service the connecting rod (59), pistonhousing(�0),crankshaft(57),frontbearing(68),backbearing(56),orseal(54).

Tools and Supplies•Toolsrequiredforhydraulicendonly: •Snap-ringpliers •Smallhook •8-mmsocketwrench

To Service Pistons Without Removing Motor or Crankshaft

1. Disassemble Pistons With the manifold, valve plate, diaphragm plate, and

diaphragms removed,and theoildrained from thepump(seetheFluid-EndServiceSection):

a.Removethesnapring(�7)fromoneofthepistons,usingastandardsnap-ringpliers.

b.Pullout thevalveplunger(�4).Thisalsoremovesthewasher(�6)andspring(�5).

c.Insertasmallhookthroughthecenterholeofthevalvecylinder(��),andpullthecylinderoutofthepiston.Becarefulnottodamagethepiston.

d. Inspectallparts,andreplacetheO-ringandanyotherpartsthatarewornormaybedamaged.

e.Repeatsteps“a”through“d”fortheremainingpistons.

2. Reassemble Pistons a.Tipthepumpsothepistonsarevertical. b.Dropaball (�1) into theopening in thebottomof the

piston. c. Insertthevalveplunger(�4)intoavalvecylinder(��).

Slide a spring (�5) over the plunger, inside the valvecylinder.

d.Slidetheassembledvalvecylinder,plunger,andspring(��-�5)intothepiston(�0).

e. Insertthewasher(�6)overtheplunger. f. Usingthesnap-ringpliers, insertasnapring(�7)into

thepiston. g.Repeattheaboveprocedurefortheothertwopistons.

To Service Remainder of Hydraulic End

1. Remove Pump Housing a.Remove the manifold, valve plate, diaphragm plate,

anddiaphragms,asoutlined in theFluid-EndServiceSection.

b.Drain theoil from thepumphousingby removing thedrainplug(60).

c. Standthepumponend,withthedriveshaftup. d.Removethebolts(50)thatsecurethebackcover(5�)

tothehousing(78).Usean8-mmsocketwrench.SavetheO-rings(51).

e.RemovethecoverandthecoverO-ring(53). f. Remove the crankshaft (57) by pulling it through the

connectingrods(59).

2. Remove and Replace Pistons Toremovethepistons(�0),firstremovetheconnectingrod

(59)andpin(58)bypressingthepinthroughtheconnectingrod.

Reversetheprocesstoreinstallthepiston. RefertoSteps5and6belowtoreplacethediaphragmand

reassemblethepump.

16 D04-991-�400A

D/G-04 Service (Hydraulic End)3. Replace Shaft Seal NOTE: Inspect the shaft seal (54) before continuing. If

it looks damaged in any way, replace it. a.Pressthebackbearing(55)andseal(54)outofthecover

(5�).Discardtheseal. b.Apply a coating of Loctite High-Performance Pipe

Sealant with PTFE, or a comparable product, to theoutersurfaceofanewsealandtheinsidesurfaceoftheopeninginthebackcover(5�)wherethesealwillrest.

c. Pressthenewsealintothebackcover. d. Inspectthebearing(55).Ifpittedordamaged,replace

it. e.ApplyacoatingofLoctiteRc/609RetainingCompoundor

comparableproducttotheoutersurfaceofthebearing.Pressthebearingintothebackcoveruntilitrestsontheshoulder.Theshieldonthebearingmustfaceawayfromthebackcover.

4. Reassemble Housing and Back Cover a.Standthepumponend. b.Withthepistonsandconnectingrodsinplace,reinstall

the crankshaft by threading it through the connectingrods.

c. Reinstallthebackcover,coverO-ring,andbolts(withtheirO-rings).

5. Reinstall Diaphragms a.Screw the plunger guide lifter (from the Wanner Tool

KitorRepairKit)intothevalveplunger(�4).Pullouttoexposethecrossholesintheplunger.Rotatetheshaftuntilthepistonisattopdeadcenter.

b. Inserttheplungerholdertool(fromtheWannerToolKit),throughtheplungerhole—toholdtheplungerawayfromthediaphragmplate(18),andtokeeptheplungerfromturningwhenthediaphragmisbeinginstalled.

c. Engage the diaphragm insert threads to the plungerthreads,andturnthediaphragmbyhanduntiltheinserthitstheshoulderofthevalveplunger(�4).

d.Holdtheplungerholdertooltosecurethevalveplunger,andtorquethediaphragminsertto10in.-lbs(110N-cm)usinga5/16-in.(8-mm)open-endwrench.

e.Repeat the above procedure for the plungers anddiaphragmsoftheothertwocylinders.

f. Fillthereservoirwithfreshoilandprimethepump,asoutlinedintheFluid-EndServiceSection.

6. Reassemble Pump ReassemblethepumpasoutlinedintheFluid-EndService

Section.

17 D04-991-�400A

D/G-04 TroubleshootingCavitation• Inadequatefluidsupplybecause: —Inletlinecollapsedorclogged —Cloggedlinestrainer —Inletlinetoosmallortoolong —Airleakininletline —Wornordamagedinlethose —Suctionlinetoolong —Toomanyvalvesandelbowsininletline• Fluidtoohotforinletsuctionpipingsystem.• Airentrainedinfluidpipingsystem.• Aerationandturbulenceinsupplytank.• Inletvacuumtoohigh(refertotheInstallationSection,Inlet

Calculations).

Symptoms of Cavitation•Excessivepumpvalvenoise•Prematurefailureofspringorretainer•Volumeorpressuredrop•Rough-runningpump•Prematurefailureofdiaphragms

Drop in Volume or PressureAdropinvolumeorpressurecanbecausedbyoneormoreofthefollowing:

• Airleakinsuctionpiping• Cloggedsuctionlineorsuctionstrainer• Suctionlineinletabovefluidlevelintank• Inadequatefluidsupply• PumpnotoperatingatproperRPM• Reliefvalvebypassingfluid• Wornpumpvalveparts• Foreignmaterialininletoroutletvalves• Lossofoilprimeincellsbecauseoflowoillevel• Ruptureddiaphragm• Cavitation• Warpedmanifoldfromoverpressurizedsystem• O-ringsforcedoutoftheirgroovesfromoverpressurization• Airleakinsuctionlinestrainerorgasket• Crackedsuctionhose.• Emptysupplytank• Excessiveaerationandturbulenceinsupplytank• Cavitation• Abrasivesinthefluid• Valveincompatiblewithcorrosivesinthefluid• Pumprunningtoofast• Wornandslippingdrivebelt(s)• Wornspraynozzle(s)

Pump Runs Rough• Wornpumpvalves• Airlockinoutletsystem• Oillevellow• Wrongweightofoilforcoldoperatingtemperatures(change

tolighterweight)• Cavitation• Airinsuctionline• Restrictionininlet/suctionline• Hydrauliccellsnotprimedafterchangingdiaphragm• Foreignmaterialininletoroutletvalve• Damageddiaphragm• Fatiguedorbrokenvalvespring

Premature Failure of Diaphragm• Frozenpump• Puncturebyaforeignobject• Elastomerincompatiblewithfluidbeingpumped• Pumprunningtoofast• Excesspressure• Cavitation

Water (or Process Fluid) in Oil Reservoir• Condensation• Ruptureddiaphragm• Hydraulic cell not properly primed af ter diaphragm

replacement• Frozenpump

Strong Water (or Process Fluid) PulsationsNOTE: Small pulsations are normal in single-acting pumps with multiple pumping chambers.

• Foreignobjectlodgedinpumpvalve• Lossofprimeinhydrauliccellbecauseoflowoillevel• Airinsuctionline• Valvespring(8)broken• Cavitation• Aerationorturbulenceinsupplytank

18 D04-991-�400A

Valve Wear• Normalwearfromhigh-speedoperation• Cavitation• Abrasivesinthefluid• Valveincompatiblewithcorrosivesinthefluid• Pumprunningtoofast

Loss of Oil• Externalseepage• Ruptureofdiaphragm• Frozenpump• Wornshaftseal• Oildrainpipingorfillcaploose.• Valveplateandmanifoldboltsloose• Pumphousingporosity

Premature Failure of Valve Spring or Retainer• Cavitation• Foreignobjectinthepump• Pumprunningtoofast• Spring/retainer material incompatible with fluid being

pumped• Excessiveinletpressure.

D/G-04 Troubleshooting

19 D04-991-�400A

Limited WarrantyWannerEngineering,Inc.extendstotheoriginalpurchaserofequipmentmanufacturerdbyitandbearingitsname,a limitedone-yearwarranty from thedateofpurchaseagainstdefectsinmaterialorworkmanship,providedthattheequipment is installedandoperated inaccordancewith the recommendationsand instructionsofWannerEngineering, Inc. Wanner Engineering, Inc. will repairorreplace,atitsoption,defectivepartswithoutchargeif such parts are returned with transportation chargesprepaid to Wanner Engineering, Inc., 1�04 ChestnutAvenue,Minneapolis,Minnesota55403.

Thiswarrantydoesnotcover:

1. The electric motors (if any), which are covered bythe separatewarrantiesof themanufacturersof thesecomponents.

�.Normalwearand/ordamagecausedbyorrelatedtoabrasion,corrosion,abuse,negligence,accident,faultyinstallationortamperinginamannerwhichimpairsnormaloperation.

3.Transportationcosts.

This limitedwarranty isexclusive,and is in lieuofanyotherwarranties(expressorimplied)includingwarrantyofmerchantabilityorwarrantyoffitnessforaparticularpurpose and of any noncontractual liabilities includingproductliabilitiesbasedonnegligenceorstrict liability.Every form of liability for direct, special, incidental orconsequential damages or loss is expressly excludedanddenied.

D/G-04 Warranty

�0

WANNER ENGINEERING, INC.1204 Chestnut Avenue, Minneapolis, MN 55403 TEL: (612) 332-5681 FAX: (612) 332-6937 TOLL-FREE FAX [US only]: (800) 332-6812

www.hydra-cell.com email: sales@wannereng.com ©�004WannerEngineering,Inc.PrintedinUSA

D04-991-�400A5/�004,Revised�/�007