HP Hewlett Packard Water Pump D 04 User Manual

INSTALLATION & SERVICE  
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  
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D/G-04 Specifications  
Performance  
Net Positive Suction Head –  
RPM  
NPSHr  
0
200  
400  
600  
800  
1000  
1200  
1400  
1600  
1800  
12.5  
12  
3.33  
3.5  
11  
10  
3.00  
11.25  
10  
3.0  
2.5  
D/G-04-X  
D/G-04-E  
D/G-04-S  
D/G-04-X  
9
8
7
6
5
2.66  
2.33  
2.00  
1.66  
1.33  
1.00  
0.66  
0.33  
500 PSI (35 bar)  
1500 PSI (100 bar)  
2500 PSI (170 bar)  
2.0  
8.75  
7.5  
D/G-04-E  
1.5  
1.0  
4
3
2
6.25  
5.0  
0 .5  
1
0
0
200  
400  
600  
800 1000 1200 1400 1600 1800  
RPM  
D/G-04-S  
3.75  
2.5  
Dry Lift  
8.0  
7.0  
6.0  
5.0  
4.0  
3.0  
2.0  
1.0  
0
240  
220  
200  
180  
160  
1.25  
D/G-04-X  
D/G-04-E  
D/G-04-S  
0
0
140  
120  
100  
80  
60  
40  
20  
0
200 400 600 800 1000 1200 1400 1600 1800  
RPM  
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D/G-04 Dimensions  
D/G-04 Models with Metallic Pumping Head  
Brass  
304 Stainless Steel  
316 Stainless Steel  
10.38  
(263.7)  
9.93  
(252.2)  
7.01  
(178)  
D-04: 1/2" NPT  
G-04: 1/2" BSPT  
Outlet  
2.25  
(57.2)  
1.73  
8.71  
(221.2)  
(43.9)  
Good Key  
0.189  
(4.8)  
4.97  
(126)  
0.875  
(22.23)  
4.250  
(107.9)  
4.25  
(108)  
3.52  
(89.4)  
D-04: 1/2" NPT  
G-04: 1/2" BSPT  
Inlet  
5.00  
(127)  
1.71  
(43.4)  
0.75  
(19.1)  
0.75  
(19.1)  
2.25  
(57.2)  
2.75  
(69.9)  
6.55  
(166)  
3.35  
(85.1)  
2.75  
(69.9)  
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D/G-04 Installation  
NOTE: The numbers in parentheses are the Reference  
Numbers on the illustrations in the Parts Manual.  
Important Precautions  
Adequate Fluid Supply. To avoid cavitation and  
premature pump failure, be sure that the pump will have  
an adequate fluid supply and that the inlet line will not be  
obstructed. See Inlet Piping.  
Location  
Locate the pump as close to the supply source as possible.  
Install it in a lighted clean space where it will be easy to inspect  
and maintain. Allow room for checking the oil level, changing  
the oil, and removing the pump head (manifold, valve plate and  
related items).  
Positive Displacement. This is a positive-displacement  
pump. To avoid severe system damage if the discharge  
line ever becomes blocked, install a relief valve  
downstream from the pump. See Discharge Piping.  
Safety Guards. Install adequate safety guards over all  
pulleys, belts, and couplings. Follow all codes and  
regulations regarding installation and operation of the  
pumping system.  
Mounting  
The pump shaft can rotate in either direction.To prevent  
vibration, securely attach the pump to a rigid base.  
Shut-Off Valves. Never install shut-off valves between  
the pump and discharge pressure regulator, or in the  
regulator bypass line.  
On a belt-drive system, align the sheaves accurately; poor  
alignment wastes horsepower and shortens the belt and bearing  
life. Make sure the belts are properly tightened, as specified by  
the belt manufacturer.  
Freezing Conditions. Protect the pump from freezing.  
See also the Maintenance Section.  
On a direct-drive system, align the shafts accurately. Unless  
otherwise specified by the coupling manufacturer, maximum  
parallel misalignment should not exceed .015and angular  
misalignment should be held to 1 degree maximum. Careful  
alignment extends life of the coupling, pump, shafts, and support  
bearings. Consult coupling manufacturer for exact alignment  
tolerances.  
Consult the Factory for the following situations:  
Extreme temperature applications above 160° F (71°C)  
or below 40° F (4°C)  
Pressure feeding of pumps  
Viscous or abrasive fluid applications  
Chemical compatibility problems  
On a close-coupled system, coat the motor shaft liberally with  
anti-seize.  
Hot ambient temperatures above 110° F(43°C)  
Conditions where pump oil may exceed 200° F (93°C)  
because of a combination of hot ambient temperatures,  
hot fluid temperature, and full horsepower load an  
oil cooler may be required  
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D/G-04 Installation  
Inlet Piping (Suction Feed)  
Inlet Piping (Pressure Feed)  
Provide for permanent or temporary installation of a vacuum/  
pressure gauge to monitor the inlet vacuum or pressure.  
Pressure at the pump inlet should not exceed 500 psi (34 bar);  
if it could get higher, install an inlet pressure regulator.  
CAUTION: When pumping at temperatures above 160° F  
(71° C), use a pressure-feed system.  
Install draincocks at any low points of the suction line, to permit  
draining in freezing conditions.  
Do not supply more than one pump from the same inlet line.  
Provide for permanent or temporary installation of a vacuum  
gauge to monitor the inlet suction. To maintain maximum flow,  
vacuum at the pump inlet should not exceed 7 in. Hg at 3 gpm  
and 70° F (180 mm Hg at 11.4 liters/min and 21° C). Do not  
supply more than one pump from the same inlet line.  
Inlet Calculations  
Acceleration Head  
Supply Tank  
Calculating the Acceleration Head  
Use a supply tank that is large enough to provide time for any  
trapped air in the fluid to escape. The tank size should be at  
least twice the maximum pump flow rate.  
Use the following formula to calculate acceleration head losses.  
Subtract this figure from the NPSHa, and compare the result to  
the NPSHr of the Hydra-Cell pump.  
Isolate the pump and motor stand from the supply tank, and  
support them separately.  
Ha = (L x V x N x C) ÷ (K x G)  
where:  
Install a separate inlet line from the supply tank to each pump.  
Ha = Acceleration head (ft of liquid)  
L= Actual length of suction line (ft) not equivalent length  
Install the inlet and bypass lines so they empty into the supply  
tank below the lowest water level, on the opposite side of the  
baffle from the pump suction line.  
V= Velocity of liquid in suction line (ft/sec) [V = GPM x (0.408 ÷  
pipe ID2)]  
If a line strainer is used in the system install it in the inlet line to  
the supply tank.  
N= RPM of crank shaft  
C= Constant determined by type of pump use 0.066 for the  
To reduce aeration and turbulence, install a completely  
submerged baffle plate to separate the incoming and outgoing  
liquids.  
D-04 and G-04 Hydra-Cell pumps  
K= Constant to compensate for compressibility of the fluid —  
use: 1.4 for de-aerated or hot water; 1.5 for most liquids;  
2.5 for hydrocarbons with high compressibility  
G=Gravitational constant (32.2 ft/sec2)  
Install a vortex breaker in the supply tank, over the outlet port  
to the pump.  
Place a cover over the supply tank, to prevent foreign objects  
from falling into it.  
Hose Size and Routing  
Use the shortest, most-direct route from the supply tank to the  
pump. If elbows are needed, 45° are recommended. Any  
restrictions in the inlet piping may cause pump output to drop.  
Do not install any 90° elbows in the pump inlet.  
Use flexible noncollapsible hose between the pump and rigid  
piping or supply tank. This will absorb vibration, and allow  
for expansion or contraction.  
Use the largest practical hose. The smallest permissible size  
is 5/8 in. (16 mm) I.D.  
All valves, fittings, and unions must also have 5/8-in. (16  
mm) minimum I.D. Do not exceed 5 feet of hose and piping  
between and supply tank and the pump inlet.  
Support the pump and piping independently.  
Make sure all joints are sealed and tight, to prevent the pump  
from drawing air into the inlet.  
Do not use a line strainer or filter in the suction line unless  
regular maintenance is assured. If used, it should have a  
free-flow area of at least three times the free-flow area of  
the inlet.  
Loctite is a registered trademark of Loctite Corporation.  
Teflon is a registered trademark of E. I. DuPont de Nemours & Co. Inc.  
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D/G-04 Installation  
Friction Losses  
Discharge Piping  
NOTE: Consult the Factory before manifolding two or more  
pumps together.  
Calculating Friction Losses in Suction Piping  
When following the above recommendations (under inlet  
Piping) for minimum hose/pipe I.D. and maximum length,  
frictional losses in the suction piping are negligible (i.e., Hf = 0)  
if you are pumping a water-like fluid.  
NOTE: Single-acting pumps create a pulsing flow. Using  
pulsation dampening devices in the discharge line can  
reduce or eliminate this.  
When pumping more-viscous fluids such as lubricating oils,  
sealants, adhesives, syrups, varnishes, etc., frictional losses  
in the suction piping may become significant. As Hf increases,  
the available NPSH (NPSHa) will decrease, and cavitation will  
occur.  
Hose and Routing  
Use the shortest, most-direct route for the discharge line.  
Select pipe or hose with a working pressure rating of at least  
1.5 times the maximum system pressure. EXAMPLE: Select a  
3000-psi W.P.-rated hose for systems to be operated at 2000-  
psi-gauge pressure.  
In general, frictional losses increase with increasing viscosity,  
increasing suction-line length, increasing pump flowrate, and  
decreasing suction-line diameter. Changes in suction-line  
diameter have the greatest impact on frictional losses: a 25%  
increase in suction-line diameter cuts losses by more than two  
times, and a 50% increase cuts losses by a factor of five times.  
Use about 6 ft (1.8 m) of flexible hose between the pump and  
rigid piping.  
Support the pump and piping independently.  
Consult the factory before pumping viscous fluids.  
Minimizing Acceleration Head and Frictional Losses  
To minimize the acceleration head and frictional losses:  
Pressure Regulation  
IInstall a pressure regulator or unloader in the discharge  
line. Bypass pressure must not exceed the pressure limit of  
the pump.  
Keep inlet lines less than 3 ft (1 m) long  
Use at least 5/8 in. (16 mm) I.D. inlet hose  
Size the regulator so that, when fully open, it will be large enough  
to relieve the full capacity of the pump without overpressurizing  
the system.  
Use soft hose (low-pressure hose, noncollapsing) for the  
inlet lines  
Minimize fittings (elbows, valves, tees, etc.)  
Use a suction stabilizer on the inlet.  
Locate the valve as close to the pump as possible and ahead  
of any other valves.  
Adjust the pressure regulating valve to no more than 10% over  
the maximum working pressure of the system. Do not exceed  
the manufacturers pressure rating for the pump or regulator.  
Net Positive Suction Head  
NPSHa must be equal to or greater than NPSHr. If not, the  
pressure in the pump inlet will be lower than the vapor pressure  
of the fluidand cavitation will occur.  
Route the bypass line to the supply tank, or to the suction line  
as far as possible from the pump (to reduce the chance of  
turbulence and cavitation).  
Calculating the NPSHa  
If the pump may be run for a long time with the discharge closed  
and fluid bypassing, install a thermal protector in the bypass  
line (to prevent severe temperature buildup in the bypassed  
fluid).  
Use the following formula to calculate the NPSHa:  
NPSHa = Pt + Hz - Hf - Ha - Pvp  
where:  
CAUTION: Never install shutoff valves in the bypass line  
or between the pump and pressure regulator or relief valve.  
Pt = Atmospheric pressure  
Hz = Vertical distance from surface liquid to pump centerline (if  
liquid is below pump centerline, the Hz is negative)  
Provide for permanent or temporary installation of a pressure  
gauge to monitor the discharge pressure at the pump.  
Hf = Friction losses in suction piping  
Ha = Acceleration head at pump suction  
Pvp =Absolute vapor pressure of liquid at pumping temperature  
NOTES:  
For additional system protection, install a pop-offsafety relief  
valve in the discharge line, downstream from the pressure  
regulator.  
In good practice, NPSHa should be 2 ft greater than NPSHr  
All values must be expressed in feet of liquid  
Atmospheric Pressure at Various Altitudes  
Altitude Pressure Altitude Pressure  
(ft)  
0
500  
(ft of H2O)  
33.9  
(ft)  
(ft of H2O)  
32.1  
1500  
2000  
5000  
33.3  
32.8  
31.5  
28.2  
1000  
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D/G-04 Installation  
Before Initial Start-Up  
Before you start the pump, be sure that:  
Initial Start-Up Procedure  
1. Turn on power to the pump motor.  
2. Check the inlet pressure or vacuum. To maintain maximum  
flow, inlet vacuum must not exceed 7 in. Hg at 70° F (180  
mm Hg at 21° C). Inlet pressure must not exceed 500 psi  
(34 bar).  
All shutoff valves are open, and the pump has an adequate  
supply of fluid.  
All connections are tight.  
The oil level is 1/4 inch (6 mm) above the cast surface in  
the upper oil reservoir.  
The relief valve on the pump outlet is adjusted so the pump  
starts under minimum pressure.  
3. Listen for any erratic noise, and look for unsteady flow. If  
the pump does not clear, refer to the Trouble-shooting  
Section.  
4. If the system has an air lock and the pump fails to prime:  
All pulleys and belts are properly aligned, and belts are  
tensioned according to specification.  
a.  
b.  
Turn off the power.  
Remove the pressure gauge or plug from the tee fitting  
All pulleys and belts have adequate safety guards.  
at the pump outlet (refer to the illustration on page 3).  
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.  
Jog the system on and off until the fluid coming from  
this port is air-free.  
d.  
e.  
Turn off the power.  
Remove the plumbing that was temporarily installed,  
and reinstall the pressure gauge or plug.  
5. Adjust the discharge pressure regulator to the desired  
operating and bypass pressures. Do not exceed the  
maximum pressure rating of the pump.  
6. After the pressure regulator is adjusted, set the pop-off”  
safety relief valve at 100 psi (7 bar) higher than the desired  
operating pressure. To verify this setting, adjust the  
discharge pressure regulator upward until the relief valve  
opens. Follow the recommendations in the above NOTE  
(step 4b) for handling the fluid that will come from the relief  
valve.  
7. Reset the discharge pressure regulator to the desired system  
pressure.  
8. Provide a return line from the relief valve to the supply tank,  
similar to the bypass line from the pressure regulator.  
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D/G-04 Maintenance  
NOTE: The numbers in parentheses are the Ref. Nos. on  
the illustrations in the Parts Manual.  
Shutdown Procedure During  
Freezing Temperatures  
Take 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.  
Daily  
Check the oil level and the condition of the oil. The oil level  
should be 1/4 in. (6 mm) above the cast surface in the upper oil  
reservoir.  
1. Adjust the discharge pressure regulating valve so the pump  
runs under minimum pressure. Stop the pump.  
Use the appropriate Hydra-Oil for the application (contact  
Wanner Engineering if in doubt).  
2. Drain supply tank; open any draincocks in system piping  
and collect drainage. Drain as much fluid from the pump  
manifold and plumbing attached directly to the pump  
manifold by loosening fittings or removing plugs or gauges.  
3. Close draincocks in system piping and tighten or replace  
any fittings, gauges or plugs.  
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.  
4. Fill supply tank with enough antifreeze to fill system piping  
and pump.  
NOTE: Disconnect the system return line from the  
supply tank and connect it to a separate reservoir.  
5. Start the pump and allow it to run until the system is filled  
with antifreeze. NOTE: If the system has an airlock and  
the pump fails to prime, follow step 4 of the Initial Start-  
up Procedure to clear the air.  
Periodically  
Change the oil after the first 100 hours of operation, then change  
according to the quidelines below. When changing, remove the  
drain plug (60) at the bottom of the pump so all oil and  
accumulated sediment will drain out.  
6. When mostly antifreeze is flowing from the system return  
line, stop the pump. Connect the system return line back to  
the supply tank and circulate the antifreeze for a short period.  
Hours Between Oil Changes @ Various  
Process Fluid Temperatures  
7. It is also good practice to change the oil in the hydraulic end  
before storage for an extended period. This will remove any  
accumulated condensation and sediment from the oil  
reservoir. Drain and refill the hydraulic end with the  
appropriate Hydra-Oil and operate the pump for a short  
period to assure smooth performance.  
<90°F  
(32°C)  
<139°F  
(60°C)  
<180°F  
(82°C)  
2,000  
1,500  
Pressure  
RPM  
<1500 psi (100 bar) <1200  
<1800  
6,000  
3,000  
4,000  
2,000  
<2500 psi (170 bar) <1200  
<1800  
3,000  
1,500  
2,000  
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.  
Check the inlet pressure or vacuum periodically with a gauge.  
If vacuum at the pump inlet exceeds 7 in. Hg (180 mm Hg),  
check the inlet piping system for blockages. If the pump inlet is  
located above the supply tank, check the fluid supply level and  
replenish if too low.  
CAUTION: Protect the pump from freezing. Refer also to  
the “Shutdown Procedure”.  
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D/G-04 Service (Fluid End)  
Bolt Torque Specifications  
Ref. No.  
D-04  
G-04  
70 Nm  
110 Ncm  
1
17  
50 ft-lbs  
10 in-lbs  
10  
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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.  
2. Inspect Valves (5-11)  
The three inlet and three outlet valve assemblies are identical  
(but face in opposite directions). Inspect each valve as  
follows:  
This section explains how to disassemble and inspect all easily  
serviceable parts of the pump. Repair procedures for the  
hydraulic end (oil reservoir) of the pump are included in a later  
section of the manual.  
a. Check the spring retainer (10), and replace if worn.  
b. Check the valve spring (8). If shorter than a new spring,  
replace it (do not stretch a used spring).  
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.  
c. Check the valve (7). If worn excessively, replace it.  
d. Remove the valve seat (6), O-ring (5), and dampening  
washer (11) (See note below). A seat puller is included  
in the Wanner Tool Kit. Inspect all parts for wear. In all  
instances, O-ring (5) should be replaced. Replace the  
valve seat and/or dampening washer if necessary.  
CAUTION: The two capscrews (16) that screw through the  
diaphragm plate in the pump housing hold the diaphragm plate  
over the hydraulic end of the pump. Do not remove them except  
when repairing the hydraulic end.  
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.  
Tools and Supplies  
Straightedge (at least 6 in. long)  
Grease or petroleum jelly  
Torque wrench, rated to at least 50 ft-lbs (70 N-m)  
Emery cloth  
1/2-in. drive socket wrench  
5/16-in. (8-mm) open-end wrench  
5-mm hex Allen wrench  
e. Reinstall the valve assemblies:  
Clean the valve ports and shoulders with emery cloth,  
and lubricate them with lubricating gel or petroleum jelly.  
Install the O-ring (5) on the valve seat (6).  
Inlet (3 lower valves in the illustration below). Insert  
the spring retainer (10) into the valve plate, then insert  
the spring, valve, Tetra seal, valve seat, and dampening  
washer (8,7,9,6,11). A flat O-ring (Tetra seal, 9) goes  
between the retainer and seat.  
8-mm hex bit socket (1/2 inch drive)  
Wanner D-04/G-04 Tool Kit, which includes the following:  
Seat puller  
Plunger holder  
Outlet (3 upper valves in the illustration below).  
Insert the dampening washer, valve seat, Tetra seal,  
valve, and spring, then the retainer. Install the flat O-ring  
(Tetra seal, 9) between the retainer and seat.  
Plunger guide lifter  
Shaft rotator  
Service Procedures  
1. Remove Manifold (3) and Valve  
Plate (12)  
a. Remove all eight capscrews (1) around the manifold.  
Use an 8-mm hex Allen wrench.  
b. Remove the manifold (3).  
c. Inspect the manifold for warping or wear around the inlet  
and outlet ports. If wear is excessive, replace the  
manifold.  
To check if the manifold is warped, place a straightedge  
across it. A warped manifold should be replaced.  
d. Remove the two socket-head capscrews (14) that hold  
the valve plate to the pump housing. Use a 5-mm hex  
Allen wrench.  
e. Inspect the valve plate in the same manner as the  
manifold, for excessive wear and/or warping. Replace if  
necessary.  
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D/G-04 Service (Fluid End)  
3. Inspect and Replace  
Diaphragms (17)  
4. Flush Contaminant from  
Hydraulic End  
a. Lift a diaphragm by one edge, and turn the pump shaft  
until the diaphragm moves up to top dead center. This  
will expose machined cross-holes in the plunger shaft  
behind the diaphragm.  
(only if a diaphragm has ruptured)  
a. With the valve plate and manifold still removed (see  
above), remove the oil drain cap (60) allow all oil and  
contaminant to drain out.  
b. Insert the plunger holder tool through one of the  
machined cross-holes, to hold the diaphragm up. (Dont  
remove the tool until the new diaphragm is installed in  
step fbelow.)  
b. Fill the reservoir with kerosene or solvent, manually turn  
the pump shaft to circulate the kerosene, and drain.  
Dispose of this contaminated fluid properly.  
c. Repeat the flushing procedure (step babove).  
d. Fill the reservoir with fresh oil, manually turn the pump  
shaft to circulate the oil, and drain again.  
e. Refill the reservoir. If the oil appears milky, there is still  
contaminant in the reservoir. Repeat the flushing  
procedure until the oil appears clean.  
c. Unscrew the diaphragm. Use a 5/16-in. (8-mm) open-  
end wrench, and turn counterclockwise.  
d. Inspect the diaphragm carefully. A damaged diaphragm  
generally indicates a pumping system problem and  
replacing only the diaphragm will not solve the larger  
problem. Inspect the diaphragm for the following:  
Small puncture. Usually caused by a sharp foreign  
object in the fluid, or by an ice particle.  
Diaphragm pulled away from the metal insert. Usually  
caused by excessive inlet vacuum, or by  
overpressurization of the pump inlet.  
Outer diaphragm bead extruded. Usually caused by  
overpressurization of the pump.  
Diaphragm becoming stiff and losing flexibility.  
Usually caused by pumping a fluid that is incompatible  
with the diaphragm material.  
5. Prime the Hydraulic Cells  
a. With the pump horizontal, fill the reservoir with the  
appropriate Hydra-oil for the application.  
b. All air in the oil within the hydraulic cell (behind the  
diaphragms) must be forced out by turning the shaft —  
and thus pumping the piston. Use a glove when turning  
the shaft by hand.  
Turn the shaft until a bubble-free flow of oil comes from  
behind all the diaphragms. Watch the oil level in the  
reservoir: if it gets too low during priming, air will be drawn  
into the piston (inside the hydraulic end). This will cause  
the pump to run rough, and you will have to start over  
again with priming the hydraulic cells.  
Cut diaphragm convolute. Usually caused by  
excessive inlet vacuum.  
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.  
c. After the Hydra-Cells are fully primed, ensure that the  
oil level is 1/4 in. (6 mm) above the cast surface in the  
upper oil reservoir.  
d. Wipe excess oil from the diaphragm plate and  
diaphragms.  
e. Clean away any spilled oil.  
f. Install a good or new diaphragm and tighten to 10 in.-lbs  
(110 N-cm).  
g. Repeat the above inspection procedure (and  
replacement, if necessary) with the other two  
diaphragms.  
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D/G-04 Service (Fluid End)  
6. Reinstall Valve Plate (12) and  
Manifold (3)  
a. Reinstall the valve plate (12), with the valve assemblies  
installed as outlined above, onto the diaphragm plate  
(18) and alignment pins (29).  
Tighten the two socket-head capscrews evenly and  
snugly to compress the outer diaphragm beads and hold  
the valve plate in place.  
b. Reinstall the O-rings (4) on the front side of the valve  
plate. Use petroleum jelly or lubricating gel to hold them  
in place.  
c. Reinstall the manifold onto the valve plate.  
d. Insert all capscrews (1), with washers (2), around the  
edge of the manifold, and alternately tighten opposite  
bolts until all are secure. Torque to 50 ft-lbs (70 N-m).  
e. Recheck all bolts for tightness and proper torque.  
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D/G-04 Service (Hydraulic End)  
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D/G-04 Service (Hydraulic End)  
NOTE: The numbers in parentheses are the Ref. Nos. on  
the illustrations in the Parts Manual.  
2. Reassemble Pistons  
a. Tip the pump so the pistons are vertical.  
b. Drop a ball (21) into the opening in the bottom of the  
piston.  
This section explains how to disassemble and inspect the  
hydraulic end (oil reservoir) of the pump.  
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.  
c. Insert the valve plunger (24) into a valve cylinder (22).  
Slide a spring (25) over the plunger, inside the valve  
cylinder.  
d. Slide the assembled valve cylinder, plunger, and spring  
(22-25) into the piston (20).  
Depending on the repair you are attempting, you may or may  
not have to remove the motor from a direct-drive pump/motor  
unit.  
e. Insert the washer (26) over the plunger.  
f. Using the snap-ring pliers, insert a snap ring (27) into  
the piston.  
Internal piston components (21-27) can be serviced without  
removing the motor or crankshaft. The motor and crankshaft  
must be removed to service the connecting rod (59), piston  
housing (20), crankshaft (57), front bearing (68), back bearing  
(56), or seal (54).  
g. Repeat the above procedure for the other two pistons.  
To Service Remainder of  
Hydraulic End  
Tools and Supplies  
Tools required for hydraulic end only:  
1. Remove Pump Housing  
Snap-ring pliers  
a. Remove the manifold, valve plate, diaphragm plate, and  
diaphragms, as outlined in the Fluid-End Service Section.  
b. Drain the oil from the pump housing by removing the  
drain plug (60).  
Small hook  
8-mm socket wrench  
c. Stand the pump on end, with the drive shaft up.  
To Service Pistons Without  
Removing Motor or Crankshaft  
d. Remove the bolts (50) that secure the back cover (52)  
to the housing (78). Use an 8-mm socket wrench. Save  
the O-rings (51).  
e. Remove the cover and the cover O-ring (53).  
1. Disassemble Pistons  
f. Remove the crankshaft (57) by pulling it through the  
connecting rods (59).  
With the manifold, valve plate, diaphragm plate, and  
diaphragms removed, and the oil drained from the pump  
(see the Fluid-End Service Section):  
a. Remove the snap ring (27) from one of the pistons, using  
a standard snap-ring pliers.  
2. Remove and Replace Pistons  
To remove the pistons (20), first remove the connecting rod  
(59) and pin (58) by pressing the pin through the connecting  
rod.  
b. Pull out the valve plunger (24). This also removes the  
washer (26) and spring (25).  
c. Insert a small hook through the center hole of the valve  
cylinder (22), and pull the cylinder out of the piston. Be  
careful not to damage the piston.  
Reverse the process to reinstall the piston.  
Refer to Steps 5 and 6 below to replace the diaphragm and  
reassemble the pump.  
d. Inspect all parts, and replace the O-ring and any other  
parts that are worn or may be damaged.  
e. Repeat steps athrough dfor the remaining pistons.  
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D/G-04 Service (Hydraulic End)  
3. Replace Shaft Seal  
5. Reinstall Diaphragms  
NOTE: Inspect the shaft seal (54) before continuing. If  
it looks damaged in any way, replace it.  
a. Press the back bearing (55) and seal (54) out of the cover  
(52). Discard the seal.  
a. Screw the plunger guide lifter (from the Wanner Tool Kit  
or Repair Kit) into the valve plunger (24). Pull out to  
expose the cross holes in the plunger. Rotate the shaft  
until the piston is at top dead center.  
b. Insert the plunger holder tool (from the Wanner Tool Kit),  
through the plunger hole to hold the plunger away  
from the diaphragm plate (18), and to keep the plunger  
from turning when the diaphragm is being installed.  
b. Apply a coating of Loctite High-Performance Pipe Sealant  
with Teflon©, or a comparable product, to the outer  
surface of a new seal and the inside surface of the  
opening in the back cover (52) where the seal will rest.  
c. Engage the diaphragm insert threads to the plunger  
threads, and turn the diaphragm by hand until the insert  
hits the shoulder of the valve plunger (24).  
c. Press the new seal into the back cover.  
d. Inspect the bearing (55). If pitted or damaged, replace  
it.  
d. Hold the plunger holder tool to secure the valve plunger,  
and torque the diaphragm insert to 10 in.-lbs (110 N-cm)  
using a 5/16-in. (8-mm) open-end wrench.  
e. Apply a coating of Loctite Rc/609 Retaining Compound  
or comparable product to the outer surface of the bearing.  
Press the bearing into the back cover until it rests on the  
shoulder. The shield on the bearing must face away from  
the back cover.  
e. Repeat the above procedure for the plungers and  
diaphragms of the other two cylinders.  
f. Fill the reservoir with fresh oil and prime the pump, as  
outlined in the Fluid-End Service Section.  
4. Reassemble Housing and  
Back Cover  
6. Reassemble Pump  
a. Stand the pump on end.  
Reassemble the pump as outlined in the Fluid-End Service  
Section.  
b. With the pistons and connecting rods in place, reinstall  
the crankshaft by threading it through the connecting  
rods.  
c. Reinstall the back cover, cover O-ring, and bolts (with  
their O-rings).  
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D/G-04 Troubleshooting  
Cavitation  
Pump Runs Rough  
Inadequate fluid supply because:  
Inlet line collapsed or clogged  
Clogged line strainer  
Inlet line too small or too long  
Air leak in inlet line  
Worn pump valves  
Airlock in outlet system  
Oil level low  
Wrong weight of oil for cold operating temperatures (change  
to lighter weight)  
Cavitation  
Air in suction line  
Worn or damaged inlet hose  
Suction line too long  
Restriction in inlet/suction line  
Hydraulic cells not primed after changing diaphragm  
Foreign material in inlet or outlet valve  
Damaged diaphragm  
Too many valves and elbows in inlet line  
Fluid too hot for inlet suction piping system.  
Air entrained in fluid piping system.  
Aeration and turbulence in supply tank.  
Inlet vacuum too high (refer to Inlet Calculations, page 3).  
Fatigued or broken valve spring  
Premature Failure of Diaphragm  
Symptoms of Cavitation  
Frozen pump  
Excessive pump valve noise  
Puncture by a foreign object  
Elastomer incompatible with fluid being pumped  
Pump running too fast  
Excess pressure  
Premature failure of spring or retainer  
Volume or pressure drop  
Rough-running pump  
Premature failure of diaphragms  
Cavitation  
Drop in Volume or Pressure  
A drop in volume or pressure can be caused by one or more of  
Water (or Process Fluid) in Oil  
Reservoir  
the following:  
Condensation  
Air leak in suction piping  
Ruptured diaphragm  
Hydraulic cell not properly primed after diaphragm  
Clogged suction line or suction strainer  
Suction line inlet above fluid level in tank  
Inadequate fluid supply  
Pump not operating at proper RPM  
Relief valve bypassing fluid  
replacement  
Frozen pump  
Worn pump valve parts  
Strong Water (or Process Fluid)  
Pulsations  
NOTE: Small pulsations are normal in single-acting pumps  
with multiple pumping chambers.  
Foreign material in inlet or outlet valves  
Loss of oil prime in cells because of low oil level  
Ruptured diaphragm  
Cavitation  
Warped manifold from overpressurized system  
O-rings forced out of their grooves from overpressurization  
Air leak in suction line strainer or gasket  
Cracked suction hose.  
Foreign object lodged in pump valve  
Loss of prime in hydraulic cell because of low oil level  
Air in suction line  
Valve spring (8) broken  
Empty supply tank  
Excessive aeration and turbulence in supply tank  
Cavitation  
Cavitation  
Aeration or turbulence in supply tank  
Abrasives in the fluid  
Valve incompatible with corrosives in the fluid  
Pump running too fast  
Worn and slipping drive belt(s)  
Worn spray nozzle(s)  
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D/G-04 Troubleshooting  
Valve Wear  
Normal wear from high-speed operation  
Cavitation  
Abrasives in the fluid  
Valve incompatible with corrosives in the fluid  
Pump running too fast  
Loss of Oil  
External seepage  
Rupture of diaphragm  
Frozen pump  
Worn shaft seal  
Oil drain piping or fill cap loose.  
Valve plate and manifold bolts loose  
Pump housing porosity  
Premature Failure of Valve  
Spring or Retainer  
Cavitation  
Foreign object in the pump  
Pump running too fast  
Spring/retainer material incompatible with fluid being  
pumped  
Excessive inlet pressure.  
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Limited Warranty  
Wanner Engineering, Inc. extends to the original purchaser  
of equipment manufacturerd by it and bearing its name, a  
limited one-year warranty from the date of purchase against  
defects in material or workmanship, provided that the  
equipment is installed and operated in accordance with  
the recommendations and instructions of Wanner  
Engineering, Inc. Wanner Engineering, Inc. will repair or  
replace, at its option, defective parts without charge if such  
parts are returned with transportation charges prepaid to  
Wanner Engineering, Inc., 1204 Chestnut Avenue,  
Minneapolis, Minnesota 55403.  
This warranty does not cover:  
1. The electric motors (if any), which are covered by the  
separate warranties of the manufacturers of these  
components.  
2. Normal wear and/or damage caused by or related to  
abrasion, corrosion, abuse, negligence, accident, faulty  
installation or tampering in a manner which impairs normal  
operation.  
3. Transportation costs.  
This limited warranty is exclusive, and is in lieu of any other  
warranties (express or implied) including warranty of  
merchantability or warranty of fitness for a particular  
purpose and of any noncontractual liabilities including  
product liabilities based on negligence or strict liability.  
Every form of liability for direct, special, incidental or  
consequential damages or loss is expressly excluded and  
denied.  
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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  
©2004 Wanner Engineering, Inc. Printed in USA  
D04-991-2400 5/1/04  
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