HP D-04 User's Manual
Contents
1. INSTALLATION amp SERVICE I UM Models D 04 G 04 ME 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 D G 04 Contents Page SPeCiiCAatlOns zili ala all 2 DIMONSIONS ir aaa sada eee hese aia n 4 Instalati sea n crate aves A anne Bee 5 Maintenance micaia Ns ee 9 Service Fluid End renren veaseeuineniedes tectehenandesasteee 10 Service Hydraulic End ceecceeeeeeeeeeeeeeeeeeeeeeeeseaeeeeeeee 14 Troubleshooting js ccsssceseessecesescapceneseeseesaceesascesestaccanersaneetane 17 D G 04 Specifications Max Pressure 2 500 psi 170 bar Capacity Max Pressure rom gpm l min D G 04 X 1750 2 9 11 0 D G 04 E 1750 2 1 7 8 D G 04 S 1750 1 6 6 1 Delivery Rated Pressure revs gal 500 psi 1500 psi 2500 psi D G 04 X 565 583 603 D G 04 E 761 795 833 D G 04 S 921 972 1 093 revs liter 35 bar 100 bar 170 bar D G 04 X 149 154 159 D G 04 E 201 211 224 D G 04 S 244 257 287 Max Inlet Pressure 500 psi 35 bar Max Temperature 250 F 121 C consult factory for temperatures above 160 F 71 C D 04 1 2 inch NPT G 04 1 2 inch BSPT Inlet Port D 04 1 2 inch NPT G 04 1 2 inch BSPT Discharge Port Shaft Diameter 7 8 inch 22 22 mm Shaft Rotation Bi directional Bearings Ball bearings Oil Capacity 1 1 US quarts2. edge of the manifold and alternately tighten opposite bolts until all are secure Torque to 50 ft lbs 70 N m Recheck all bolts for tightness and proper torque 13 D04 991 2400 5 1 04 D G 04 Service Hydraulic End Piston Assembly 56 See Fluid End for Detail 14 D04 991 2400 5 1 04 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 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 Depending on the repair you are attempting you may or may not have to remove the motor from a direct drive pump motor unit 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 Tools and Supplies Tools required for hydraulic end only Snap ring pliers e Small hook 8 mm socket wrench To Service Pistons Without Removing Motor or Crankshaft 1 Disassemble Pistons With the manifold valve plate diaphragm plate and diaphragms removed and the oil drained from the pump see the Fluid End Servic
3. install an inlet pressure regulator Do not supply more than one pump from the same inlet line Inlet Calculations Acceleration Head Calculating the Acceleration Head 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 Ha Lx V x N x C K x G where Ha Acceleration head ft of liquid L Actual length of suction line ft not equivalent length V Velocity of liquid in suction line ft sec V GPM x 0 408 pipe ID N RPM of crank shaft C Constant determined by type of pump use 0 066 for the 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 sec D04 991 2400 5 1 04 D G 04 Installation Friction Losses 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 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 cavitat
4. 2 000 lt 1800 3 000 2 000 1 500 lt 2500 psi 170 bar lt 1200 3 000 2 000 1 500 lt 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 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 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 1 Adjust the discharge pressure regulating valve so the pump runs under minimum pressure Stop the pump 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 o
5. fluid that will come from the relief valve Reset the discharge pressure regulator to the desired system pressure Provide a return line from the relief valve to the supply tank similar to the bypass line from the pressure regulator D04 991 2400 5 1 04 D G 04 Maintenance NOTE The numbers in parentheses are the Ref Nos on the illustrations in the Parts Manual 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 Use the appropriate Hydra Oil for the application contact Wanner Engineering if in doubt 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 witha 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 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 Hours Between Oil Changes Various Process Fluid Temperatures lt 90 F lt 139 F lt 180 F Pressure RPM 32 C 60 C 82 C lt 1500 psi 100 bar lt 1200 6 000 4 000
6. rings 51 e Remove the cover and the cover O ring 53 f Remove the crankshaft 57 by pulling it through the connecting rods 59 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 Reverse the process to reinstall the piston Refer to Steps 5 and 6 below to replace the diaphragm and reassemble the pump D04 991 2400 5 1 04 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 b Press the back bearing 55 and seal 54 out of the cover 52 Discard the seal 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 Press the new seal into the back cover Inspect the bearing 55 If pitted or damaged replace it 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 4 Reassemble Housing and Back Cover a b Stand the pump on end With the pistons and connecting rods in place reinstall the crankshaft by threading it through the connecting rods Rei
7. 1 05 liters Weight 37 lbs 16 8 kg Calculating Required Horsepower kW 6xrpm gpm x ps z electric motor HP 63 000 1 460 psi 200 20 6xrpm gpm x bar z electric motor kW 84 428 511 45155 4 rom equals pump shaft rom HP kW is required application power Use caution when sizing motors with variable speed drives D04 991 2400 5 1 04 D G 04 Specifications RPM 0 200 400 600 80 1200 1400 1600 3 33 3 00 p pioax Pi F 2 66 g 500 PSI 35 bar F 1500 PSI 100 bar 2500 PSI 170 bar sy 2 33 AA p i D G 04 E y H Ale 2 F d 5 2 00 d g 1 F Z o g N 7 a E 1 66 So g PZ a 1 33 D G 04 S 1 00 0 66 0 33 Net Positive Suction Head ies NPSHr 0 0 200 400 600 800 1000 1200 1400 1600 1800 RPM D04 991 2400 125 11 25 10 3 D 2 5 2 8 75 2 x 2 a a a 75 z o 625 5 0 0 200 400 600 800 1000 1200 1400 1600 1800 RPM 3 75 Dry Lift 25 240 1 25 220 200 180 0 5 160 o 140 S o s 120 g 2 10 g 80 60 40 20 5 1 04 D G 04 Dimensions D G 04 Models with Metallic Pumping Head Brass 304 Stainle
8. Cavitation Air in suction line Restriction in inlet suction line e Hydraulic cells not primed after changing diaphragm e Foreign material in inlet or outlet valve Damaged diaphragm Fatigued or broken valve spring Premature Failure of Diaphragm e Frozen pump e Puncture by a foreign object e Elastomer incompatible with fluid being pumped Pump running too fast e Excess pressure e Cavitation Water or Process Fluid in Oil Reservoir e Condensation e Ruptured diaphragm e Hydraulic cell not properly primed after diaphragm replacement Frozen pump Strong Water or Process Fluid Pulsations NOTE Small pulsations are normal in single acting pumps with multiple pumping chambers e Foreign object lodged in pump valve e Loss of prime in hydraulic cell because of low oil level Air in suction line e Valve spring 8 broken e Cavitation Aeration or turbulence in supply tank D04 991 2400 5 1 04 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 in
9. alve seat and dampening washer 8 7 9 6 11 A flat O ring Tetra seal 9 goes between the retainer and seat e 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 INSTALLING INLET AND OUTLET VALVES OUTLET VALVES INLET VALVES D04 991 2400 5 1 04 D G 04 Service Fluid End 3 Inspect and Replace Diaphragms 17 a Lift a diaphragm by one edge and turn the pump shaft 4 Flush Contaminant from Hydraulic End only if a diaphragm has ruptured until the diaphragm moves up to top dead center This will expose machined cross holes in the plunger shaft a With the valve plate and manifold still removed see behind the diaphragm above remove the oil drain cap 60 allow all oil and Insert the plunger holder tool through one of the contaminant to drain out machined cross holes to hold the diaphragm up Don t b Fill the reservoir with kerosene or solvent manually turn remove the tool until the new diaphragm is installed in the pump shaft to circulate the kerosene and drain step f below Dispose of this contaminated fluid properly Unscrew the diaphragm Use a 5 16 in 8 mm open c Repeat the flushing procedure step b above end wrench and turn counterclockwise d Fill the reservoir with fresh oil manually turn the pump Inspect th
10. and denied D04 991 2400 5 1 04 ME 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 20 2004 Wanner Engineering Inc Printed in USA D04 991 2400 5 1 04
11. compatible with fluid being pumped Excessive inlet pressure D04 991 2400 5 1 04 19 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
12. d 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 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 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 Tools and Supplies Straightedge at least 6 in long e Grease or petroleum jelly e Torque wrench rated to at least 50 ft lbs 70 N m e Emery cloth e 1 2 in drive socket wrench 5 16 in 8 mm open end wrench e 5 mm hex Allen wrench e 8 mm hex bit socket 1 2 inch drive Wanner D 04 G 04 Tool Kit which includes the following Seat puller e Plunger holder Plunger guide lifter e 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 Awarped manifold should be replaced d Remove the two socket head capscrews 14 that hold the
13. d too hot for inlet suction piping system e Air entrained in fluid piping system Aeration and turbulence in supply tank Inlet vacuum too high refer to Inlet Calculations page 3 Symptoms of Cavitation e Excessive pump valve noise e Premature failure of spring or retainer e Volume or pressure drop e Rough running pump e Premature failure of diaphragms Drop in Volume or Pressure A drop in volume or pressure can be caused by one or more of the following e Air leak in suction piping Clogged suction line or suction strainer e Suction line inlet above fluid level in tank e Inadequate fluid supply Pump not operating at proper RPM e Relief valve bypassing fluid Worn pump valve parts e Foreign material in inlet or outlet valves e Loss of oil prime in cells because of low oil level e Ruptured diaphragm e Cavitation e Warped manifold from overpressurized system O rings forced out of their grooves from overpressurization e Air leak in suction line strainer or gasket e Cracked suction hose e Empty supply tank e Excessive aeration and turbulence in supply tank Cavitation e Abrasives in the fluid e Valve incompatible with corrosives in the fluid Pump running too fast e Worn and slipping drive belt s e Worn spray nozzle s Pump Runs Rough Worn pump valves e Airlock in outlet system Oil level low Wrong weight of oil for cold operating temperatures change to lighter weight e
14. e Section a Remove the snap ring 27 from one of the pistons using a standard snap ring pliers 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 d Inspect all parts and replace the O ring and any other parts that are worn or may be damaged e Repeat steps a through d for the remaining pistons 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 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 e Insert the washer 26 over the plunger f Using the snap ring pliers insert a snap ring 27 into the piston g Repeat the above procedure for the other two pistons To Service Remainder of Hydraulic End 1 Remove Pump Housing 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 c Stand the pump on end with the drive shaft up d Remove the bolts 50 that secure the back cover 52 to the housing 78 Use an 8 mm socket wrench Save the O
15. e diaphragm carefully A damaged diaphragm shaft to circulate the oil and drain again generally indicates a pumping system problem and e Refill the reservoir If the oil appears milky there is still 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 contaminant in the reservoir Repeat the flushing procedure until the oil appears clean 5 Prime the Hydraulic Cells 4 a With the pump horizontal fill the reservoir with the caused by pian tea sles vacuum or by appropriate Hydra oil for the application overpressurizatioin Ol The pump inlet b All air in the oil within the hydraulic cell behind the Outer diaphragm bead extruded Usually caused by diaphragms must be forced out by turning the shaft overpiessurization of the pump and thus pumping the piston Use a glove when turning e Diaphragm becoming stiff and losing flexibility the shaft by hand Usually caused by pumping a fluid that is incompatible Turn the shaft until a bubble free flow of oil comes from with the diaphragm material behind all the diaphragms Watch the oil level in the Cut diaphragm convolute Usually caused by reservoir if it gets too low during priming air will be drawn excessive inlet vacuum into the piston inside the hydraulic end This will ca
16. greater than NPSHr All values must be expressed in feet of liquid Atmospheric Pressure at Various Altitudes Altitude Pressure Altitude Pressure ft ft of H O ft ft of H O 0 33 9 1500 32 1 500 33 3 2000 31 5 1000 32 8 5000 28 2 Discharge Piping NOTE 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 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 Use about 6 ft 1 8 m of flexible hose between the pump and rigid piping Support the pump and piping independently Pressure Regulation Install a pressure regulator or unloader in the discharge line Bypass pressure must not exceed the pressure limit of the pump 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 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 manufacturer s pressure rating for the pump or regulator Route the bypass li
17. ings Consult coupling manufacturer for exact alignment tolerances On a close coupled system coat the motor shaft liberally with anti seize DISCHARGE LINE 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 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 Shut Off Valves Never install shut off valves between the pump and discharge pressure regulator or in the regulator bypass line Freezing Conditions Protect the pump from freezing See also the Maintenance Section 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 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 c
18. ion will occur 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 Consult the factory before pumping viscous fluids Minimizing Acceleration Head and Frictional Losses To minimize the acceleration head and frictional losses e Keep inlet lines less than 3 ft 1 m long e Use at least 5 8 in 16 mm I D inlet hose e Use soft hose low pressure hose noncollapsing for the inlet lines e Minimize fittings elbows valves tees etc e Use a suction stabilizer on the inlet 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 fluid and cavitation will occur Calculating the NPSHa Use the following formula to calculate the NPSHa NPSHa Pt Hz Hf Ha Pvp where Pt Atmospheric pressure Hz Vertical distance from surface liquid to pump centerline if liquid is below pump centerline the Hz is negative Hf Friction losses in suction piping Ha Acceleration head at pump suction Pvp Absolute vapor pressure of liquid at pumping temperature NOTES e In good practice NPSHa should be 2 ft
19. ne to the supply tank or to the suction line as far as possible from the pump to reduce the chance of turbulence and cavitation 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 CAUTION Never install shutoff valves in the bypass line or between the pump and pressure regulator or relief valve Provide for permanent or temporary installation of a pressure gauge to monitor the discharge pressure at the pump For additional system protection install a pop off safety relief valve in the discharge line downstream from the pressure regulator D04 991 2400 5 1 04 D G 04 Installation Before Initial Start Up Before you start the pump be sure that 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 All pulleys and belts are properly aligned and belts are tensioned according to specification All pulleys and belts have adequate safety guards Initial Start Up Procedure 1 2 Turn on power to the pump motor 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 press
20. nstall the back cover cover O ring and bolts with their O rings 16 5 Reinstall Diaphragms 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 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 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 Hold the plunger holder tool to secure the valve plunger and torque the diaphragm insert to 10 in Ibs 110 N cm using a 5 16 in 8 mm open end wrench Repeat the above procedure for the plungers and diaphragms of the other two cylinders Fill the reservoir with fresh oil and prime the pump as outlined in the Fluid End Service Section 6 Reassemble Pump Reassemble the pump as outlined in the Fluid End Service Section D04 991 2400 5 1 04 D G 04 Troubleshooting Cavitation e 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 or damaged inlet hose Suction line too long Too many valves and elbows in inlet line e Flui
21. ooler may be required Pressure Gauge Pressure 9 Regulator Vacuum Pressure Gauge BYPASS LINE D04 991 2400 5 1 04 D G 04 Installation Inlet Piping Suction Feed 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 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 gom 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 Supply Tank 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 Isolate the pump and motor stand from the supply tank and support them separately Install a separate inlet line from the supply tank to each pump 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 If a line strainer is used in the system install it in the inlet line to the supply tank To reduce aeration and turbulence install a completely submerged baffle plate to separate the incoming and outgoing liquids Install a vortex breaker in the supply tank over the outlet port to the p
22. r plugs 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 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 7 Itis 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 D04 991 2400 5 1 04 D G 04 Service Fluid End Piston Assembly see Detail A Valve Assemblies see Detail B DETAIL A Piston Assembly DETAIL B Valve Assemblies Plastic Retainer Retainer Bolt Torque Specifications Ref No D 04 G 04 1 50 ft lbs 70 Nm 17 10 in lbs 110 Ncm 10 D04 991 2400 5 1 04 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 This section explains how to disassemble an
23. ss Steel 316 Stainless Steel YY 7 01 178 D 04 1 2 NPT Outlet G04 1 2 BSPT 743 9 Good Key 0 189 o 4 97 A 126 Inlet 04 1 2 NPT 25 V 5 9 G 04 1 2 BSPT y By By A I aa 38 A N N a A w to a D04 991 2400 5 1 04 D G 04 Installation NOTE The numbers in parentheses are the Reference Numbers on the illustrations in the Parts Manual 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 Mounting The pump shaft can rotate in either direction To prevent vibration securely attach the pump to a rigid base 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 On a direct drive system align the shafts accurately Unless otherwise specified by the coupling manufacturer maximum parallel misalignment should not exceed 015 and angular misalignment should be held to 1 degree maximum Careful alignment extends life of the coupling pump shafts and support bear
24. ump 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 e 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 e 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 e Make sure all joints are sealed and tight to prevent the pump from drawing air into the inlet e 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 s a registered trademark of Loctite Corporation Teflon is a registered trademark of E I DuPont de Nemours amp Co Inc 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
25. ure must not exceed 500 psi 34 bar Listen for any erratic noise and look for unsteady flow If the pump does not clear refer to the Trouble shooting Section If the system has an air lock and the pump fails to prime a Turn off the power b Remove the pressure gauge or plug from the tee fitting 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 Turn off the power e Remove the plumbing that was temporarily installed and reinstall the pressure gauge or plug Adjust the discharge pressure regulator to the desired operating and bypass pressures Do not exceed the maximum pressure rating of the pump 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
26. use CAUTION If a diaphragm has ruptured and foreign the pump to run rough and you will have to start over material or water has entered the oil reservoir do again with priming the hydraulic cells not operate the pump Check all diaphragms then c After the Hydra Cells are fully primed ensure that the flush the reservoir completely as outlined below oil level is 1 4 in 6 mm above the cast surface in the and refill it with fresh oil Never let the pump stand upper oil reservoir with foreign material or water in the reservoir or with d Wipe excess oil from the diaphragm plate and the reservoir empty Clean away any spilled oil Install a good or new diaphragm and tighten to 10 in lbs 110 N cm Repeat the above inspection procedure and replacement if necessary with the other two diaphragms 12 diaphragms D04 991 2400 5 1 04 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 Reinstall the O rings 4 on the front side of the valve plate Use petroleum jelly or lubricating gel to hold them in place Reinstall the manifold onto the valve plate Insert all capscrews 1 with washers 2 around the
27. 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 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 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 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 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 Reinstall the valve assemblies e 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 e Inlet 3 lower valves in the illustration below Insert the spring retainer 10 into the valve plate then insert the spring valve Tetra seal v
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