Hydra-Cell D 40, G 40 industrial pump Installation & service

INSTALLATION & SERVICE
G40-991-2400B
Models: D-40, G-40
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: [email protected]
W0349
D/G-40 Contents
Page
Installation................................................................................2
Maintenance.............................................................................5
Service (Fluid End)..................................................................6
Service (Hydraulic End)...........................................................9
Troubleshooting.....................................................................11
D/G-40 Installation
Freezing Conditions. Protect the pump from freezing. See
also the Maintenance Section.
NOTE: The numbers in parentheses are the Reference
Numbers on the exploded view illustrations.
Consult the Factory for the following situations:
Location
• Extreme temperature applications (above 160° F or below
40° F)
• Pressure feeding of pumps
• Viscous or abrasive fluid applications
• Chemical compatibility problems
• Hot ambient temperatures (above 110° F)
• Conditions where pump oil may exceed 200° F because
of a combination of hot ambient temperatures, hot fluid
temperature, and full horsepower load — an oil cooler may
be required
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
Do not exceed the maximum pump speed.
The pump shaft rotation is reversible.
Inlet Piping (Suction Feed)
To prevent vibration, mount the pump securely on a level rigid
base.
CAUTION: When pumping at temperatures above 160° F
(71° C), use a pressure-feed system.
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.
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. Vacuum at the pump
inlet should not exceed 7 in. Hg (180 mm Hg). With PTFE
diaphragms, the inlet must be flooded.
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
bearings. Consult coupling manufacturer for exact alignment
tolerances.
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.
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”.
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.
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”.
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.
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.
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.
Shut-Off Valves. Never install shut-off valves between the
pump and discharge pressure regulator, or in the regulator
bypass line.
G40-991-2400B
D/G-40 Installation
W0350
Inlet Piping (Pressure Feed)
Install a vortex breaker in the supply tank, over the outlet port
to the pump.
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 40 psi (275 kPa); if
it could get higher, install an inlet pressure reducing regulator.
Place a cover over the supply tank, to prevent foreign objects
from falling into it.
Hose and Routing
Do not supply more than one pump from the same inlet line.
Inlet Calculations
Size the suction line at least one size larger than the pump
inlet, and so that the velocity will not exceed 1-3 ft/sec (0.3 to
0.9 m/s):
Discharge Piping
NOTE: Consult the Factory before manifolding two or more
pumps together.
For pipe in inches: Velocity (ft/sec) = 0.408 x GPM/Pipe ID2
For pipe in mm: Velocity (m/sec) = 21.2 x LPM/Pipe ID2
Hose and Routing
Keep the suction line as short and direct as possible.
Size the discharge line one or two sizes larger than the pump
discharge opening. Use the shortest, most-direct route for the
discharge line.
Use flexible hose and/or expansion joints to absorb vibration,
expansion, or contraction.
If possible, keep the suction line level. Do not have any high
points to collect vapor unless these high points are vented.
Select pipe or hose with a working pressure rating of at least
1.5 times the maximum system pressure. EXAMPLE: Select a
1500-psi W.P.-rated hose for systems to be operated at 1000psi-gauge pressure.
To reduce turbulence and resistance, do not use 90° elbows.
If turns are necessary in the suction line, use 45° elbows or
arrange sweeping curves in the flexible inlet hose.
Use about 6 ft (1.8 m) of flexible hose between the pump and
rigid piping to absorb vibration, expansion or contraction.
If a block valve is used, be sure it is fully opened so that the flow
to the pump is not restricted. The opening should be at least
the same diameter as the inlet plumbing ID.
Support the pump and piping independently. Size the discharge
line so that the velocity of the fluid will not exceed 8-10 ft/sec
(2-3 m/sec):
Do not use a line strainer or filter in the suction line unless
regular maintenance is assured. If used, it should have a freeflow area of at least three times the free-flow area of the inlet.
For pipe in inches: Velocity (ft/sec) = 0.408 x GPM/Pipe ID2
For pipe in mm: Velocity (m/sec) = 21.2 x LPM/Pipe ID2
Install piping supports where necessary to relieve strain on the
inlet line and to minimize vibration.
Loctite is a registered trademark of Loctite Corporation.
G40-991-2400B
D/G-40 Installation
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.
5.
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).
6.
If the pump will be operating 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.
7.
Provide for permanent or temporary installation of a pressure
gauge to monitor the discharge pressure at the pump.
8.
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 drain plug (2).
Adjust the discharge pressure regulator to the desired
operating and bypass pressures.
After the pressure regulator is adjusted, set the 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.
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.
For additional system protection, install a safety relief valve in
the discharge line, downstream from the pressure regulator.
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 is approximately 1 inch (2.5 cm) from the
top of the fill port – so that the floor of the upper reservoir
within the pump housing is flooded and the chamber itself
is about 1/4 full, allowing for oil expansion as the pump runs
and heats up.
• The relief valve on the outlet of the pump 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. Turn on power to the pump motor.
2. Check the inlet pressure or vacuum. Inlet vacuum must not
exceed 7 in. Hg at 70°F (180 mm Hg at 21°C). Inlet pressure
must not exceed 40 psi (275 kPa).
3. If you hear any erratic noise or if the flow is unsteady, refer
to the Troubleshooting Section.
4. If the system has an air lock and the pump fails to prime:
a. Turn off the power
b. Remove the drain plug (2) on the bottom center of the
manifold.
G40-991-2400B
D/G-40 Maintenance
Daily
CAUTION: Do not turn the drive shaft while the oil reservoir
is empty.
Check the oil level and the condition of the oil. The oil level is
is approximately 1 inch (2.5 cm) from the top of the fill port – so
that the floor of the upper reservoir within the pump housing
is flooded and the chamber itself is about 1/4 full, allowing for
oil expansion as the pump runs and heats up.
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.
Use the appropriate Hydra-Oil for the application (contact
Wanner Engineering if in doubt).
CAUTION: Protect the pump from freezing. Refer also to
the “Shutdown Procedure”.
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 (22) may be damaged. Refer to the
Fluid-End Service Section. Do not operate the pump with
a damaged diaphragm.
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.
Periodically
Change the oil after the first 100 hours of operation, and then
according to the guidelines below. When changing, remove
the pipe cap (34) at the bottom of the pump so all oil and
accumulated sediment will drain out.
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; remove plug (2) from manifold and collect
drainage.
3. Close draincocks in system piping and replace manifold
plug.
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. It is also good practice to change the oil in the Hydraulic
End before storage for an extended period. This will remove
Hours Between Oil Changes @ Various
Process Fluid Temperatures
Pressure RPM
<90°F
(32°C)
<139°F
(60°C)
<180°F
(82°C)
Metallic Pump Head
<800 psi (56 bar)
<800
6,000
4,0002,000
<12003,0002,000
1,500
<1200 psi (83 bar)
<8003,0002,000
<1200
1,500
—
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).
G40-991-2400B
D/G-40 Service (Fluid End)
2. Inspect Valves (8-15)
NOTE: The number in parentheses are the Reference
numbers on the illustration on the preceeding page.
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.
CAUTION: Do not disassemble the hydraulic end unless
you are a skilled mechanic. For assistance, contact
Wanner Engineering (612-332-5681) or the distributor in
your area.
The three inlet and three outlet valve assemblies are
identical, but face in opposite directions. Inspect them while
they are still in the valve plate (18): look for excess wear on
the valve seat (10) and valve (11), or for foreign material in
the valve assembly.
If further inspection is necessary or if they must be replaced,
remove them as outlined below.
CAUTION: Do not remove the four socket-head capscrews
(25) that go through the back of the pump housing and
thread into the cylinder housing, unless you are repairing
the hydraulic end of the pump.
Service Procedure
1. Remove Manifold and Valve
Plate (5, 18)
a. Manifold. Using 1/2 inch (14 mm) hex socket and boxend wrench, remove the centerbolts (1) and washers
(if appropriate) in the center of the manifold. Do not
remove the four socket-head capscrews. Remove the
manifold.
NOTE: When you remove the valve plate in the following
step, some oil will leak out from behind the diaphragms.
Provide something to catch this oil leakage.
CAUTION: Don’t turn the pump drive shaft while
the manifold and valve plate are off the pump,
except when removing diaphragms or repriming the
hydraulic cells.
b. Remove all nuts (31) and bolts (3) around the manifold.
Do not remove the four bolts (25) that are installed
through the back of the pump housing.
c. Remove the manifold (5).
d. Inspect the manifold for warping or wear around the inlet
and outlet ports. If wear is excessive, replace the manifold
or return it to Wanner Engineering for resurfacing.
W0351
Remove Valves
a. Inlet (3 center valves). From the front side of the valve
plate (18), insert a seat remover (from the Wanner Tool
Kit) through the valve seat (10), and pull on it. The valve
seat (10), will come loose, followed by the valve (11),
valve spring (12), washer (14) and retainer (15).
b. Outlet (3 outer valves). Grasp and pull the spring retainer
(15) from the front side of the valve plate.
To check if the manifold is warped, remove the O-rings
and place a straightedge across it. A warped manifold
should be replaced.
Note: Before removing the valve plate in steps e. and
f. below, insert two bolts (3) from the shaft end of the
pump, through two holes in the top of the clinder casting
(24), and into the valve plate (18). This will hold the valve
plate in place when the socket head cap screws are
removed.
e. With a 3/8 inch (10 mm) hex head socket, remove the
four socket head cap screws (17).
d. Remove and inspect the valve plate 18).
Remove the retainer, washer (14), valve spring (12) and
valve (11).
Use the wrench-operated Valve Seat Removal Tool
included in the Wanner Tool Kit to remove the valve
seat (10).
G40-991-2400B
D/G-40 Service (Fluid End)
Do not remove the plunger from the plunger shaft.
Smooth the surfaces and edges as necessary with emery
cloth or a fine file, being careful to keep particles out of
the pump.
CAUTION: If a diaphragm was damaged 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.
f. Install a new diaphragm ridge-side out. We recommend
that you not reuse old diaphragms, because the material
may have taken a compression set and thus will not seal
properly.
g. Clean the screw (19), follower (21), and the threads in the
valve plunger. Remove any oil from the valve plunger.
Apply a medium-strength threadlocker (Loctite ® 242)
to the screw (19). Re-install the screw, O-ring (20), and
follower, and tighten the screw.
h. Repeat the above inspection and replacement procedure
with the other two diaphragms.
Disasemble and Inspect Valves
c. Remove the O-ring (13).
d. Insert a large screwdriver between the spring retainer (15)
and valve seat (10), and twist.
e. Inspect the O-rings. Replace if worn.
f. Inspect the valves and valve seats for wear, and replace if
necessary. Replace the valve springs and spring retainers
whenever the valves are replaced.
g. Apply grease to the outside of the valve seat and O-ring
(9), then reassemble the valve assemblies.
Reassemble Valves
Reinstall Valves
h. Clean the valve ports and shoulders with emery cloth,
and lubricate with grease or petroleum jelly.
i. Inlet (3 center valves). Insert the valve assemblies into
the valve plate, retainer first.
j. Outlet (3 outer valves). Insert the valve asemblies into
the valve plate, valve seat first.
3. Inspect and Replace
Diaphragms (22)
4. Flush Contaminates from
Hydraulic End
a. Lift the diaphragm by one edge, and turn the pump
shaft until the diaphragm pulls up. This will expose
machined cross-holes in the valve plunger (52) behind
the diaphragm.
b. Insert the Valve Plunger Holder (from the Wanner Tool
Kit) through the top hole, to hold the diaphragm up.
c. Grasp the Plunger Holder so the valve plunger (52) won’t
rotate, remove the screw (19), O-ring (20), and follower
(21) from the center of the diaphragm.
d. Remove the diaphragm and inspect it 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:
• Half-moon marks. Usually caused by cavitation of the
pump (refer to “Troubleshooting”).
• Concentric circular marks. Usually caused by
cavitation of the pump (refer to “Troubleshooting”).
• Small puncture. Usually caused by a sharp object in
the fluid, or by an ice particle.
• Diaphragm pulled away from the center screw or from
the cylinder sides. Usually caused by fluid being frozen
in the pump, or by overpressurization of the pump.
• Diaphragm becoming stiff and losing flexibility,
Usually caused by pumping a fluid that is incompatible
with the diaphragm material.
• Slice in ridge of diaphragm. Usually occurs when a
diaphragm is operated at temperatures below its rated
capability.
• Diaphragm edge chewed away. Usually caused by
overpressurizing the system.
e. Inspect the plunger (23) for any rough surfaces or edges.
(only if a diaphragm has ruptured)
a. With the valve plate and manifold still removed (see
above), remove the oil drain cap (34). Allow all oil
and contaminate to drain out (catch and dispose of it
properly).
b. Fill the reservoir with kerosene or solvent, manually turn
the pump shaft to circulate the kerosene, and drain. Catch
and dispose of the contaminated fluid properly.
CAUTION: If you have EPDM diaphragms, or if foodgrade oil is in the reservoir, do not use kerosene or
solvents. Instead, flush with the same lubricant that
is in the reservoir. Pumps with EPDM diaphragms
have an “E” as the 7th digit of the Model No.
c. Repeat the flushing procedure (step b).
d. Fill the reservoir with fresh oil, manually turn the pump
shaft to circulate the oil, and drain once again. Catch the
oil and dispose of it properly.
e. Refill the reservoir. If the oil appears milky, there is
still contaminate in the reservoir. Repeat the flushing
procedure until the oil appears clean.
5. Prime the Hydraulic Cells
a. With the pump horizontal, and the fluid-end head removed,
fill the reservoir with the appropriate Hydra-oil for the
application. Have a catch basin for oil that leaks from
behind the diaphragms when priming. Catch the oil and
dispose of it properly; do not reuse it.
G40-991-2400B
D/G-40 Service (Fluid End)
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). A shaft rotator is included in the
Wanner Tool Kit. 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 pistons (inside the hydraulic end)
and will cause the pump to run rough.
c. Wipe excess oil from the cylinder casting and
diaphragms.
d. Ensure that the oil is 1 inch (25 mm) from the top of the
fill port.
e. Replace oil fill cap (27).
6. Reinstall Valve Plate and
Manifold (18, 5)
a. Insert two bolts (3) from the shaft end of the pump, through
the top two holes of the pump.
b. Hang the valve plate on these two bolts.
c. Insert four socket head cap screws (17) through the valve
plate, and hand tighten the valve plate to the cylinder
casting. Watch the alignment.
d. Using petroleum jelly or grease, install the outlet valve Orings (16) and centerbolt O-rings (6) on the valve plate.
e. Again using petroleum jelly or grease, install the manifold
O-ring (7) on the manifold.
f. Hang the manifold on the two bolts (3).
g. Install centerbolts (1) and washers if appropriate. Torque
to 180 ft-lbs (240 N-m).
h. Install the bolts (3), washers (4), and nuts (31) around the
edge of the manifold. Torque to 90 ft-lbs (120 N-m).
i. Recheck all bolts for tightness.
G40-991-2400B
D/G-40 Service (Hydraulic End)
3. Reassemble Pistons
NOTE: The number in parentheses are the Reference
numbers on the illustrations in the Parts Manual.
NOTE: When reassembling the hydraulic pistons, use
new plungers (23). They are press-fit onto the valve
plungers (52) and are not reusable.
a. Drop a ball (57) into each opening in the bottom of the
piston assembly (58).
NOTE: Using grease on the O-rings, and lubricating the
parts, will aid in assembly.
b. Insert a retaining washer (56) and O-ring (55) to hold the
balls in place.
c. Insert a valve plunger (52) into the valve cylinder (54).
Slide a spring (51) over the valve plunger, inside the valve
cylinder.
d. Insert an O-ring (53) into the spring retainer (50).
e. Install an O-ring on a valve cylinder.
f. Lubricate the inside of a spring retainer, then slide the
assembled valve cylinder, plunger, and spring (51-54)
into the retainer.
g. Lubricate the inside of wall of the piston.
h. Slide the complete cylinder-and-retainer assembly (50-55)
into the piston assembly (58).
i. Insert a piston return spring (49) into the piston
assembly.
j. Repeat the above procedure for the other two pistons.
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 (612-332-5681) or the distributor in your area.
CAUTION: The four bolts (25) that screw through the back of
the pump housing into the cylinder housing (24) hold these
parts together. Do not remove these four screws except
when repairing the hydraulic end.
NOTE: The following service procedures refer several times to
the Wanner Tool Kit. We strongly urge you not to try to repair
the hydraulic end of the pump without using the tools in this Kit
(available from Wanner Engineering or your local distributor).
Service Procedure
1. Remove Pump Housing
a. Remove the head of the pump and diaphragms as outlined
in the Fluid End Service Section.
b. Drain the oil from the pump housing by removing the drain
plug (34). Dispose of the oil properly.
c. Remove the baseplate (35).
d. Set the hydraulic end of the pump face-down on the
cylinder casting (24).
e. Check the shaft for sharp burrs. Smooth any burrs,
to prevent scarring the housing seals (64) when you
disassemble the pump.
f. Remove the bolts (25) that secure the pump housing to
the cylinder casting (remove two opposite bolts at a time,
loosening them evenly). The piston return springs (49) will
force the cylinder casting and pump housing apart. The
bearing adjusting plate (61) and disc springs (60) may fall
out.
g. Lift off the pump housing (30).
h. Inspect the cam assembly (62), and the bearing race in
the rear of the pump housing. If the bearings are pitted
or binding, or if the pump housing race is worn, contact
Wanner Engineering.
4. Remove Shaft Seals (64)
5. Reassemble Pump Housing
and Cylinder Casting
a. Place the cylinder casting (24) face-down on two boards,
avoiding contact between the diaphragms and boards.
b. Insert the disc springs (60) and bearing adjusting plate
(61) into the cylinder casting. If they don’t stick together
as a unit, reassemble them, pack them with grease and
hold them together while inserting them into the cylinder
casting.
Insert the small bearing cup with the larger inside diameter
facing out. The bearing cup must be flush with or lower
than the cylinder casting.
c. Insert the assembled pistons (49-58) into the cylinder
casting.
d. Note the location of the outer ring of holes in the cylinder
casting and in the pump housing flange - in particular, the
holes where bolts (25) will be installed.
e. Stand the camshaft assembly (62) on the cylinder casting
(24).
Caution: The pilot bearing MUST be properly nested
in the bearing race during assembly. If misaligned,
the bearing will be damaged and the pump will fail
within the first hours of operation.
2. Disassemble Pistons
a. With the pump housing removed (see above), turn the
cylinder casting (24) over and set it on a flat surface, piston
side down. Be careful so the pistons don’t separate from
the cylinder casting.
b. Remove the punger (23) from the valve plunger (52). The
plunger is press-fit on the valve plunger: (see the Fluid
End Service Section), use a flat-tiped rod or punch to
tap the valve plunger in the middle of the plunger. With
light tapping, the plunger (23) should slip off the valve
plunger.
Inspect the shaft seals (64) before continuing. If they look
damaged in any way, replace them. Remove by pounding
them out from inside the pump housing. Replace both shaft
seals at the same time. Clean the bore in the housing using
emery cloth or Scotch-Brite™.
The hydraulic piston assembly (49-58) can now be
disassembled. Inspect all parts, and replace all O-rings
and any other part that are worn or damaged.
c. Repeat step b. for the remaining pistons.
G40-991-2400B
D/G-40 Service (Hydraulic End)
f. Wrap the seal protector bag (part of Wanner Tool Kit) over
the shaft.
g. Install the O-ring (65) into the pump housing (30), using
grease or petroleum jelly to hold it in place.
d. Hold the bottom of the guide with a 1 inch (25 mm) wrench,
and turn the top of the guide with a 9/16 inch (15 mm)
wrench. Press the plunger onto the valve plunger (52).
This is a press fit. When installed, the plunger should be
tight against the shoulder of the valve plunger.
Note: Do not remove the plunger guide until the
diaphragm is installed (see following).
e. Install the diaphragm as outlined following, then repeat the
procedure for the other two plungers and diaphragms.
Slide the pump housing down over the shaft. Be sure the
holes in the pump housing and the cylinder casting are
properly aligned.
h. Drop the bolts through the four appropriate holes in the
pump housing (30). Screw the bolts (from the Wanner Tool
Kit) into the four threaded holes in the cylinder casting,
but don’t tighten them yet. You may want to insert a few
bolts (3) into the unthreaded holes of the pump housing
and cylinder casting (24) to help align the parts.
i. Alternately tighten the bolts to evenly draw the pump
housing down to the cylinder casting. Be sure the
O-ring (65) stays in place.
8. Reinstall Diaphragms (22)
Also, as you tightem the nuts keep checking the shaft
alignment by turning the shaft (use the rotator in the
Wanner Tool Kit). If the shaft begins to bind and becomes
difficult to turn, back off the nuts and realign the shaft.
When the pump housing is tight against the cylinder
casting you should be able to turn the shaft smoothly.
j. After all the bolts are tightened, remove two opposite bolts.
Insert two cap screws (25) with washers into the same
holes, and tighten.
Remove the two remaining bolts, and replace them with
cap screws.
k. Turn the shaft again to check its alignment.
NOTE: Keep the Valve Plunger Holder through the
valve plunger (52), as described above under “Reinstall
Plungers”.
a. Place the diaphragm (22) onto the plunger (23), ridge side
out.
b. Center the follower (21) on the diaphragm.
c. Place the O-ring (20) onto the follower screw (19).
d. Apply a small amount of threadlocker (e.g., Loctite 242)
to the threads of the follower screw.
e. Insert the follower screw, with its O-ring, through the
follower and diaphragm. Then screw it into the valve
plunger (52).
f. Hold the Valve Plunger Holder and tighten the follower
screw to 18 in-lbs (200 N-m).
g. Repeat the above procedure for the other two cylinders.
h. Fill the reservoir with fresh oil and prime the pump, as
outlined in the Fluid-End Service Section.
6. Install Shaft Seals (64)
9. Reassemble Pump Head
a. Apply an anaerobic sealant or bearing retaining compound
(such as Loctite® 601 or 609) to the outer surface of both
seals and the inside surface of the opening in the pump
housing where the seals will rest.
b. With a soft mallet and the larger diameter side of the flat
plate, tap the first seal (wth its spring side into the pump)
into the housing. With the reverse side of the plate, push
the seal 1/8 inch (3 mm) further into the housing.
c. Pack the inside (spring side) of the second seal half-full
with grease. With the larger diameter of the plate, tap the
second seal flush with the pump housing (30).
Reassemble the pump head as outlined in the Fluid End
Service Section.
7. Reinstall Plungers (23)
NOTE: If the plungers (23) have been removed from the
valve plungers (52), do not reuse them. Install new ones
instead.
a. With the pump shaft appropriately rotated, place a plunger
(23) onto the exposed screw end of the Plunger Guide
Lifter Tool (from the Wanner Tool Kit). The flat side of the
plunger should face the tool.
b. Screw the Guide Tool (with the plunger) into the valve
plunger (52) until tight.
c. Pull the valve plunger up until its cross holes are exposed.
Insert the Valve Plunger Holder (from the Wanner Tool Kit)
through the top cross hole.
10
G40-991-2400B
D/G-40 Troubleshooting
Cavitation
•
•
•
•
•
• Foreign material in inlet or outlet valve
• Damaged diaphragm
• Fatigued or broken valve spring
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
— NPSHa is less than NPSHr
Fluid too hot for inlet suction piping system.
Air entrained in fluid piping system.
Aeration and turbulence in supply tank.
Inlet vacuum too high
Premature Failure of Diaphragm
•
•
•
•
•
Water (or Process Fluid) in Oil
Reservoir
• Condensation
• Ruptured diaphragm
• Hydraulic cell not properly primed after diaphragm
replacement
• Frozen pump
Symptoms of Cavitation
•
•
•
•
Frozen pump
Puncture by a foreign object
Elastomer incompatible with fluid being pumped
Pump running too fast
Excess pressure
Excessive pump valve noise
Premature failure of spring or retainer
Volume or pressure drop
Rough-running pump
Drop in Volume or Pressure
Water (or Process Fluid)
Pulsations
A drop in volume or pressure can be caused by one or more of
the following:
NOTE: Small pulsations are normal in single-acting pumps
with multiple pumping chambers.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Air leak in suction piping
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
Worn pump valve parts
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.
Empty supply tank
Excessive aeration and turbulence in supply tank
Worn and slipping drive belt(s)
Worn spray nozzle(s)
•
•
•
•
•
•
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
•
•
•
•
•
•
Pump Runs Rough
•
•
•
•
Foreign object lodged in pump valve
Loss of prime in hydraulic cell because of low oil level
Air in suction line
Valve spring broken
Cavitation
Aeration or turbulence in supply tank
External seepage
Rupture of diaphragm
Frozen pump
Worn shaft seal
Oil drain piping or fill cap loose.
Valve plate and manifold bolts loose
Premature Failure of Valve
Spring or Retainer
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
Restriction in inlet/suction line
Hydraulic cells not primed after changing diaphragm
•
•
•
•
11
Cavitation
Foreign object in the pump
Pump running too fast
Spring/retainer material incompatible with fluid being
pumped
G40-991-2400B
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.
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: [email protected]
© 1999 Wanner Engineering, Inc. Printed in USA
G40-991-2400B 1/1999, Revised 12/2006
12
G40-991-2400B