D-17_IOM_Manual

INSTALLATION & SERVICE
D17-991-2400A
Models: D-17, G-17
W0094A
WANNER ENGINEERING, INC.
1204 Chestnut Avenue, Minneapolis, MN 55403
TEL: (612) 332- 5681 FA X: (612) 332- 6937
TOLL-FREE FAX [US only]: (800) 332-6812
www.hydra-cell.com
email: [email protected]
D/G-17 Contents
Page
Specifications...........................................................................2
Dimensions..............................................................................4
Installation................................................................................6
Maintenance...........................................................................10
Service (Fluid End)................................................................11
Service (Hydraulic End).........................................................15
Troubleshooting.....................................................................18
Warranty................................................................................ 20
D/G-17 Specifications
Max Pressure
1500 psi (100 bar) @ 1750 rpm (D/G-17-E Cam only);
2000 psi (138 bar) @ 1450 rpm;
2500 psi (172 bar) @ 1150 rpm
Capacity @ Rated Pressure psi
rpm
D/G-17-X
1450
500
1450 1500
1450 2000
1150
2500
D/G-17-E
1750
500
1750
1500
1450 2000
1150
2500
Delivery @ Rated Pressure
psi
revs/liter
D/G-17-X
500
1500
2000
2500
D/G-17-E
500
1500
2000
2500
bar
35
100
140
170
35
100
140
170
gpm
13.4
13.0
12.7
10.3
15.1
14.1
11.5
9.4
bar
revs/gal
35
100
140
170
35
100
140
170
109
112
114
112
116
124
126
122
Calculating Required
Horsepower (kW)*
80 x rpm
63,000
I/min
50
48
48
39
57
53
44
35
80 x rpm
84,428
+
+
gpm x psi
1,460 – psi – 500
20
)
gpm x bar
bar – 35
4
)
(
511 –
(
= electric motor HP*
= electric motor kW*
* rpm equals pump shaft rpm. HP/kW is required application
power. Use caution when sizing motors with variable speed
drives.
28.8
29.6
30.2
29.6
30.6
32.8
33.3
32.3
Max Inlet Pressure 500 psi (35 bar)
Max Temperature
250°F (121°C) – consult factory for temperatures above 180°F (82°C)
Inlet Port*
D-17: 1-1/4 inch NPT
G-17: 1-1/4 inch BSPT
Discharge Port*
D-17: 3/4 inch NPT
G-17: 3/4 inch BSPT
Shaft Diameter
1-1/8 inch (28.58 mm)
Shaft Rotation
Bi-directional
Bearings
Tapered roller bearings
Oil Capacity
2.9 US quarts (2.8 liters)
Weight
145 lbs (66 kg)
D17-991-2400A
D/G-17 Specifications
Net Positive Suction Head - NPSHr
Performance
RPM
400
600
800
1000
1200
1400
1600
22
1800
15
650
56
1450
14
20
18
52
D/G-17-E
NPSHr (feet of water)
12
44
500 PSI (35 bar)
1500 PSI (100 bar)
2000 PSI (140 bar)
2500 PSI (170 bar)
500
16
48
11
550
D/G-17-X
D/G-17-X
13
600
D/G-17-E
40
10
450
14
400
12
350
10
300
250
8
200
6
36
9
150
4
100
GPM
28
I/min
32
8
NPSHr (cm of water)
200
1450
0
7
2
0
50
0
200
400
600
800
1000 1200 1400 1600 1800
RPM
0
W0102
24
6
Dry Lift
20
5
8
8
2
Lift (feet of water)
W0103
225
7
4
1
0
*Pump NPSHr and Lift performance based on randomly
selected pumps with water at 70°F (21°C)
D/G-17-E
200
6
175
5
150
4
125
3
100
75
2
50
1
0
25
0
200 400 600 800 1000 1200 1400 1600 1800
RPM
250
Lift (cm of water)
3
0
D/G-17-X
12
1750
9
1450
16
4
0
W0100
D17-991-2400A
D/G-17 Specifications
Dimensions
inches (mm)
Oil Reservoir
8.67
(220.2)
Cap with Plug
3.4
(86.4)
5.6
(142.2)
6.7
(170.2)
2.29
(58.2)
3.00
(76.2)
Outlet D-17: 3/4" NPT
G-17: 3/4" BSPT
2X 3/8" NPT Drain
4.75
(120.7)
Inlet D-17: 1-1/4" NPT
G-17: 1-1/4" BSPT
OUT
11.0
(279.4)
IN
¨
4.75
(120.7)
4X
Ø0.53
(13.5)
4.00
(101.6)
4.75
(120.7)
W0095A
10.7
(271.8)
D17-991-2400A
D/G-17 Specifications
Dimensions
inches (mm)
IEC Adapters: A04-041-1201; A04-041-1205
NEMA Adapters: A04-041-1200; A04-041-1202
IEC Adapter: A04-041-1203
D
D
E
E
ØC
(4 x)
ØC
(4 x)
Maximum
Coupler O.D.
4.75
(120.7)
A
Maximum
Coupler O.D.
4.75
(120.7)
A
B
Shaft to Shaft
End Clearance
W0106
W0105
Kit Part Number
A04-041-1200 A04-041-1202 A04-041-1203 A04-041-1201 A04-041-1205 Adapter Kit Motor Size
NEMA 182/184TC NEMA 213/215TC NEMA 254/256TC NEMA 284/286TC IEC 160 B14 Face
IEC 132 B5 Flange IEC 160/180 B5 Flange B
Shaft to Shaft
End Clearance
A
8.75
8.75
8.75
10.75
(250)
(328)
(328)
B
7.25
7.25
7.25
9.00
(215)
(265)
(300)
Dimensions in (mm)
C
D
0.54
8.0
0.54
8.0
0.54
8.0
0.54
8.4
(13.1)
(208.3)
(13.1)
(203.2)
(17.0)
(208.3)
E
1.71
0.96
0.33
0.14
(3.8)
(27.7)
(3.8)
F
1.125
1.375
1.625
1.875
(42)
(38)
(42/48)
D17-991-2400A
D/G-17 Installation
Important Precautions
Location
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”.
NOTE: The numbers in parentheses are the Reference
Numbers on the exploded view illustrations found later in
this manual and in the Parts Manual.
The D-17 and G-17 pumps are designed to run vertically with
the head submerged in the fluid being pumped. The pump/
motor must be rigidly mounted to the fluid supply tank. Note:
the fluid supply tank must be capable of supporting the weight
of the pump/motor assembly (see next sections of Installation
instructions for more details). Allow enough space for the
assembly to be raised and lowered from the supply tank for
servicing. Note: hydraulic end oil can be changed (drained and
refilled) without removing the pump from its installation on the
fluid supply tank.
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.
Construction of the Tank
The Installation Illustration shows the recommended minimum
inside height, the top cutout, and the hole size and locations
required to mount the pump base. Determine the desired pump
orientation before drilling the mounting holes, as the hole pattern
in the pump base plate is not symmetric.
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 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
Construct the tank so it will adequately support the weight of
the pump/motor assembly. The combined pump/motor weight
could be up to 650 lbs (295 kg). Consult the motor manufacturer
for the actual motor weight.
Typical machine tool coolant tanks are of sheet metal
construction and will not adequately support the D-17 or G-17
pump/motor assembly. Risers inside the tank, support plates,
weld nuts, and other techniques should be used to ensure the
pump/motor assembly will be secure. Additionally, the pump
and mounting must be able to withstand vibrations and on/off
shocks that will be present as the pump runs and cycles on and
off with demand.
The tank should be large enough to avoid aerating the fluid.
Return flow from the system as well as bypass from the pressure
regulating valve should be returned to the tank as far away from
the pump inlet as practical. Preferably in an isolated section of
the tank, baffled from area the pump sits in.
Mounting the Pump
Isolate the pump and tank from the system by using flexible high
pressure hose from the discharge piping and flexible wiring to
the motor. Allow long enough flexible hose and wiring for removal
of the complete pump/motor assembly from the supply tank, or
attach quick disconnect fittings for easy maintenance.
With the discharge fluid connection secure and the unit in place
on the supply tank, fasten the pump base plate to the tank using
four 1/2” or 12mm cap screws. Use lock washers beneath the
heads of the cap screws and torque to 30 ft-lbs (40 N-m).
D17-991-2400A
D/G-17 Installation
11.0
(279.4)
5.5
(139.7)
Ø8.25
(209.6)
(Minimum Cutout
for Pump Head
Clearance)
16.6
(422)
Reference Only,
Consult Motor
Manufacturer
for Actual Dims.
4.75
(120.7)
4.75
(120.7)
3/4" NPT
(3/4" BSPT)
OUT
3.00
(76.2)
5.525
4.75 (140.3)
(120.7)
¨
10.7
(271.8)
2.29
(58.2)
Motor
4.00
(101.6) 5.187
(131.7)
IN
2X 3/8" NPT Drain
(2X 3/8" BSPT Drain)
8.0 - 8.4
(203 - 213)
Motor
Adapter
Oil Reservoir
Maintain Appoximately
1/4 Full When Cold
16.7 - 17.1
(424 - 434)
4X Ø0.53
(13.5)
1-1/4" NPT
(1-1/4" BSPT)
Bypass Pressure
Regulating Valve
High Pressure
Outlet Hose with Swivel
Connections at Both Ends
Plugged
Cap
D-17/G-17
Pump
IN
Fine Mesh Filter
To
System
OUT
From
System
Coarse Mesh Filter
3.4
(86)
Bypass
Flow
Inlet
Pipe
90 High Pressure
Outlet Fitting
Return Flow
W0099A
1.00 Minimum
(25.4) Clearance
Inlet Piping
Before entering the section of the tank where the pump inlet
is submersed, the fluid should be filtered to one size smaller
than the smallest nozzle or tool orifice in the system. Set up
baffling in the tank to allow chips and large particles to settle
out before getting close to the pump inlet. Install at least two
stages of filtering to ensure an adequate supply of fluid to the
pump inlet: a coarse mesh followed by a fine mesh to section off
the tank closest to the pump. Install the filters in the tank where
they can be checked and cleaned regularly; plugged filters can
result in pump cavitation, drop in volume or pressure output,
or damage to the pump. Do not connect a line strainer or filter
directly onto the pump inlet port.
If the fluid being pumped gets too hot a chiller may be required. If
pumping machine tool coolant, operate below the manufacturers
maximum temperature rating for the coolant.
If using the pump isolated from the supply tank, with the inlet fed
by a hose or pipe, consult the factory for instructions regarding
“Inlet Piping (Suction Feed)”, “Inlet Piping (Pressure Feed)”,
and “Inlet Calculations (Acceleration Head, Friction Losses,
and NPSH)”. Specific instructions for this situation can also be
found in the D15-991-2400 Installation/Service Manual.
D17-991-2400A
DG-17 Installation
Discharge Piping
NOTE: Consult the Factory before manifolding two or more
pumps together.
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 2000psi-gauge pressure.
Use about 6 ft (1.8 m) of flexible hose between the pump and
rigid piping to absorb vibration, expansion or contraction, and
to isolate the pump/motor/tank from the system.
Size the discharge line so that the velocity of the fluid will not
exceed 7-10 ft/sec (2-3 m/sec):
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 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.
Mount the bypass pressure regulator to the supply tank as far
away from the pump inlet as practical, preferably in an isolated
section of the tank, baffled from the pump.
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 safety relief valve in
the discharge line, downstream from the pressure regulator.
D17-991-2400A
D/G-17 Installation
Before Initial Start-Up
Initial Start-Up Procedure
Before you start the pump, be sure that:
1. Turn on power to the pump motor.
2. Listen for any erratic noise, and look for unsteady flow. If the pump does not clear, refer to the Trouble-shooting
Section.
3. If the system has an air lock and the pump fails to prime:
a. Turn off the power.
b. Disconnect the discharge hose from the inlet port
of the pressure regulating valve (refer to installation
illustration.)
NOTE: Fluid may come out when the hose is removed.
Provide an adequate catch basin for fluid spillage, if
required. Fluid will come out of this hose when the pump
is started; route the hose back to the supply tank or to
a catch basin so fluid will not be sprayed or lost. Use
high-pressure-rated hose and fittings. 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. Reconnect the discharge hose to the inlet port of the
pressure regulating valve.
4. Adjust the discharge pressure regulator to the desired
operating and bypass pressures. Do not exceed the
maximum pressure rating of the pump.
5. 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 3b) for handling
the fluid that will come from the relief valve.
6. Reset the discharge pressure regulator to the desired system
pressure.
7. Provide a return line from the relief valve to the supply
tank.
• The pipe plug in the pump housing has been removed and
the oil reservoir (39) has been installed. The reservoir allows
for oil expansion during pump operation, and serves as a
sight glass for monitoring condition and level of the oil. Fill
the oil reservoir 1/4 full when the pump is cold.
• All shutoff valves are open, and the pump has an adequate
supply of fluid.
• All connections are tight.
• The relief valve on the pump outlet is adjusted so the pump
starts under minimum pressure. This allows air in the
system to be expelled easily, and fluid to enter the pump
and system.
• The coupler that connects the pump and motor shafts has
been sized and installed correctly.
• All electrical wiring has been done correctly to electrical
codes.
D17-991-2400A
D/G-17 Maintenance
Shutdown Procedure During
Freezing Temperatures
Daily
NOTE: The numbers in parentheses are the Reference
Numbers on the exploded view illustrations found later in
this manual and in the Parts Manual.
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.
Check the oil level and the condition of the oil. The oil reservoir
should be 1/4 full.
Use the appropriate Hydra-Oil for the application (contact
Wanner Engineering if in doubt).
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 plugs (0) from manifold and
collect drainage.
3. Close draincocks in system piping and replace manifold
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. 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.
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 (21) 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.
Periodically
Change the oil after the first 100 hours of operation, then
change according to the guidelines below. When changing,
remove the drain plug cap (26) at the bottom of the pump so
all oil and accumulated sediment will drain out. Then, remove
the magnetic plug (33) and clean all accumulated debris from
it. Replace the magnetic plug and drain plug cap and refill with
the appropriate Hydra-Oil.
Hours Between Oil Changes @ Various
Process Fluid Temperatures
Pressure RPM
<90°F
(32°C)
<139°F
(60°C)
<180°F
(82°C)
<1500 psi (100 bar) <1200
<1750
4,000
2,000
3,000
1,500
2,000
1,000
<2000 psi (140 bar) <1200
<1450
2,000
1,500
—
—
1,500
1,000
<2500 psi (170 bar) <1200
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”.
10
D17-991-2400A
D/G-17 Service (Fluid End)
DETAIL "A"
(Valve Assemblies)
INLET VALVE
Metal
Retainer
14
OUTLET VALVE
See Pump/Motor
Adapters for details
15
Plastic
Retainer
16
12
17
11
18
13
19
10
39
20
9
Plastic
Retainer
Metal
Retainer
35
36
27
37
28
33
23
34
24
8
3
21
34
29
22
6
Valve
Assemblies
(see Detail A)
38
5
7
4
31
32
W0096A
3
3
2
30
1
Bolt Torque Specifications
0
11
Ref. #
Assembly Torque
1
45 ft-lbs
60 N-m
2
45 ft-lbs
60 N-m
22
45 ft-lbs
60 N-m
29
15 ft-lbs
20 N-m
32
45 ft-lbs
60 N-m
42
25 ft-lbs
35 N-m
D17-991-2400A
D/G-17 Service (Fluid End)
Service Procedures
NOTE: The number in parentheses are the Reference
numbers on the illustration on the preceding page and in
the Parts Manual.
Begin with the pump assembly removed from the system, and
the pump disconnected from the motor and motor adapter.
Secure the pump baseplate (30) to a stable workbench with
clamps, or bolts and nuts (the bolts passing through the unused
holes in the solid portion of the baseplate).
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
(TEL 612-332-5681 or FAX 612-332-6937) or the distributor in
your area.
1. Remove Manifold (4) and Valve Plate (24)
CAUTION: Don not remove the four socket-head capscrews
(29) that go through the cylinder housing (23), unless you are
repairing the hydraulic end of the pump.
Tools and Supplies
The following tools and supplies are recommended for servicing
the pump:
• Straightedge (at least 8 in. long)
• Grease or petroleum jelly
• 1/2” drive torque wrench, rated to at least 50 ft-lbs (70 Nm)
• Emery cloth and Scotch-Britetm pad
• 11/16” socket (3/8” or 1/2” drive)
• 19 mm socket (1/2” drive)
• 3/8” drive socket wrench with extensions
• 1/2” drive socket wrench with extensions
• 5/16” (8 mm) open-end wrench
• Wanner Hydra-Oil (appropriate Grade, as determined by
digit 12 of your pump model number).
• Anaerobic seal sealant (for shaft seals if servicing Hydraulic
End)
• Wanner D-15 Tool Kit, which includes the following:
– Valve seat puller
– Plunger guide lifter
– 3/32 x 6 in. T-handle hex wrench
– 8 mm hex bit socket (1/2” drive)
– Shaft rotator
– Seal protector
– Seal inserter
– 5/16” hex Allen wrench
– 7/16” 8-point socket (3/8” drive)
– 6 mm hex Allen wrench
a. Manifold. Use the 8 mm hex bit socket included in the
Wanner D-15 Tool Kit to remove the 12 capscrews (2) and
five capscrews (1) at the front of the manifold. Remove
and inspect the manifold for warping or wear around
the inlet and outlet ports and flow channels. If wear is
excessive replace the manifold. To check if the manifold
is warped, place a straightedge across it; check both
sides. A warped manifold should be replaced.
b. Valve Plate. Using the 8 mm hex bit socket remove
capscrew (22). Remove and inspect the valve plate in
the same manner as the manifold, for excessive wear or
warping. Replace if necessary.
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.
2. Remove and Inspect Valves
(9-20)
NOTE: Wanner Valve Kits include items and all O-rings for
sealing the manifold to the valve plate. The five inlet and
five outlet valve assemblies are different in size and face
in opposite directions.
12
a. Remove the inlet valve seat (10) using the seat puller tool
included in the Wanner D-15 Tool Kit. Inspect the valve
seat for wear, and replace if necessary.
NOTE: Whenever any valve or seat is replaced it is
recommended to replace all valve assemblies to ensure
the most reliable operation. All necessary parts are
included in a replacement Valve Kit.
b. Remove the remaining inlet valve components (11-14)
and outlet valve components (17-20) by hand or with a
small needle nose pliers. c. Check the spring retainers (14, 20) and replace if worn,
cracked, or damaged.
d. Check the valve springs (12, 19) and replace if worn,
broken, or shorter than a new spring. Never attempt to
stretch a used spring.
D17-991-2400A
D/G-17 Service (Fluid End)
e. Check the valves (11, 18) for wear or damage and replace
if necessary. Polishing of the valves during operation is
normal. If you can feel a ridge in the valve surface the
valve should be replaced.
NOTE: Pumps with plastic spring retainers (14, 20)
include a Tetra Seal (13, 17 - square section O-ring)
between the spring retainer and valve seat. Pumps with
metal spring retainers do not include a Tetra Seal.
f. Reinstall the valve assemblies:
• Clean the valve ports and shoulders in the valve plate
(24) with a Scotch-Brite pad or fine emery cloth. Wash
the valve plate after cleaning, and lubricate the valve
ports with a compatible grease, oil, or petroleum jelly.
• Install new O-rings (9, 15) on seats (10, 16) and
lubricate all O-rings.
• Inlet Valves (five center, larger valves). Insert the
spring retainer (14) into the valve plate (24), followed by
the Tetra seal (13) if spring retainer is plastic. Insert the
spring (12) into the retainer, followed by the valve (11)
onto the spring. Finally, insert seat (10) with new O-ring
into the valve bore with the larger I.D. chamfer (seating
surface) facing down, towards the valve.
• Outlet Valves (five outer, smaller valves). Insert the
outlet seat (16) with new O-ring into the valve bore with
the larger I.D. chamfer (seating surface) facing up. Insert
a Tetra Seal (17) if valve spring retainers are plastic. Insert the valve (18) and spring (19) onto the seat. Finally,
insert the spring retainer (20) into the valve bore. • Make sure the springs are all properly nested into the
spring retainers to ensure proper valve performance.
4. Flush Contaminant from Hydraulic End
3. Inspect and Replace Diaphragms (21)
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 or by extremely high
temperatures.
• Diaphragm becoming stiff and losing flexibility. Usually caused by pumping a fluid that is incompatible
with the diaphragm material.
• 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.
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 four diaphragms.
(only if a diaphragm has ruptured)
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 valve plunger
(51) behind the diaphragm.
b. Insert a 3/32 x 6 in. hex wrench through one of the
machined cross-holes, to hold the diaphragm up and to
keep the valve plunger from rotating. The proper size tool
is included in the Wanner Tool Kit. (Don’t remove the tool
until the new diaphragm is installed in step “f” below.)
c. Unscrew the diaphragm. Use a 5/16-in. (8-mm) open-end
wrench, and turn counterclockwise.
13
a. With the valve plate and manifold still removed (see
above), remove the oil drain cap (26) allow all oil and
contaminant to drain out.
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 “b” above).
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.
D17-991-2400A
D/G-17 Service (Fluid End)
6. Reinstall Valve Plate (24) and Manifold (4)
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.
b. All air in the oil within the hydraulic cell (behind the
diaphragm) must be forced out by turning the shaft (and
thus pumping the piston). A Shaft Rotator is included in
the Wanner D-15 Tool Kit. Rotate the shaft two revolutions
and refill the reservoir. Rotate it two more revolutions and
refill again. Continue to do this until the oil that is being
pumped from the back of all five diaphragms is free of
air.
c. Wipe excess oil from the cylinder housing (23) and
diaphragms (21).
d. Ensure that the pump housing is completely full of oil.
e. Replace oil fill cap (28).
14
a. Reinstall the valve plate (24), with the valve assemblies
installed as outlined above, onto the cylinder housing
center spud and alignment pin (8).
b. Install capscrew (22) with flat washer (3) through center
hole in valve plate and torque to 45 ft-lbs (60 N-m).
c. Install new O-rings (5, 6, 7) into the grooves in the front
side of the valve plate. Use grease or petroleum jelly to
hold them in place.
d. Reinstall the manifold (4) over alignment pin (8), engaging
the center spud of the manifold into the center of the valve
plate.
e. Install capscrews (1) with flat washers (3) through the
five center holes in the manifold. Thread each capscrew
in several turns, but do not torque yet.
f. Install capscrews (2) with flat washers (3) through the
twelve outer holes at the perimeter of the manifold.
Thread each capscrew in several turns, but do not torque
yet.
g. Return to the five capscrews at the center of the manifold
and alternately tighten opposite bolts until all are secure. Torque to 45 ft-lbs (60 N-m).
h. Return to the twelve capscrews at the perimeter of the
manifold and alternately tighten opposite bolts until all
are secure. Torque to 45 ft-lbs (60 N-m).
i. Recheck all capscrews for tightness and proper torque,
starting with the five at the center of the manifold, then
the twelve at the perimeter.
D17-991-2400A
D/G-17 Service (Hydraulic End)
23
38
39
47
40
48
41
49
42
Cross-Section
Assembly
50
43 A
43
57
51
52
43
53
44
54
43 B
55
*
56
45
* Qty per piston: 4
46
37
Bolt Torque Specifications
W0097
15
Ref. #
Assembly Torque
40
15 ft-lbs (20 N-m)
D17-991-2400A
D/G-17 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 (612-332-5681) or the distributor in
your area.
2. Disassemble Pistons
CAUTION: The four socket-head capscrews (29) that screw
through the cylinder housing (23) into the pump housing
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 D-15 Tool Kit. We strongly urge you not to repair
the hydraulic end of the pump without using the tools in this Kit
(available from Wanner Engineering or your local distributor).
Refer also to the list of tools and supplies in the Fluid-End
Service Section.
NOTE: Before Step 1 Remove Pump Housing, scribe a line
on the perimeter of the cylinder housing and onto the pump
housing. This will simplify alignment during reassembly.
1. Remove Pump Housing
Inspect and clean all parts of the hydraulic piston assemblies
(57). Replace all O-rings and any other parts that are worn
or damaged.
3. Reassemble Pistons
Service Procedure
h. Inspect the cam and bearings (43), and the bearing cup
(43B) in the housing. If the bearings are pitted or binding,
or if the bearing cup in the housing is worn, contact
Wanner Engineering.
CAUTION: If a bearing cup or bearing cone is replaced,
they must be replaced as a pair or premature failure will
result.
a. Remove the manifold and valve plate, and the diaphragms,
from the pump. Refer to the Fluid-End Service Section
b. Drain the oil from the pump housing by removing plug
(33), then tipping the pump up onto the cylinder housing
(23). Remove oil reservoir (39), clean and set aside.
Return the pump to its secure horizontal position.
Dispose of the oil properly.
c. Check the shaft for sharp burrs. Smooth any burrs,
to prevent scarring the seals (45) when removing the
shaft.
d. Reinsert two perimeter bolts (2) through the cylinder
housing (23) into the pump housing (37), at the 10 and
2 o’clock positions, to support the parts as the pump is
being disassembled.
e. Remove the four socket-head capscrews (29) loosening
alternately so the cylinder housing separates evenly from
the pump housing. Slide the cylinder housing out on the
two bolts (2) that were inserted for support in Step d
above. The preload on the piston return springs will push
the cylinder housing out of the pump housing. Remove
the support bolts and cylinder housing assembly.
NOTE: the piston assemblies will be free to slide out
of the cylinder housing, so keep the cylinder housing
orientated with pistons up, for later disassembly.
f. Remove the shaft assembly (43) sliding the shaft out of
the seals (45). The parts are heavy.
g. Remove the bearing adjustment plate (41) and inspect
the bearing cup (43A). Inspect all parts for wear, and
replace if necessary.
a. Drop a ball (55) into each opening in the bottom of the
piston assembly (56).
NOTE: Using grease on the O-rings, and lubricating the
parts, will aid in assembly.
b. Insert a retaining washer (54) and O-ring (53) to hold the
balls in place.
c. Insert a valve plunger (51) into the valve cylinder (52). Slide a spring (50) over the valve plunger (51), inside the
valve cylinder (52).
d. Insert an O-ring (49) into the spring retainer (48).
e. Slide the assembled valve cylinder (52), valve plunger
(51), and spring (50) into the spring retainer (48).
f. Slide the complete cylinder-and-retainer assembly into
the piston assembly.
g. Insert a piston return spring (47) into the piston assembly,
with the larger end going into the piston first. This is a
tight fit, and can best be done by “screwing” the spring
in counterclockwise.
h. Repeat the above procedure for the other four pistons.
4. Remove Shaft Seals (45)
Inspect the shaft seals (45) 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™.
5. Reassemble Pump Housing (37), Cam Assembly (43), and Cylinder Housing (23)
16
a. With the pump housing vertical and the baseplate
removed, set it with the open end up on a workbench. Grease the groove at the face of the housing and install
O-ring (46). Set aside.
D17-991-2400A
D/G-17 Service (Hydraulic End)
6. Install Shaft Seals (45)
b. Set the cylinder housing, with the diaphragm pockets
facing down, onto smooth, clean, 4” high blocks. Insert
the bearing adjustment plate (41), with the bearing cup
(43A) and dowel pin (42) into the cylinder housing. The
dowel pin engages into the largest of the five slots in the
cylinder housing.
c. Insert the five piston assemblies into the cylinder
housing.
d. Set the cam assembly onto the cylinder housing subassembly such that the piston feet support the cam
assembly and the nose bearing is centered over bearing
cup (43A). Note: the cam assembly will be able to move
from side to side slightly, as the nose bearing is not fully
engaged into the bearing cup.
e. If the shaft seals (45) are still in the pump housing, slide
the seal protector (from the D-15 Tool Kit) over the shaft. Pick up the pump housing, lining up the marks made
earlier on it and the cylinder housing. Slowly lower the
pump housing over the shaft until the bearing cup (43B)
rests on the upper bearing of the cam assembly.
f. Start the four capscrews (29) by hand, using the 6 mm
hex Allen wrench from the Wanner D-15 Tool Kit. Thread
them through the counter bored holes in the cylinder
housing, engaging the threads into the pump housing. Two full turns of each screw should be able to be achieved
before noticeable resistance is met from the piston return
springs. If this cannot be done remove the pump housing
and check alignment of the cam assembly to the cylinder
housing subassembly.
g. Lift the pump assembly off the 4” blocks and set it onto
the workbench. Position the baseplate (30) and gasket
(38) onto the blocks so the cylinder housing and pin (8)
can pass through the baseplate cutout. Set the pump
assembly onto the gasket so the edge of the fins rest
on the gasket. Using cap screws (32) and lockwashers
(31), apply threadlocker (e.g. Loctite 242) to the threads
of the capscrews and torque to 45 ft-lbs (60 N-m).
h. Lift the pump assembly off of the 4” blocks and set it onto
the workbench. Tip the pump assembly so it sits upright
on the baseplate.
Return to the four cylinder housing capscrews
(29) and tighten them to establish and maintain an
even gap between the cylinder housing and pump
housing. This will draw the cylinder housing into the
pump housing, compressing the five piston return
springs and the six disk springs that pre-load the
cam assembly. Note: there is very minimal clearance
between the cylinder housing pilot diameter and
the main pump housing bore, so it is very important
to alternately tighten the four capscrews, until the
housings are flush together. The last 1/8” (3mm)
requires more force to bring the housings together
as all of the springs are nearing their maximum
compression. Torque all four capscrews to 15 ft-lbs
(20 N-m). Remove the shaft seal protector.
a. Apply a thin film of grease on the seal protector tool
(included in the Wanner D-15 Tool Kit). Slide both seals
onto the tool, with the spring side of the seals toward
the open end of the tool. Apply a heavier coat of grease
between the seals and press them together.
b. Apply an anaerobic seal sealant or bearing retaining
compound (e.g. Loctite 601 or 609) to the outside
diameter of the seals.
c. Apply a light film of grease to the pump shaft and slide
the seal protector (with seals) over the shaft.
d. Slide the seal inserter tool (included in the Wanner D-15
Tool Kit) over the seal protector tool, and press the seals
completely into place. Tap the tool with a soft mallet to
firmly seat the seals flush to the pump housing.
7. Reinstall Diaphragms (21)
a. Screw the plunger guide lifter (from the Wanner Tool
Kit or Repair Kit) into the valve plunger (51). Pull out to
expose the cross holes in the plunger. Rotate the shaft
until the piston is at top dead center.
b. Insert the 3/32-in. T-handle hex wrench (from the Wanner
Tool Kit), through the plunger hole — to hold the plunger
away from the cylinder housing (23), and to keep the
plunger from turning when the diaphragm is being
installed.
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 (51).
d. Hold the T-handle hex wrench 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. Repeat the above procedure for the plungers and
diaphragms of the other four cylinders.
f. Fill the reservoir with fresh oil and prime the pump, as
outlined in the Fluid-End Service Section.
8. Reassemble Pump
17
Reassemble the pump as outlined in the Fluid-End Service
Section.
D17-991-2400A
D/G-17 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 or damaged inlet hose
— Suction line too long
— 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 Installation, Inlet piping).
•
•
•
•
•
•
•
Premature Failure of Diaphragm
Symptoms of Cavitation
•
•
•
•
•
•
• Excessive pump valve noise
• Premature failure of spring or retainer
• Volume or pressure drop
• Rough-running pump
• Premature failure of diaphragms
Drop in Volume or Pressure
•
•
•
•
•
•
•
•
•
Frozen pump
Puncture by a foreign object
Elastomer incompatible with fluid being pumped
Pump running too fast
Excess pressure
Cavitation
Water (or Process Fluid) in Oil
Reservoir
A drop in volume or pressure can be caused by one or more
of the following:
•
•
•
•
•
•
•
•
•
•
•
•
•
Worn pump valves
Air lock 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
Foreign material in inlet or outlet valve
Damaged diaphragm
Fatigued or broken valve spring
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
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)
• Condensation
• Ruptured diaphragm
• Hydraulic cell not properly primed af ter diaphragm replacement
• Frozen pump
Water (or Process Fluid)
Pulsations
NOTE: Small pulsations are normal in single-acting pumps
with multiple pumping chambers.
•
•
•
•
•
•
18
Foreign object lodged in pump valve
Loss of prime in hydraulic cell because of low oil level
Air in suction line
Valve spring (12, 19) broken
Cavitation
Aeration or turbulence in supply tank
D17-991-2400A
D/G-17 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.
19
D17-991-2400A
Limited Warranty
Wanner Engineering, Inc. extends to the original purchaser
of equipment manufactured 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 non contractual 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 FA X: (612) 332- 6937
TOLL-FREE FAX [US only]: (800) 332-6812
www.hydra-cell.com
email: [email protected]
© 2004 Wanner Engineering, Inc. Printed in USA
D17-991-2400A 5/2004, Revised 2/2007
20