HP G-04, D-04 manual Replace Shaft Seal, Reassemble Housing and Back Cover, Reinstall Diaphragms

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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.Press the back bearing (55) and seal (54) out of the cover (52). Discard the seal.

b.Apply a coating of Loctite High-Performance Pipe Sealant with Teflon© , or a comparable product, to the outer surface of a new seal and the inside surface of the opening in the back cover (52) where the seal will rest.

c.Press the new seal into the back cover.

d.Inspect the bearing (55). If pitted or damaged, replace it.

e.Apply a coating of Loctite Rc/609 Retaining Compound or comparable product to the outer surface of the bearing. Press the bearing into the back cover until it rests on the shoulder. The shield on the bearing must face away from the back cover.

4.Reassemble Housing and Back Cover

a.Stand the pump on end.

b.With the pistons and connecting rods in place, reinstall the crankshaft by threading it through the connecting rods.

c.Reinstall the back cover, cover O-ring, and bolts (with their O-rings).

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.

b.Insert the plunger holder tool (from the Wanner Tool Kit), through the plunger hole — to hold the plunger away from the diaphragm plate (18), and to keep the plunger from turning when the diaphragm is being installed.

c.Engage the diaphragm insert threads to the plunger threads, and turn the diaphragm by hand until the insert hits the shoulder of the valve plunger (24).

d.Hold the plunger holder tool to secure the valve plunger, and torque the diaphragm insert to 10 in.-lbs (110 N-cm) using a 5/16-in. (8-mm) open-end wrench.

e.Repeat the above procedure for the plungers and diaphragms of the other two cylinders.

f.Fill the reservoir with fresh oil and prime the pump, as outlined in the Fluid-End Service Section.

6.Reassemble Pump

Reassemble the pump as outlined in the Fluid-End Service Section.

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D04-991-2400 5/1/04

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Contents Models D-04, G-04 04 Contents 04 SpecificationsNet Positive Suction Head NPSHr PerformanceDry Lift 04 Dimensions 04 Models with Metallic Pumping Head04 Installation Important PrecautionsLocation MountingInlet Piping Pressure Feed Inlet Piping Suction FeedInlet Calculations Discharge Piping Friction LossesNet Positive Suction Head Hose and RoutingInitial Start-Up Procedure Before Initial Start-Up04 Maintenance Shutdown Procedure During Freezing TemperaturesDaily PeriodicallyBolt Torque Specifications 04 Service Fluid EndRef. No Remove Manifold 3 and Valve Plate Tools and SuppliesInspect Valves Inspect and Replace Diaphragms Flush Contaminant from Hydraulic EndPrime the Hydraulic Cells Only if a diaphragm has rupturedReinstall Valve Plate 12 and Manifold 04 Service Hydraulic End Remove Pump Housing Disassemble PistonsReassemble Pistons Remove and Replace PistonsReassemble Housing and Back Cover Reinstall DiaphragmsReplace Shaft Seal Reassemble Pump04 Troubleshooting Loss of Oil Valve WearPremature Failure of Valve Spring or Retainer Limited Warranty Wanner ENGINEERING, INC
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