HP G-04, D-04 manual Before Initial Start-Up, Initial Start-Up Procedure

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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.Turn on power to the pump motor.

2.Check the inlet pressure or vacuum. To maintain maximum flow, inlet vacuum must not exceed 7 in. Hg at 70° F (180

mmHg at 21° C). Inlet pressure must not exceed 500 psi (34 bar).

3.Listen for any erratic noise, and look for unsteady flow. If the pump does not clear, refer to the Trouble-shooting Section.

4.If the system has an air lock and the pump fails to prime:

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.

5.Adjust the discharge pressure regulator to the desired operating and bypass pressures. Do not exceed the maximum pressure rating of the pump.

6.After the pressure regulator is adjusted, set the “pop-off” safety relief valve at 100 psi (7 bar) higher than the desired operating pressure. To verify this setting, adjust the discharge pressure regulator upward until the relief valve opens. Follow the recommendations in the above NOTE (step 4b) for handling the fluid that will come from the relief valve.

7.Reset the discharge pressure regulator to the desired system pressure.

8.Provide a return line from the relief valve to the supply tank, similar to the bypass line from the pressure regulator.

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D04-991-2400 5/1/04

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Contents Models D-04, G-04 04 Contents 04 SpecificationsDry Lift PerformanceNet Positive Suction Head NPSHr 04 Dimensions 04 Models with Metallic Pumping Head04 Installation Important PrecautionsLocation MountingInlet Calculations Inlet Piping Suction FeedInlet Piping Pressure Feed Discharge Piping Friction LossesNet Positive Suction Head Hose and RoutingInitial Start-Up Procedure Before Initial Start-Up04 Maintenance Shutdown Procedure During Freezing TemperaturesDaily PeriodicallyRef. No 04 Service Fluid EndBolt Torque Specifications Inspect Valves Tools and SuppliesRemove Manifold 3 and Valve Plate 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 Premature Failure of Valve Spring or Retainer Valve WearLoss of Oil Limited Warranty Wanner ENGINEERING, INC
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