HP D-04, G-04 Maintenance, Daily, Periodically, Shutdown Procedure During Freezing Temperatures

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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 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 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

 

 

<90° F

<139° F

<180° F

Pressure

RPM

(32° C)

(60° C)

(82° C)

<1500 psi (100 bar)

<1200

6,000

4,000

2,000

 

<1800

3,000

2,000

1,500

 

 

 

 

 

<2500 psi (170 bar)

<1200

3,000

2,000

1,500

 

<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 or 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.

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D04-991-2400 5/1/04

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Contents Models D-04, G-04 04 Specifications 04 ContentsPerformance Net Positive Suction Head NPSHrDry Lift 04 Models with Metallic Pumping Head 04 DimensionsImportant Precautions 04 InstallationLocation MountingInlet Piping Suction Feed Inlet Piping Pressure FeedInlet Calculations Friction Losses Discharge PipingNet Positive Suction Head Hose and RoutingBefore Initial Start-Up Initial Start-Up ProcedureShutdown Procedure During Freezing Temperatures 04 MaintenanceDaily Periodically04 Service Fluid End Bolt Torque SpecificationsRef. No Tools and Supplies Remove Manifold 3 and Valve PlateInspect Valves Flush Contaminant from Hydraulic End Inspect and Replace DiaphragmsPrime the Hydraulic Cells Only if a diaphragm has rupturedReinstall Valve Plate 12 and Manifold 04 Service Hydraulic End Disassemble Pistons Remove Pump HousingReassemble Pistons Remove and Replace PistonsReinstall Diaphragms Reassemble Housing and Back CoverReplace Shaft Seal Reassemble Pump04 Troubleshooting Valve Wear Loss of OilPremature Failure of Valve Spring or Retainer Limited Warranty Wanner ENGINEERING, INC