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Wanner Engineering Hydra-Cell G-25-SD, Installation Service

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Wanner Engineering Hydra-Cell G-25-SD Installation Service Download Page 16

16

H5-991-406A

H/G-25-SD Service (Hydraulic End)

1. Remove Pump Housing

a...Remove. the. head. of. the. pump,. and. the. 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... Set.the.hydraulic.end.of.the.pump.face-down.on.the.cylinder.

casting.(5).

d...Check.the.shaft.for.sharp.burrs..Smooth.any.burrs,.to.prevent.

scarring.the.housing.seals.(64).when.you.disassemble.the.

pump.

e...Alternately.loosen.the.four.capscrews.(6).that.secure.the.

housing.to.the.cylinder.casting..The.piston.return.springs.

(50).will.force.the.cylinder.casting.and.housing.apart..Loosen.

each.screw.one.to.two.turns.before.going.to.the.next.one,.

continuing.until.all.four.screws.are.removed.

f... Lift.off.the.housing.(30).
g...Inspect.the.cam.and.bearings.(6),.and.the.bearing.race.

in. the. rear. of. the. housing.. If. the. bearings. are. pitted. or.

binding,. or. if. the. housing. race. is. worn,. contact. Wanner.

Engineering.

2. Disassemble Pistons

a...With. the. pump. housing. removed. (see. above),. turn. the.

cylinder.casting.over.and.set.it.on.a.flat.surface,.piston.side.

down.

b...With.the.diaphragms.removed.(see.the.Fluid.End.Service.

Section),.reinsert.a.follower.screw.(19).into.the.hole.in.one.of.

the.valve.plungers.(54)..Tap.the.screw.lightly.with.a.hammer;.

the.plunger.(3).should.slip.off.the.valve.plunger.(54).

c... Repeat.step.“b”.for.the.remaining.pistons.
d...Each. hydraulic. piston. assembly. (50-59). can. now. be.

disassembled..Lift.the.cylinder.casting.straight.up.and.off.

the.pistons..Inspect.all.parts,.and.replace.all.O-rings.and.

any.other.parts.that.are.worn.or.damaged.

.

Note: When you reassemble the hydraulic piston, use 

new  plungers  (23).  They  are  press-fit  onto  the  valve 

plungers (54) and are generally not reusable.

3. Reassemble Pistons

a...Drop.a.ball.(58).into.each.opening.in.the.bottom.of.a.piston.

assembly.(59).

b.. Insert.a.retaining.washer.(57).and.O-ring.(56).to.hold.the.

ball.in.place.

c.. Insert.a.valve.plunger.(54).into.a.valve.cylinder.(55)..Slide.

a.spring.(53).over.the.plunger,.inside.the.valve.cylinder.

d...Insert.an.O-ring.(5).into.a.spring.retainer.(51).
e...Install.two.O-rings.(5).on.the.valve.cylinder.(55).
f... Slide. the. assembled. valve. cylinder,. plunger,. and. spring.

(53-55).into.the.spring.retainer.(51).

g...Install.an.O-ring.(56).on.the.spring.retainer.(51).
h...Slide.the.complete.cylinder-and-retainer.assembly.(51-56).

into.the.piston.assembly.(59).

i... Insert.a.return.spring.(50).into.the.piston.assembly.
j... Repeat.the.above.procedure.for.the.other.two.pistons.

4. Reassemble Pump Housing, 

Shaft Assembly, and Cylinder 

Casting

Note: Inspect the shaft seals (64) before continuing. If they 

look damaged in any way, replace them. We recommend 

changing the shaft seals whenever the camshaft assembly 

is removed from the pump housing. New shaft seals will 

be installed after the pump housing has been assembled 

over the camshaft and fastened to the cylinder casting (see 

Step 5 below). Both seals should be replaced at the same 

time. Remove the seals by pounding them out from inside 

the pump housing, then clean the seal bore in the housing 

using emery cloth or ScotchBrite™.

a...Screw.three.10-mm.assembly.studs.(from.the.Wanner.Tool.

Kit).into.three.of.the.four.threaded.holes.in.the.

outer

.ring.of.

holes.within.the.cylinder.casting.(5).

.

Thread.them.in.all.the.way,.from.the.diaphragm.side.of.the.

cylinder.casting,.until.the.head.bottoms.out.against.the.face.

of.the.cylinder.casting.

.

Apply.a.slight.torque.to.them.so.they.will.resist.rotation.during.

the.following.steps.

b...Place.the.cylinder.casting.face-down.on.a.flat.surface..It.will.

rest.on.the.heads.of.the.three.assembly.studs.just.added..

This.is.especially.important.if.the.diaphragms.and.pistons.

are.already.assembled.to.the.cylinder.casting..

Never lay 

the cylinder casting face-down with the weight of the 

casting and/or the pump housing on the diaphragms.

c... Insert. the. assembled. pistons. (50-59). into. the. cylinder.

casting..Check.each.piston.to.be.sure.all.check.balls.(58).

are.in.place.

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.capscrews.(6).will.be.installed.

e...Stand.the.camshaft.assembly.(6).on.the.cylinder.casting.

(5),.and.place.the.seal.protector.(from.the.Wanner.Tool.Kit).

over.the.end.of.the.shaft.

.

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.

f... Using.grease.to.retain.it,.install.the.O-ring.(65).and.slide.

the.housing.(30).down.over.the.shaft.and.onto.the.threaded.

studs.(from.step.“a”)..Be.sure.the.holes.in.the.housing.and.

the.cylinder.casting.are.properly.aligned.

g...Install.washers.(6).and.nuts.(31).on.the.threaded.studs,.but.

don’t.tighten.yet..You.may.want.to.insert.two.or.more.bolts.

(5).into.the.unthreaded.holes.of.the.housing.and.cylinder.

casting.to.help.align.the.parts.

h...Alternately.tighten.the.three.nuts.(31).to.evenly.draw.the.

housing.down.to.the.cylinder.casting..Be.sure.the.O-ring.(65).

stays.in.place..Also,.as.you.tighten.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.become.

difficult.to.turn,.back.off.the.nuts.and.realign.the.shaft..When.

the.pump.housing.is.tight.against.the.cylinder.casting,.you.

should.still.be.able.to.turn.the.shaft.smoothly.

Summary of Contents for Hydra-Cell G-25-SD

Page 1: ...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 sales wannereng com H 25 SD G 25 SD SLURRY DUTY PUMPS INSTALLATION SERVICE H25 991 2406A ...

Page 2: ...x Temperature Pump Head 140 F 60 C Hydraulic End 180 F 82 C Inlet Port H 25 SD 1 1 2 inch NPT G 25 SD 1 1 2 inch BSPT Discharge Port H 25 SD 1 inch NPT G 25 SD 1 inch BSPT Shaft Diameter 1 1 8 inch 28 58 mm Shaft Rotation Bi directional Bearings Tapered roller Oil Capacity 2 1 2 US quarts 2 4 liters Weight 90 lbs 40 9 kg 50 x rpm 63 000 gpm x psi 1 460 electric motor HP H G 25 SD Specifications 50...

Page 3: ...0 48 0 52 0 56 0 60 0 64 0 68 0 72 0 76 0 80 0 84 0 88 0 4 0 8 0 12 0 0 24 0 0 22 0 20 0 18 0 16 0 14 0 12 0 10 0 8 0 6 0 4 0 2 0 300 PSI 21 bar W0211 Performance Net Positive Suction Head NPSHr H G 25 SD Dimensions 3 2 81 3 18 0 457 14 8 376 0 50 12 7 0 50 12 7 3 1 78 7 11 0 279 0 8 20 3 1 5 38 1 7 5 190 5 10 0 254 0 25 6 4 Slot Width 0 42 10 7 Slot Width 4 5 114 2 25 57 2 3 4 86 4 10 0 254 5 63 ...

Page 4: ... compatibility problems Hot ambient temperatures above 110 F 43 C Conditions where pump oil may exceed 180 F 82 C because of a combination of hot ambient temperatures hot fluid temperature and full horsepower load an oil cooler may be required Location 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 r...

Page 5: ...at the velocity will not exceed 1 to 3 ft sec 0 3 to 0 9 m sec Velocity ft sec 0 408 x GPM Pipe I D 2 where pipe I D is in inches Keep the suction line as short and direct as possible The smallest permissible inlet hose size is 1 to 10 gpm 1 1 2 in I D 11 to 20 gpm 2 in I D 1 to 38 liters min 38 mm I D 39 to 76 liters min 50 mm I D Use flexible hose and or expansion joints to absorb vibration expa...

Page 6: ... NPSHa and compare the result to the NPSHr of the Hydra Cell pump Ha L x V x N x C K x G where Ha Acceleration head ft of liquid L Actual length of suction line ft not equivalent length V Velocity of liquid in suction line ft sec V GPM x 0 408 pipe ID2 N RPM of crank shaft C Constant determined by type of pump use 0 066 for the H 25 SD and G 25 SD Hydra Cell pumps K Constant to compensate for comp...

Page 7: ... 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 H G 25 SD Installation The smallest permissible discharge hose size is 1 to 10 gpm 11 16 0 687 in I D 11 to 20 gpm 1 in I D 1 to 38 liters min 17 mm I D 39 to 76 liters min 25 mm I D Use fle...

Page 8: ... 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...

Page 9: ...tible solvent for cleaning The numbers in parentheses are the Reference Numbers on the exploded view illustrations found in this manual and also in the Parts Manual 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 th...

Page 10: ... that are installed through the back of the pump housing b With a 10 mm hex Allen wrench remove the centerbolt 1 and its washer 2 in the center of the manifold support plate Caution Do not turn the pump drive shaft while the manifold and valve plate are off the pump except when removing diaphragms or repriming the hydraulic cells c Remove the manifold support 43 and manifold 7 d Inspect the manifo...

Page 11: ...r wear in the area of the recess that supports the spring The polyurethane washer should have minimized or prevented wear in this area if it stayed in place during operation Press out the old spring retainer and push in a new one if required It is always a good idea to use a new polyurethane washer in the spring retainer recess Be careful to put only one washer into each retainer recess b Check th...

Page 12: ...e shell subassemblies 45 16 17 into the inlet valve bores They too may have to be pressed slightly as there is a line to line fit between the outer diameter of the shell and the valve bore Be sure the nose of the shell 45 presses into the inner diameter of the crush seal 46 The shaft rotator from the Wanner Tool Kit can be used to press down evenly on the shell subassembly to get the proper fit Be...

Page 13: ...pty f Install a new diaphragm or reinstall the old one as appropriate ridge side out g Clean and dry the screw 19 removing any oil from it Apply medium strength threadlocker to the screw Reinstall the screw the follower 21 and a new O ring 20 Tighten to 18 in lbs 2 0 N m h Repeat the above inspection procedure and replacement if necessary with the other two diaphragms 4 Flush Contaminant from Hydr...

Page 14: ...lace the oil fill cap and complete installation Method 2 head pressure greater than 2 psi This simple and clean method of priming the Hydra cells requires an inlet head pressure of at least 5 feet 1 5 m or 2 psi 14 bar The pressure source is required to hold the diaphragms back while the piston moves so as to force out the air Completely assemble the pump and fill the reservoir with the appropriat...

Page 15: ...ution 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 Caution The four capscrews 26 that screw through the back of the housing into the cylinder casting 25 hold the casting to the pump housing Do not remove them except when repairing the hydraulic end Note The follo...

Page 16: ...ntinuing If they look damaged in any way replace them We recommend changing the shaft seals whenever the camshaft assembly is removed from the pump housing New shaft seals will be installed after the pump housing has been assembled over the camshaft and fastened to the cylinder casting see Step 5 below Both seals should be replaced at the same time Remove the seals by pounding them out from inside...

Page 17: ...cleaned set screws 24 then screw them into the cylinder casting until they contact the bearing adjusting plate 61 g Remove the centerbolt 1 7 Install Plungers Note If the plungers 23 have been removed from the valve plungers 54 do not reuse them Install new ones instead a Rotate the pump shaft so the piston is in the top dead center position b With the nut turned back toward the hex head of the pl...

Page 18: ...rization Air leak in suction line strainer or gasket Cracked suction hose Empty supply tank Excessive aeration and turbulence in supply tank Cavitation 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 Cracked cylinder casting Pump Runs Rough Worn pump valves Airlock in outlet system Oil level low Wrong w...

Page 19: ...epage Rupture of diaphragm Frozen pump Diaphragm screw O ring 20 missing or cracked Worn shaft seal Oil drain piping or fill cap loose Valve plate and manifold bolts loose 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 Washes 17 44 missing or dislodged f...

Page 20: ... 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 parti...

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