Installation, Operation & Maintenance

G25-991-2400C

Models: G25, H25

W0452

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/metering
email: sales@wannereng.com
G/H-25 Contents
Page
Specifications...........................................................................2
Dimensions..............................................................................4
Installation................................................................................5
Maintenance.............................................................................9
Service (Fluid End).................................................................10
Service (Hydraulic End).........................................................15
Troubleshooting......................................................................18
Warranty................................................................................ 20

G/H-25 Specifications
Flow Capacities @ 1000 psi (69 bar) Weight
rpm gpm I/min Metallic Heads: 125 lbs (56.8 kg)
G/H25-X 1050 20.0 75.7 Non-Metallic Heads: 90 lbs (40.9 kg)
G/H25-E 1150 20.2 75.9
G/H25-S 1150 16.2 61.5
G/H25-I 1150 11.8 44.7
Delivery @ 1000 psi (69 bar)
gal/rev liters/rev
G/H25-X 0.0190 0.0721
G/H25-E 0.0174 0.0660
G/H25-S 0.0141 0.0535
G/H25-I 0.0103 0.0389
Maximum Discharge Pressure
Calculating Required
Metallic Pump Heads: 1000 psi (69 bar) Horsepower (kW)*
Non-Metallic Pump Heads: 250 psi (17 bar) Polypropylene
350 psi (24 bar) PVDF
50 x rpm gpm x psi
Maximum Inlet Pressure 250 psi (17 bar) + = electric motor hp*
63,000 1,460
Maximum Operating Temperature
Metallic Heads: 250°F (121°C) – Consult factory correct
component selection for temperatures above 160°F (71°C) lpm x bar
50 x rpm = electric motor kW*
to 250°F (121°C) +
84,428 511
Non-Metallic Heads: 140°F (60°C)
Maximum Solids Size 800 microns * rpm equals pump shaft rpm. hp/kW is required application
Inlet Port H25: 1-1/2 inch NPT power. Use caution when sizing motors with variable speed
G25: 1-1/2 inch BSPT drives.
Discharge Port H25: 1 inch NPT
G25: 1 inch BSPT
Shaft Diameter 1-1/8 inch (28.6 mm)
Shaft Rotation Reverse (bi-directional)
Bearings Tapered roller bearings
Oil Capacity 3.3 US quarts (3.1 liters)

2 G25-991-2400C
G/H-25 Specifications
Performance Net Positive Suction Head –
NPSHr
22.0 83.3 24

1050

1150
7.0

1150
80.0 22

1050
H/G25-X
H/G-25-X
20.0 76.0 H/G-25-E
20 H/G-25-S 6.0
72.0 H/G-25-I
250 PSI (17 bar)
H/G25-E 18
18.0 500 PSI (34 bar)
68.0
1000 PSI (69 bar) 5.0
16

NPSHr (meters of water)

64.0

NPSHr (feet of water)

16.0 14
60.0 4.0
56.0 12
14.0
52.0 10 3.0
H/G25-S
Gallons Per Minute

Liters Per Minute

48.0 8
12.0
44.0 2.0
6
40.0
10.0
H/G25-I 4
1.0
36.0
2
32.0
8.0
0 0
28.0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200
Revolutions Per Minute W0206A

24.0
6.0

20.0

16.0
4.0

12.0

8.0
2.0

4.0

0 0
0 200 400 600 800 1000 1200
W0207A
Revolutions Per Minute

3 G25-991-2400C
G/H-25 Dimensions
Models with Metallic Pumping Head
Brass
Cast Iron
316 Stainless Steel
Nickel Alloy (Hastelloy CW12MW)

17.01
(432.1)
13.2 9.44
(336) (239.8)
Oil Fill Cap
0.25 x 2.25 Outlet
(6.4) (57) H-25: 1" NPT
Keyway G-25: 1" BSPT

Ø1.12
(28.6)
Inlet
11.57 H-25: 1 1/2" NPT
(293.9) G-25: 1 1/2" BSPT
8.71 3/8" - 18 NPT
(221) Oil (Drain Port)
5.63
(143) 4.01 Drain
(102) 0.25
(6.4)

1.63 0.42 Slot Width W0450A 1.500

(41.4) (11) (38.10)
4.50 7.50
(114.3) (190.5)
9.38 9.98
(238.1) (253.5)

Models with Non-metallic Pump Head

Kynar ®
Polypropylene
18.00 Ø 9.44
(457.2) (239.8)
14.0
(356)
Oil Fill Cap
Outlet
0.25 x 2.25 H-25: 1" NPT
(6.4) (57) G-25: 1" BSPT
Keyway
Ø1.12
(28.6)
Inlet
11.57 H-25: 1 1/2" NPT
(293.9) G-25: 1 1/2" BSPT
8.71 3/8" - 18 NPT
(221) (Drain Port)
5.63 Oil
(143) 4.82 Drain
(122) 0.25
(6.4)

W0451A 1.500
1.63 0.42 Slot Width
(41.4) (11) (38.10)
4.50 7.50
(114.3) (190.5)
9.38 9.98
(238.1) (253.5)

4 G25-991-2400C
G/H-25 Installation
Equipment Precautions Location
Locate the pump as close to the supply source as possible.
Adequate Fluid Supply. To avoid cavitation and premature
Install it in a lighted clean space where it will be easy to inspect
pump failure, be sure that the pump will have an adequate
and maintain. Allow room for checking the oil level, changing
fluid supply and that the inlet line will not be obstructed.
the oil, and removing the pump head (manifold, valve plate and
See “Inlet Piping”.
related items).
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 Mounting
from the pump. See “Discharge Piping”. A suitable and The pump shaft can rotate in either direction. To prevent vibration,
calibrated pressure gauge should be installed in the mount the pump and motor securely on a level rigid base.
discharge line close to the pump head. On a belt-drive system, align the sheaves accurately; poor
Safety Guards. Install adequate safety guards over alignment wastes horsepower and shortens the belt and bearing
all pulleys, belts, and couplings. Follow all codes and life. Make sure the belts are properly tightened, as specified by
regulations regarding installation and operation of the the belt manufacturer.
pumping system. On a direct-drive system, align the shafts accurately. Unless
Shut-Off Valves. Never install shut-off valves between the otherwise specified by the coupling manufacturer, maximum
pump and discharge pressure regulator, or in the regulator parallel misalignment should not exceed 0.015 in. (0.4 mm)
bypass line. and angular misalignment should be held to 1° maximum.
Freezing Conditions. Protect the pump from freezing. See Careful alignment extends life of the coupling, pump, shafts,
also the Maintenance Section. and support bearings. Consult coupling manufacturer for exact
alignment tolerances.
Working Pump. The pump body will become hot during
operation even if the liquid being pumped is cold. Drive couplings, belts and pulleys must be of suitable design,
correctly sized, fitted, and rated for the maximum load required.
Consult the Factory for the following situations:
On a close-coupled system, coat the motor shaft liberally with
• Extreme temperature applications – above 160° F (71°C) anti-seize.
or below 40° F (4.4°C)
The pump, motor and related components must be adequately
• Pressure feeding of pumps
grounded.
• Viscous or abrasive fluid applications
• Chemical compatibility problems
• Hot ambient temperatures – above 110° F (43°C)
• Conditions where pump oil may exceed 200° F (93°C)
because of a combination of hot ambient temperatures,
hot fluid temperature, and full horsepower load — an
oil cooler may be required

Pressure
Gauge
Pressure
Regulator

Discharge
Baffle Line

W0571B

Suction
Line
Vacuum Pressure Inlet
Gauge To Tank

Bypass
Line

5 G25-991-2400C
G/H-25 Installation
Inlet Piping (Suction Feed) Inlet Piping (Pressure Feed)
CAUTION: When pumping at temperatures above 160° F Provide for permanent or temporary installation of a vacuum/
(71° C), use a pressure-feed system. pressure gauge to monitor the inlet vacuum or pressure.
Install draincocks at any low points of the suction line, to permit Pressure at the pump inlet should not exceed 250 psi (17 bar);
draining in freezing conditions. if it could get higher, install an inlet pressure reducing regulator.

Provide for permanent or temporary installation of a vacuum Do not supply more than one pump from the same inlet line.
gauge to monitor the inlet suction. To maintain maximum flow,
vacuum at the pump inlet should not exceed 7 in. Hg at 70° F
(180 mm Hg at 21° C). Do not supply more than one pump
from the same inlet line.
Inlet Calculations
Supply Tank Acceleration Head
Use a supply tank that is large enough to provide time for any Calculating the Acceleration Head
trapped air in the fluid to escape. The tank size should be at Use the following formula to calculate acceleration head losses.
least twice the maximum pump flow rate. Subtract this figure from the NPSHa, and compare the result to
Isolate the pump and motor stand from the supply tank, and the NPSHr of the Hydra-Cell pump.
support them separately. Ha = (L x V x N x C) ÷ (K x G)
Install a separate inlet line from the supply tank to each pump. where:
Install the inlet and bypass lines so they empty into the supply Ha = Acceleration head (ft of liquid)
tank below the lowest water level, on the opposite side of the L = Actual length of suction line (ft) — not equivalent length
baffle from the pump suction line. V = Velocity of liquid in suction line (ft/sec)
If a line strainer is used in the system, install it in the inlet line [V = GPM x (0.408 ÷ pipe ID2)]
to the supply tank. N = RPM of crank shaft
To reduce aeration and turbulence, install a completely C = Constantdeterminedbytypeofpump—use0.066for
submerged baffle plate to separate the incoming and outgoing the H-25 and G-25 Hydra-Cell pumps
liquids. K = Constant to compensate for compressibility of the fluid
Install a vortex breaker in the supply tank, over the outlet port — use: 1.4 for de-aerated or hot water; 1.5 for most
to the pump. liquids; 2.5 for hydrocarbons with high compressibility
G = Gravitational constant (32.2 ft/sec2)
Place a cover over the supply tank, to prevent foreign objects
from falling into it. Friction Losses
Hose and Routing Calculating Friction Losses in Suction Piping
Size the suction line at least one size larger than the pump inlet, When following the above recommendations (under “Inlet
and so that the velocity will not exceed 1-3 ft/sec (0.3 to 0.9 m/s): Piping”) for minimum hose/pipe I.D. and maximum length,
For pipe in inches: Velocity (ft/sec) = 0.408 x GPM/Pipe ID2 frictional losses in the suction piping are negligible (i.e., Hf = 0)
if you are pumping a water-like fluid.
For pipe in mm: Velocity (m/sec) = 21.2 x LPM/Pipe ID2
When pumping more-viscous fluids such as lubricating oils,
Keep the suction line as short and direct as possible. A maximum sealants, adhesives, syrups, varnishes, etc., frictional losses in
of 3 feet (1 m) is recommended. the suction piping may become significant. As Hf increases, the
Use flexible hose and/or expansion joints to absorb vibration, available NPSH (NPSHa) will decrease, and cavitation will occur.
expansion, or contraction. In general, frictional losses increase with increasing viscosity,
If possible, keep the suction line level. Do not have any high increasing suction-line length, increasing pump flow rate, and
points to collect vapor unless these high points are vented. decreasing suction-line diameter. Changes in suction-line
To reduce turbulence and resistance, do not use 90° elbows. diameter have the greatest impact on frictional losses: a 25%
If turns are necessary in the suction line, use 45° elbows or increase in suction-line diameter cuts losses by more than two
arrange sweeping curves in the flexible inlet hose. times, and a 50% increase cuts losses by a factor of five times.
If a block valve is used, be sure it is fully opened so that the flow Consult the factory before pumping viscous fluids.
to the pump is not restricted. The opening should be at least the Minimizing Acceleration Head and Frictional Losses
same diameter as the inlet plumbing ID. To minimize the acceleration head and frictional losses:
Do not use a line strainer or filter in the suction line unless regular
maintenance is assured. If used, it should have a free-flow area
of at least three times the free-flow area of the inlet.
Install piping supports where necessary to relieve strain on the
inlet line and to minimize vibration. Loctite is a registered trademark of Loctite Corporation.
Scotchbrite is a registered trademark of 3M Company.

6 G25-991-2400C
G/H-25 Installation
•
•
Keep inlet lines less than 3 ft (1 m) long
Use at least 1-1/2 in. (38 mm) I.D. inlet hose
Discharge Piping
• Use soft hose (low-pressure hose, non collapsing) for the NOTE: Consult the Factory before manifolding two or more
inlet lines pumps together.
• Minimize fittings (elbows, valves, tees, etc.) Hose and Routing
• Use a suction stabilizer on the inlet.
Use the shortest, most-direct route for the discharge line.
Select pipe or hose with a working pressure rating of at least
Net Positive Suction Head 1.5 times the maximum system pressure. EXAMPLE: Select
NPSHa must be equal to or greater than NPSHr. If not, the a 1500-psi W.P.-rated hose for systems to be operated at
pressure in the pump inlet will be lower than the vapor pressure 1000-psi-gauge pressure.
of the fluid — and cavitation will occur. Use about 6 ft (1.8 m) of flexible hose between the pump and
Calculating the NPSHa rigid piping to absorb vibration, expansion or contraction.
Use the following formula to calculate the NPSHa: Support the pump and piping independently. Size the discharge
line so that the velocity of the fluid will not exceed 7-10 ft/sec
NPSHa = Pt + Hz - Hf - Ha - Pvp
(2-3 m/sec):
where:
For pipe in inches: Velocity (ft/sec) = 0.408 x GPM/Pipe ID2
Pt = Atmospheric pressure
For pipe in mm: Velocity (m/sec) = 21.2 x LPM/Pipe ID2
Hz = Vertical distance from surface liquid to pump centerline (if
liquid is below pump centerline, the Hz is negative) Pressure Regulation
Hf = Friction losses in suction piping Install a pressure regulator or unloader in the discharge
Ha = Acceleration head at pump suction line. Bypass pressure must not exceed the pressure limit of
the pump.
Pvp = Absolute vapor pressure of liquid at pumping temperature
Size the regulator so that, when fully open, it will be large enough
NOTES: to relieve the full capacity of the pump without overpressurizing
• In good practice, NPSHa should be 2 ft greater than NPSHr the system.
• All values must be expressed in feet of liquid Locate the valve as close to the pump as possible and ahead
Atmospheric Pressure at Various Altitudes of any other valves.
Altitude Pressure Altitude Pressure Adjust the pressure regulating valve to no more than 10% over
(ft) (ft of H2O) (ft) (ft of H2O) the maximum working pressure of the system. Do not exceed
0 33.9 1500 32.1 the manufacturer’s pressure rating for the pump or regulator.
500 33.3 2000 31.5 Route the bypass line to the supply tank, or to the suction line
1000 32.8 5000 28.2 as far as possible from the pump (to reduce the chance of
turbulence and cavitation).
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.

7 G25-991-2400C
G/H-25 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.
• All shutoff valves are open, and the pump has an adequate 2. Check the inlet pressure or vacuum. To maintain maximum
supply of fluid. flow, inlet vacuum must not exceed 7 in. Hg at 70° F (180
• All connections are tight. mm Hg at 21° C). Inlet pressure must not exceed 250 psi (17
bar).
• The oil level is 1/4 in. (6 mm) above the cast surface in the
upper oil reservoir. 3. Listen for any erratic noise, and look for unsteady flow. If the
pump does not clear, refer to the Troubleshooting Section.
• The relief valve on the pump outlet is adjusted so the pump
starts under minimum pressure. 4. If the system has an air lock and the pump fails to prime:
• All pulleys and belts are properly aligned, and belts are a. Turn off the power.
tensioned according to specification. b. Remove the pressure gauge or plug from the tee fitting
• All pulleys, belts and shaft couplings have adequate safety at the pump outlet (refer to the illustration on page 5).
guards. 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 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.

8 G25-991-2400C
G/H-25 Maintenance
NOTE: The numbers in parentheses are the Reference
Numbers on the exploded view illustrations found in this
Freezing Temperatures
manual and in the Parts Manual. Take all safety precautions to assure safe handling of the
fluid being pumped. Provide adequate catch basins for
Daily fluid drainage and use appropriate plumbing from drain
ports, etc. when flushing the pump and system with a
Check the oil level and the condition of the oil. The oil level should compatible antifreeze.
be 1/4 in. (6 mm) above the cast surface in the upper oil reservoir.
1. Adjust the discharge pressure regulating valve so the pump
Use the appropriate Hydra-Oil for the application (contact runs under minimum pressure. Stop the pump.
Wanner Engineering if in doubt). 2. Drain supply tank; open any draincocks in system piping and
CAUTION: If you are losing oil but don’t see any external collect drainage; remove plug (4) from manifold and collect
leakage, or if the oil becomes discolored and contaminated, drainage.
one of the diaphragms (22) may be damaged. Refer to the 3. Close draincocks in system piping and replace manifold plug.
Fluid-End Service Section. Do not operate the pump with 4. Fill supply tank with enough antifreeze to fill system piping
a damaged diaphragm. and pump.
CAUTION: Do not leave contaminated oil in the pump NOTE: Disconnect the system return line from the
housing or leave the housing empty. Remove contaminated supply tank and connect it to a separate reservoir.
oil as soon as discovered, and replace it with clean oil. 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
Periodically Procedure to clear the air.
6. When mostly antifreeze is flowing from the system return line
Change the oil after the first 100 hours of operation, and then
stop the pump. Connect the system return line back to the
according to the guidelines below. When changing, remove
supply tank and circulate the antifreeze for a short period.
the drain plug cap (34) at the bottom of the pump so all oil and
accumulated sediment will drain out. 7. It is also good practice to change the oil in the hydraulic
end before storage for an extended period. This will remove
Hours Between Oil Changes @ Various any accumulated condensation and sediment from the
Process Fluid Temperatures oil reservoir. Drain and refill the hydraulic end with the
<90°F <139°F <180°F appropriate Hydra-Oil and operate the pump for a short

Pressure RPM (32°C) (60°C) (82°C) period to assure smooth performance.

Metallic Pump Head

<650 psi (45 bar) <800 6,000 4,500 3,000
<1200 4,000 3,000 2,000
<1000 psi (70 bar) <800 4,000 3,000 2,000
<1200 2,000 1,500 1,000
Non-Metallic Pump Head
<250 psi (17 bar) <800 4,000 3,000 —
<1200 2,000 1,500 —

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) for
Metallic Pump Head models or when hydraulic end oil
exceeds 180°F (82°C) for Non-Metallic Pump Head models.
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

9 G25-991-2400C
G/H-25 Service (Fluid End)
Models with Non-Metallic Pump Head
1

4
2
5

43
6

9
8

38 10

11
12
13
14
15
16

39

18

19
20
21
22
24 23

25

40
41
27 37
28 36

32 33 34 35

W0195B
29 6 30

42 26

10 G25-991-2400C
G/H-25 Service (Fluid End)
Models with Metallic Pumping Head
1
5 † With brass external-centerbolt models,
use #8; with all other models, use #3.

4
‡ With cast iron pump heads, use #17
and not #10; with all other heads, use
2
6
#10 and not #17.
* Not included with brass pump heads.

† 3 8
9 Valve Assemblies
with metal spring retainers
* 38 10 ‡
11
* 38
12
13 11
14 12
13
15 38 *
16 14
17 ‡
17 ‡ 16
39

18 18
Ref
19
20
21
22 Manifold Valve Plate
24 23 Brass

37
36

8
25
10 9

40 Manifold Valve Plate

41 Stainless
27 Steel
28

3
10 9
32 33 34 35
Manifold Valve Plate
17
W0194B Cast
29 6 30 Iron

42 26
3
9 W0208

11 G25-991-2400C
G/H-25 Service (Fluid End)
NOTE: The numbers in parentheses refer to the parts
illustrations.
2. Inspect Valve Assemblies
This section explains how to disassemble and inspect all (parts 11-16, and 38)
easily-serviceable parts of the pump. Repair procedures for the NOTE: The three inlet and three outlet valve assemblies
hydraulic end (oil reservoir) of the pump are included in a later in the pump are identical (but face in opposite
section of the manual. directions).
CAUTION: Do not disassemble the hydraulic end unless you Inspect each valve assembly as follows:
are a skilled mechanic. For assistance, contact Wanner a. Check spring retainer (16), and replace if worn.
Engineering (TEL 612-332-5681 or FAX 612-332-6937) or b. Check valve spring (14). If shorter than new spring,
the distributor in your area. replace. (Don’t stretch old spring.)
CAUTION: The four bolts (26) that screw through the back c. Check valve poppet (13). If worn, replace.
of the housing into the cylinder casting hold the casting NOTE: If pump has plastic spring retainers, there is
over the hydraulic end of the pump. Do not remove them a tetra seal O-ring (15) between the retainer (16) and
except when repairing the hydraulic end. valve seat (12).
d. Remove valve seat (12). (Seat remover is included in
Wanner Tool Kit.) On cast iron valve plates, be careful
1. Remove Manifold (7), and not to break metal ridge around O-ring groove.
Inspect valve seat for wear. If worn, replace and install
Valve Plate (18) new O-ring (11).
a. Remove all bolts (5) and lockwashers (6) around manifold e. Reinstall valve assemblies:
(7). Do not remove four bolts (26) that are installed • Clean valve ports and valve shoulders with emery cloth,
through back of pump housing (30). and grease with lubricating gel or petroleum jelly.
b. With 3/8-in (10-mm) hex Allen wrench, remove centerbolt • Install O-ring (11) on valve seat (12).
(1) and washer (2) in center of manifold. NOTE: Some pumps use plastic dampening
CAUTION: Do not turn the pump drive shaft while washers (38) between the valve seat (12) and the
the manifold and valve plate are off the pump, manifold (7) or valve plate (18). Refer to the parts
except when removing diaphragms or repriming the illustrations and the fluid-end exploded views in
hydraulic cells. the Parts Manual.
c. Remove manifold (7) and support plate (43, used on • Inlet (3 center valves). Insert retainer (16) into valve
non-metallic pump only). plate (18), then spring (14), valve (13), and valve
d. Inspect manifold for warping or wear around inlet and seat (12). If pump has plastic retainers, O-ring (15)
outlet ports. If wear is excessive, replace manifold. goes between retainer and seat.
To check for warped manifold, remove O-rings and place • Outlet (3 outer valves). Insert valve seat (12), valve
straightedge across it. If warped replace. (13), and spring (14), then retainer (16). If pump has
e. Remove three socket-head cap screws (39) with 3/16-in. plastic retainers, install the O-ring (15) between
(5-mm) hex Allen wrench. retainer and seat. If pump has metal retainers in outlet
valves, position them so leg does not point toward
f. Inspect valve plate (18) for warping as in step d for
center of pump. See illustration following.
manifold. If warped replace.
NOTE: Plastic valve plates and manifolds should also
be inspected for cracks, and replaced as necessary.

W0200A

12 G25-991-2400C
G/H-25 Service (Fluid End)
3. Inspect and Replace Hydraulic End (use if
Diaphragms (22) diaphragm has ruptured)
a. Lift diaphragm (22) by one edge, and turn pump shaft a. Remove oil drain cap (34) and allow all oil and
until diaphragm pulls up. This will expose machined cross contaminants to drain out. Replace oil drain cap.
holes in valve plunger shaft behind diaphragm. b. Remove oil cap (28) and fill reservoir with kerosene or
b. Insert Allen wrench through one of holes, to hold solvent, manually turn pump shaft to circulate kerosene,
diaphragm up. (The proper size tool is included in the and drain.
Wanner Tool Kit.) CAUTION: If you have EPDM diaphragms, or if food
c. Remove screw (19), O-ring (20), and follower (21) in center grade oil is in the reservoir, do not use kerosene or
of diaphragm. solvents. Instead, flush with the same lubricant used
d. Remove diaphragm and inspect carefully. in the reservoir. Pumps with EPDM diaphragms have
NOTE: A ruptured diaphragm indicates a pumping an “E” as the 7th digit of the Model No.
system problem, and replacing only the diaphragm c. Repeat step b.
will not solve the larger problem. d. Fill reservoir with fresh oil, manually turn pump shaft to
Inspect diaphragm (22) for following: circulate oil, and drain once again.
• Half-moon marks. Usually caused by cavitation of e. Refill reservoir. If oil appears milky, there is still
pump (See Troubleshooting section). contaminant in reservoir. Repeat flushing procedure until
• Concentric circular marks. Usually caused by oil appears clean.
cavitation of pump (See Troubleshooting section). d. Replace oil cap (28).
• Small puncture. Usually caused by sharp foreign
object in fluid, or by ice particle.
• Diaphragm pulled away from center screw or from 5A. Prime Hydraulic Cells on
cylinder sides. Usually caused by fluid being frozen in
pump, or by overpressurization of pump. Standard Pumps
• Diaphragm stiff and inflexible. Usually caused by a. With pump horizontal, and fluid-end head removed,
pumping fluid incompatible with diaphragm material, remove oil cap (28) and fill reservoir with correct Hydra-
or diaphragm operated at temperatures below rated oil for application. Have catch basin for oil leaks from
capability. behind diaphragms when priming. Catch oil and dispose
• Diaphragm edge chewed away. Usually caused by of properly. Do not reuse.
overpressurizing system. b. Force air out of oil in hydraulic cell (behind diaphragms)
f. Inspect plunger (23) for any rough surfaces or edges. by turning shaft and pumping piston. (A shaft rotator is
Do not remove plunger from valve plunger (54). Smooth included in the Wanner Tool Kit.) Turn shaft until bubble-
surfaces and edges as necessary with emery cloth or free flow of oil comes from behind all diaphragms. Watch
fine file. oil level in reservoir. If oil gets too low during priming,
CAUTION: If a diaphragm has ruptured and foreign air will be drawn into pistons (inside hydraulic end) and
material or water has entered the oil reservoir, do cause pump to run rough.
not operate the pump. Check all diaphragms, then c. Wipe excess oil from cylinder housing (25) and
flush the reservoir completely (as outlined below) diaphragms (22).
and refill it with fresh oil. Never let the pump stand d. Ensure that oil is one inch (25 mm) from top of fill port.
with foreign material or water in the reservoir, or with e. Replace oil cap (28).
the reservoir empty.
g. Install new diaphragm (22) or reinstall old diaphragm (if
good) ridge side out. 5B. Prime Hydraulic Cells
h. Clean screw (19) including any oil. Apply medium-strength
threadlocker to screw. Reinstall screw, follower (21), and on Kel-Cell Pumps
new O-ring (20). Tighten to 18 in.-lbs (2.0 N-m). NOTE: Providing oil prime to Kel-Cell fitted pumps
i. Repeat steps a. thru h. for other two diaphragms (22). requires pressure be applied to the diaphragms. This
Replace diaphragms if indicated. can be done manually, with the system head pressure,
or with pressurized air if available. Review all methods
4. Flush Contaminant from below to determine the procedure most suitable.

5B. Prime Hydraulic Cells

13 G25-991-2400C
G/H-25 Service (Fluid End)
on Kel-Cell Pumps (Cont’d) moves to force out the air.
a. Completely assemble pump.
Method #1 (with system head pressure b. Remove oil cap (28) and fill reservoir with correct Hydra-oil
less than 2 psi) to top of fill port.
a. Install valve plate (18) without outlet valves (leave seats When tank head pressure is being used to prime,
(12) installed) onto cylinder housing (25). Tighten two use the following steps:
socket-head screws (39).
b. Remove oil cap (28) and fill reservoir with correct Hydra- c. Install pump in system and connect tank supply line to
oil to top of fill port. pump inlet. Connect pump discharge line. Leave end of
line open to allow air to pass out.
c. With blunt pointer (eraser end of pencil), reach in through
each outlet valve port and push follower-diaphragm d. Slowly turn pump shaft by hand and watch for bubbles at
backwards. Note air bubbles coming out at oil fill port. oil reservoir fill opening. This will take several rotations.
Now turn shaft about 1/2 turn. When no more bubbles come out and reservoir level has
dropped about 1” (25 mm), hydraulic cells are primed.
d. Repeat depressing diaphragms and rotating shaft
(approximately 4 to 6 times) until no more air bubbles e. Replace oil cap (28) and complete installation.
escape and oil has dropped about 1 inch (25 mm) from When compressed air is being used to prime, use
top of fill port. Hydraulic cells are now primed. Replace the following steps:
oil cap (28).
e. Install outlet valve assemblies in each outlet valve port. c. Insert clean air hose to pump inlet and restrict pump
See parts illustration for correct assembly order. You may outlet. Turn shaft quarter turn and apply air pressure
have to tip pump (head upward) in order to keep valve into manifold to put pressure on diaphragms. Note air
centered on seat (12) and allow retainer (16) to fit flush bubbles at reservoir opening. Repeat for several rotations
in port. until no more air bubbles come out and reservoir level
has dropped about 1” (25 mm). Hydraulic cells are now
f. Install manifold (7) and complete installation.
primed.
Method #1 Alternative (with system head d. Replace oil cap (28) and complete installation.
pressure less than 2 psi)
a. With pump horizontal, and fluid-end head removed, 6. Reinstall Valve Plate (18), and
remove oil cap (28) and fill reservoir with correct Hydra-
oil. Have catch basin for oil leaks from behind diaphragms
Manifold (7)
when priming. Catch oil and dispose of properly. Do not a. Install valve assemblies in valve plate (18) as outlined in
reuse. paragraph 2, step e.
b. Force air out of oil in hydraulic cell (behind diaphragms) b. Install valve plate (18) on cylinder housing (25) with three
by turning shaft and pumping piston. (A shaft rotator cap screws (39).
is included in the Wanner Tool Kit.) Keep pressure on c.. Reinstall O-rings (8, 9, and 10) between valve plate
diaphragms while turning shaft until bubble-free flow of and manifold (7). (See illustrations to determine which
oil comes from behind all diaphragms. Watch oil level O-rings to use depending on pumping head material.) Use
in reservoir. If oil gets too low during priming, air will be petroleum jelly or lubricating gel to hold them in place.
drawn into pistons (inside hydraulic end) and cause pump d. Reinstall manifold (7) onto valve plate (18). Be sure drain
to run rough. plug (4) is at bottom of manifold. If pumping head is non-
c. Quickly attach assembled valve plate (18) (before oil runs metallic, support plate (43) is also used.
out past diaphragms) with socket head screw (39). Do not e. Insert all bolts (5), washers (6), and nuts (31) around edge
tighten screw completely. Leave gap between valve plate of manifold, and centerbolt (1) with washer (2). Hand
and cylinder housing (25). Turn shaft 2-3 turns to force tighten.
out any remaining air behind diaphragms. Hydraulic cells f. H-25 (external centerbolt models only). Install
are now primed. Complete valve plate installation with centerbolt (1), with washer (2), and tighten. Torque to 60
two socket head screws (39) and add pump mani- fold N-m.
(7). For Model H-25
d. Wipe off excess oil from around pump head. g. Torque centerbolt to 45 ft-lbs.
e. Check that oil level is 1 inch (25 mm) from top of fill port. h. Alternately tighten opposite bolts (5) until all are secure.
f. Replace oil cap (28) and complete installation. Torque to 45 ft-lbs.
For Model G-25
Method #2 (with system head pressure
g. Alternately tighten opposite bolts (5) until all are secure.
greater than 2 psi) Torque to 60 N-m.
NOTE: This simple and clean method of priming the h. Torque centerbolt to 60 N-m.
Hydra-cells requires an inlet head pressure of at
least 5 feet (1.5 m) or 2 psi (.14 bar). This pressure is
required to hold the diaphragms back while the piston

14 G25-991-2400C
G/H-25 Service (Hydraulic End)

Kel-Cell
Models
60

61

A 62 25

50

62
51

63 56
52
B 62
53

64 54

52

65
66 55

56

57

58
*

59
W0197B

* Quantity per piston: 4

15 G25-991-2400C
G/H-25 Service (Hydraulic End)
NOTE: The numbers in parentheses are the Reference
Numbers used in the Parts Manual illustrations.
3. Reassemble Pistons (66)
a. Drop ball (58) into each opening in bottom of piston
CAUTION: Do not disassemble the hydraulic end unless
assembly (59).
you are a skilled mechanic. For assistance, contact Wanner
Engineering (TEL 612-332-5681 or FAX 612-332-6937) or the b. Insert retaining washer (57) and O-ring (56) to hold ball
distributor in your area. in place.
c. Insert valve plunger (54) into valve cylinder (55). Slide
CAUTION: The four socket head screws (26) that screw spring (53) over plunger, inside valve cylinder.
through the back of the pump housing (30) into the cylinder
d. Insert O-ring (52) into spring retainer (51).
housing (25) hold the cylinder housing to the pump
housing. Do not remove them except when repairing the e. Install two O-rings (52) on valve cylinder (55).
hydraulic end. f. Slide assembled valve cylinder, plunger, and spring into
spring retainer (51).
NOTE: The following service procedures refer several times
to the Wanner Tool Kit. We strongly urge you not to try to g. Install O-ring (56) on spring retainer.
repair the hydraulic end of the pump without using the tools h. Slide complete cylinder and retainer assembly (51-56)
in this kit (available from Wanner or your local distributor). into piston assembly (59).
i. Insert return spring (50) into piston assembly.
j. Repeat above procedure for remaining two pistons.

1. Disassemble Pump Housing (30)

and Cylinder Housing (25) 4. Reassemble Pump Housing (30)
a. Remove pump head and diaphragms (22) as outlined in
Fluid-End Service Section.
and Cylinder Housing (25)
NOTE: Inspect shaft seals (64). If seals are damaged
b. Remove cap (34) and drain oil from pump housing.
in any way, replace. Remove seals by pounding
c. Set hydraulic end of pump face-down on cylinder housing them out from inside pump housing (30). Both
(25). seals should be replaced. Clean seal bore in pump
d. Check cam assembly shaft (62) for sharp burrs. Smooth housing, using emery cloth or ScotchBrite™. See
any burrs. Burrs can scar seals (64) during pump Paragraph 5. Replace Shaft Seals.
disassembly. a. Place cylinder housing (25) face-down on flat surface.
e. Remove four socket head screws (26) and washers (6) b. Insert assembled pistons (66) into cylinder housing.
that secure cylinder housing to pump housing (30). Piston
c. Note location of outer ring holes in cylinder housing and in
return springs (50) will force cylinder housing and pump
flange of pump housing — in particular four holes where
housing apart.
cap screws (26) will be installed. Screw two threaded
f. Lift off pump housing. studs (from Wanner Tool Kit) into two of four holes in
g. Inspect cam assembly and bearings (62). Inspect bearing cylinder housing. Use opposite holes.
race in rear of pump housing (30). If bearings are pitted d. Stand camshaft assembly (62) on cylinder housing (25).
or binding, or if housing race is worn, contact Wanner
CAUTION: The pilot bearing MUST be properly nested
Engineering.
in the bearing race during assembly. If misaligned,
the bearing will be damaged and the pump will fail
within the first hours of operation.
2. Disassemble Pistons (66) e. Using grease to retain it, install O-ring (65) and slide
a. With pump housing removed (see above), turn unit over pump housing (30) over shaft and onto threaded studs
and set it on flat surface, piston side down. in cylinder housing. Be sure holes in pump housing and
b. With diaphragms (22) removed (see Fluid - End cylinder housing are correctly aligned.
Service Section), reinsert screw (19) into hole in one f. Install cap screws (26) and washers (6), but don’t tighten.
of valve plungers (54). Tap screw lightly with hammer. g. Insert two or more bolts (5) into unthreaded holes of pump
Plunger (23) should slip off valve plunger (54). housing and cylinder housing to help align parts.
Disassemble hydraulic piston assembly (66). Inspect all h. Alternately tighten four cap screws to evenly draw pump
parts, and replace all O-rings (52, 56) and any other parts
that are worn or damaged.
c. Repeat step b. for remaining two pistons.
NOTE: Use new plungers (23) to reassemble hydraulic
piston. They are press-fit onto the valve plungers (54)
and are not reusable.

16 G25-991-2400C
G/H-25 Service (Hydraulic End)
housing and cylinder housing together. Be sure O-ring (65) NOTE: Install new plungers if they have been removed
stays in place. from the valve plungers (54). Do not reuse.
i. While tightening cap screws, frequently check shaft a. Rotate pump shaft so piston (66) is in top-dead-center
alignment by turning shaft with rotor (from Wanner Tool position.
Kit). If shaft begins to bind and is hard to turn, back off b. Place plunger (23) on exposed screw end of plunger
cap screws and realign shaft. When pump housing is tight guide tool (from Wanner Tool Kit). Larger-diameter side
against cylinder housing, shaft should turn smoothly. of plunger should face tool.
j. After all cap screws are tightened, remove two threaded c. Screw plunger guide tool with plunger into valve plunger (54)
studs. until tight.
k. Turn shaft again to check alignment. d. Hold single bottom handle of plunger guide tool, and
turn double top handle to force plunger to seat on valve
plunger. Plunger should be tight against shoulder of valve
5. Replace Shaft Seals (64) plunger. Plunger is press-fit when installed.
e. Leave plunger guide tool installed.
a. Apply thin coat of grease to seal protector tool (from
Wanner Tool Kit). Slide both seals (64) onto tool, with f. Install diaphragm as outlined in Reinstall Diaphragms
spring side of seals toward open end of tool. paragraph below.
b. Apply heavy coat of grease between seals and press NOTE: Do not remove the plunger guide until the
together. diaphragm is installed as outlined in Paragraph 8.
c. Apply coating of Loctite® High-Performance Pipe Sealant Reinstall Diaphragms below.
with PTFE, or comparable product to outer surface of g. Repeat steps a. thru f. for two remaining plungers and
both seals and inside surface of shaft opening in pump diaphragms.
housing (30).
d. Apply light film of grease to cam assembly drive shaft (62).
Slide seal protector tool and seals over end of shaft.
e. Slide seal inserter tool (from Wanner Tool Kit) over seal
8. Reinstall Diaphragms (22)
protector tool and press seals into place. Carefully tap a. Insure plunger guide tool (from Wanner Tool Kit) is screwed
seal inserter tool with soft mallet to firmly seat seals. into valve plunger (54) from Paragraph 7. Install Plungers
above. Pull valve plunger up until cross-holes in valve
plunger are exposed.
6. Adjust Endplay of Camshaft (62) b. Insert plunger holder (from Wanner Tool Kit) through
top hole — to hold plunger (23) away from cylinder
a. Remove and clean three set screws (24) from cylinder housing (25), and keep valve plunger from turning when
housing (25). diaphragm (22) is installed.
b. Insert centerbolt (1) into center hole of cylinder housing (25). c. Place diaphragm onto plunger, ridge-side out.
c. Turn in centerbolt to move bearing adjusting plate (61) d. Place and center follower (21) on diaphragm.
and cup tight against bearing cone. e. Place O-ring (20) on screw (19), and apply small amount
d. Back out centerbolt two full turns, then turn in until it is of threadlocker to threads of screw.
tight against adjusting plate (61). f. Insert screw with O-ring through follower and diaphragm,
e. Back out centerbolt exactly 1/4 turn. and screw it into valve plunger (54).
f. With plastic mallet (or a regular mallet and wooden board) g. Grasp plunger holder and torque screw to 18 in.-lbs
carefully rap end of camshaft (62) three or four times. This (2.0 N-m).
will provide about 0.006 in. (0.15 mm) endplay in shaft. h. Remove plunger holder and plunger guide tool.
g. Apply removable threadlocker to threads of three set
screws (24) and screw into cylinder housing until they
contact bearing adjusting plate.
h. Remove centerbolt.
9. Reassemble Pump Head
a. Reassemble pump head as outlined in Fluid-End Service
7. Install Plungers (23) Section.
b. Fill reservoir with fresh oil and prime pump, as outlined
in Fluid-End Service Section.

17 G25-991-2400C
G/H-25 Troubleshooting
Cavitation Pump Runs Rough
• Inadequate fluid supply because: • Worn pump valves
— Inlet line collapsed or clogged • Airlock in outlet system
— Clogged line strainer • Oil level low
— Inlet line too small or too long • Wrong weight of oil for cold operating temperatures (change
— Air leak in inlet line to lighter weight)
— Worn or damaged inlet hose • Cavitation
— Suction line too long • Air in suction line
— Too many valves and elbows in inlet line • Restriction in inlet/suction line
• Fluid too hot for inlet suction piping system. • Hydraulic cells not primed after changing diaphragm
• Air entrained in fluid piping system. • Foreign material in inlet or outlet valve
• Aeration and turbulence in supply tank. • Damaged diaphragm
• Inlet vacuum too high • Fatigued or broken valve spring
• Broken piston return spring (inside hydraulic end)

Symptoms of Cavitation
• Excessive pump valve noise Premature Failure of Diaphragm
• Premature failure of spring or retainer
• Frozen pump
• Volume or pressure drop
• Puncture by a foreign object
• Rough-running pump
• Elastomer incompatible with fluid being pumped
• Premature failure of diaphragms
• Pump running too fast
• Piston return spring failure (inside hydraulic end)
• Excess pressure
• Cavitation

Drop in Volume or Pressure • Broken piston return spring (50)

A drop in volume or pressure can be caused by one or more Water (or Process Fluid) in Oil
of the following:
• Air leak in suction piping Reservoir
• Clogged suction line or suction strainer • Condensation
• Suction line inlet above fluid level in tank • Ruptured diaphragm
• Inadequate fluid supply • Hydraulic cell not properly primed after diaphragm
• Pump not operating at proper RPM replacement
• Relief valve bypassing fluid • Frozen pump
• Worn pump valve parts • Diaphragm screw O-ring (18) missing or cracked
• Foreign material in inlet or outlet valves • Cracked cylinder casting
• Loss of oil prime in cells because of low oil level
• Ruptured diaphragm
• Cavitation Strong Water (or Process Fluid)
• Warped manifold from overpressurized system Pulsations
• O-rings forced out of their grooves from overpressurization
NOTE: Small pulsations are normal in single-acting pumps
• Air leak in suction line strainer or gasket
with multiple pumping chambers.
• Cracked suction hose.
• Foreign object lodged in pump valve
• Empty supply tank
• Loss of prime in hydraulic cell because of low oil level
• Excessive aeration and turbulence in supply tank
• Air in suction line
• Worn and slipping drive belt(s)
• Valve spring (13) broken
• Worn spray nozzle(s)
• Cavitation
• Cracked cylinder casting
• Aeration or turbulence in supply tank

18 G25-991-2400C
G/H-25 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
• Diaphragm screw O-ring (18) 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.

19 G25-991-2400C
 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 noncontractual 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: sales@wannereng.com
© 2004 Wanner Engineering, Inc. Printed in USA
20 G25-991-2400C 5/2004, Revised 7/2017