Hydra-Cell P400 Manual

T M
P400 Metering Pump
P400-991-2400B
Installation & Service
W0014A
Non-Metallic Pump shown
1204 Chestnut Avenue, Minneapolis, MN 55403
TEL: [phone] FA X: (612) 332- 6937
TOLL-FREE FAX [US only]: [phone]
www.hydra-cell.com/metering
email: [e-mail]

2P400-991-2400B
Steady State Accuracy ±1%
Linearity ±3%
Repeatability ±3%
Maximum Pressure
Metallic Head: 1000 psi (70 bar)
Non-Metallic Head: Polypropylene: 250 psi (17 bar)
Kynar: 350 psi (24 bar)
Maximum Inlet Pressure 250 psi (17 bar)
Maximum Temperature
Metallic Head: 250°F (121°C) – consult factory for
temperatures above 160°F (71°C)
Non-Metallic Head: 140°F (60°C)
P400 Specifications
P400 Contents
Page
Specifications..........................................................................2
Dimensions .............................................................................3
Installation...............................................................................5
Maintenance............................................................................7
Fluid End
Service .................................................................................8
Parts List ............................................................................12
Hydraulic End Parts List .......................................................14
Reducer Parts List ................................................................16
Troubleshooting.....................................................................18
Replacement Parts Kits ........................................................19
Warranty............................................................................... 20
Component Identification
W0014A
Oil Fill Cap ID Plate
Outlet
Reducer
Inlet
Pump Assembly
Fluid End
Pump Assembly
Hydraulic End
†Capacity data shown is for pumps with elastomeric diaphragms. Consult factory for
performance characteristics of pumps with PTFE diaphragms.
Inlet Port 1 inch NPT or BSPT
Discharge Port 3/4 inch NPT or BSPT
Shaft Rotation Bi-directional
Oil Capacity† 1.1 US quart (1.05 liters)
Weight
Metallic Head: 62 lbs (28.1 kg)
Non-Metallic Head: 49 lbs (22.2 kg)
Metallic Head with Motor Adapter: 68 lbs (30.8 kg)
Non-Metallic Head with Motor Adapter: 55 lbs (25 kg)
GPH All Pumps GPH Metallic Pump Heads Only Pump
RPM
Gear
Ratio
Motor
RPM
100 PSI (*)250 PSI (*)500 PSI (*)1000 PSI (*)
5.45 (¼) 5.40 (¼) 5.35 (¼) 5.19 (¼) 18 100:1
1800
6.97 (¼) 6.92 (¼) 6.86 (¼) 6.68 (¼) 22.5 80:1
9.51 (¼) 9.45 (¼) 9.38 (¼) 9.16 (¼) 30 60:1
11.54 (¼) 11.48 (¼) 11.40 (¼) 11.15 (¼) 36 50:1
14.59 (¼) 14.52 (¼) 14.43 (¼) 14.13 (¼) 45 40:1
19.66 (¼) 19.59 (¼) 19.47 (¼) 19.10 (¼) 60 30:1
23.72 (¼) 23.64 (¼) 23.51 (¼) 23.07 (½) 72 25:1
29.81 (¼) 29.72 (¼) 29.56 (¼) 29.04 (½) 90 20:1
39.96 (¼) 39.85 (¼) 39.65 (½) 38.97 (½) 120 15:1
60.27 (¼) 60.12 (¼) 59.83 (½) 58.84 (¾) 180 10:1
80.57 (¼) 80.38 (¼) 80.00 (¾) 78.71 (1) 240 7.5:1
121.2 (¼) 120.9 (½) 120.4 (1) 118.5 (1½) 360 5:1
161.8 (½) 161.4 (¾) 160.7 (1½) 158.2 (2) 480 7.5:1 3600
243.0 (½) 242.5 (1) 241.4 (2) 237.7 (3) 720 5:1
Gallons Per Hour (GPH) Maximum Flow at Designated Pressure†
*Required Motor HP

3P400-991-2400B
P400 Models with Non-Metallic Pump Head
OUT
IN
WANNER
8.68
(220.5)
18.19
(462)
0.39
(9.9)
16.91
(429.5)
14.50
(368.3)
1" NPT or
1" BSPT
3/4" NPT or
3/4" BSPT
1
1
Note:
Worm Gear Reducer available
in the following ratios: 5:1, 7.5:1,
10:1, 15:1, 20:1, 25:1, 30:1, 40:1,
50:1, 60:1, 80:1, 100:1.
Ø6.50
(165.1)
NEMA 56C
Flange
Pilot
Ø4.500
(114.3)
Bolt Circle
Ø5.875
(149.2)
NEMA
56C
Ø0.625
(15.88)
Square
Key
0.187
(4.75)
0.24
(6.1)
4.65
(118.1) 9.64
(244.9) 9.87
(250.7)
10.34
(262.6)
Ø0.41
(10.4) 4X
7.38
(187.5)
5.13
(130.3)
4.57
(116.1)
1.37
(34.8)
8.63
(219.2)
9.63
(244.6)
14.50
(368.3)
12.50
(317.5)
W0018
P400 Dimensions
316 Stainless Steel
Cast Iron
Hastelloy®C
Inches (mm)
Kynar
Polypropylene
OUT
WANNER ENG.
IN
8.68
(220.5)
17.59
(446.8)
16.32
(414.5)
14.50
(368.3)
1" NPT or
1" BSPT
3/4" NPT or
3/4" BSPT
1
1
Note:
Worm Gear Reducer available
in the following ratios: 5:1, 7.5:1,
10:1, 15:1, 20:1, 25:1, 30:1, 40:1,
50:1, 60:1, 80:1, 100:1.
Ø6.50
(165.1)
NEMA 56C
Flange
Pilot
Ø4.500
(114.3)
Bolt Circle
Ø5.875
(149.2)
NEMA
56C
Ø0.625
(15.88)
Square
Key
0.187
(4.75)
0.24
(6.1)
4.65
(118.1) 9.64
(244.9) 9.87
(250.7)
10.34
(262.6)
Ø0.41
(10.4) 4X
7.38
(187.5)
5.13
(130.3)
4.01
(101.9)
1.37
(34.8)
8.63
(219.2)
9.63
(244.6)
14.50
(368.3)
12.50
(317.5)
W0017
P400 Models with Metallic Pumping Head

4P400-991-2400B
P400 Models with Non-Metallic Pump Head and Motor Adapter
OUT
IN
WANNER
12.50
(317.5)
1.00
(25.4)
18.44
(468.4)
0.39
(9.9)
8.63
(219.2)
9.64
(244.9)
Ø0.41
(10.4)
4X
5.13
(130.3)
4.65
(118.1)
7.38
(187.4)
0.97
(24.6)
10.34
(262.6)
4.57
(116.1)
1.37
(34.8) 9.64
(244.9)
0.48
(12.2)
1" NPT or
1" BSPT
3/4" NPT or
3/4" BSPT
14.50
(368.3)
16.91
(429.5)
1
1
Worm Gear Reducer
available in the following
ratios - 5:1, 7.5:1
Note:
2. Weight = 55 lbs (25 kg) (no motor)
13.15
(334)
8.68
(220.5)
Ø7.00
(177.8)
NEMA 143/5TC Flange
Ø4.500 (114.3) Pilot
Ø5.875 (149.2) B.C.
NEMA 143/5TC
Ø0.875 (22.2)
0.187 (4.75) Square Key
W0314
P400 Dimensions
316 Stainless Steel
Cast Iron
Hastelloy®C
Inches (mm)
Kynar
Polypropylene
OUT
WANNER ENG.
IN
8.63
(219.2)
9.64
(244.9)
Ø0.41
(10.4)
4X
Ø7.00
(177.8)
NEMA 143/5TC Flange
Ø4.500 (114.3) Pilot
Ø5.875 (149.2) B.C.
NEMA 143/5TC
Ø0.875 (22.2)
0.187 (4.75) Square Key
12.50
(317.5)
17.84
(453.1)
1.00
(25.4)
14.50
(368.3)
16.32
(414.5)
1
1
Worm Gear Reducer
available in the following
ratios - 5:1, 7.5:1
Note:
2. Weight = 68 lbs (30.8 kg) (no motor)
13.15
(334)
8.68
(220.5) 5.13
(130.3)
4.65
(118.1)
7.38
(187.4)
10.34
(262.6)
4.01
(101.9)
1.37
(34.8) 9.64
(244.9)
0.48
(12.2)
1" NPT or
1" BSPT
3/4" NPT or
3/4" BSPT
W0306
P400 Models with Metallic Pumping Head and Motor Adapter

5P400-991-2400B
P400 Installation
Location
NOTE: The numbers in parentheses are Reference Numbers
located in the Parts List exploded views of this manual.
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.
Motor and Controller
The P Series pump shaft can rotate in either direction, therefore
direction of motor shaft rotation is not critical.
Accessories
Consult installation drawing below for typical precision metering
fluid system components. Contact Wanner Engineering or the
distributor in your area for more details.
Important Precautions
Adequate Fluid Supply. To avoid cavitation and
premature pump failure, be sure that the pump will have
an adequate fluid supply and that the inlet line will not be
obstructed. See Inlet Piping on page 6.
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
from the pump. See Discharge Piping on page 6.
Safety Guards. Follow all codes and regulations regarding
installation and operation of the pumping system.
Shut-Off Valves. Never install shut-off valves between
the pump and discharge pressure regulator, or in the
regulator bypass line.
Consult the Factory for the following situations:
• Extreme temperature applications (above 160° F or
below 40° F)
• Pressure feeding of pumps
• Viscous or abrasive fluid applications
• Chemical compatibility problems
• Hot ambient temperatures (above 110° F)
P400
METERING PUMP
PULSATION
DAMPENER
(OPTIONAL)
CALIBRATION
CYLINDER
Y-STRAINER
ISOLATING VALVE
BALL VALVE
RELIEF
VALVE
FLANGES & MANIFOLDS
BACK PRESSURE
VALVE
(To process)
PRESSURE
GAUGE
W0326

6P400-991-2400B
P400 Installation
Inlet Piping
Provide for permanent or temporary installation of a compound
pressure gauge to monitor the inlet pressure. To maintain
maximum flow, the pump inlet should be under flooded suction
conditions at all times. Do not supply more than one pump
from the same inlet line.
Supply Tank
Use a supply tank that is large enough to provide time for any
trapped air in the fluid to escape. The tank size should be at
least twice the maximum pump flow rate.
Install a separate inlet line from the supply tank to each
pump.
Place a cover over the supply tank, to prevent foreign objects
from falling into it.
Hose Sizing and Routing
To minimize acceleration head and frictional losses, size the
suction line at least one size larger than the pump inlet, and
keep the suction line as short and direct as possible.
Recommendations:
• Keep inlet lines less than 3 ft. (1 m) long
• Use at least 1-1/2” (38 mm) I.D. inlet hose
• Minimize fittings (elbows, valves, tees, etc.)
Inlet Piping (Pressure Feed)
Provide for permanent or temporary installation of a pressure
gauge to monitor the inlet pressure. Pressure at the pump inlet
should not exceed 250 psi (17 bar); if it could get higher, install a
pressure reducing valve. Do not supply more than one pump
from the same inlet line.
Note: System back pressure must exceed the pump inlet
pressure by at least 15 psi (1 bar) in order to prevent
flow thru.
Discharge Piping
Hose and Routing
Use the shortest, most-direct route for the discharge line.
Select pipe or hose with a working pressure rating of at least
1.5 times the maximum system pressure. EXAMPLE: Select a
1500 psi (103 bar) W.P.-rated hose for systems to be operated
at 1000 psi (69 bar) gauge pressure.
Support the pump and piping independently.
Pressure Regulation
Install a pressure relief valve in the discharge line. Bypass
pressure must not exceed the pressure limit of the pump.
Size the valve so that, when fully open, it will be large enough
to relieve the full capacity of the pump without over-pressurizing
the system.
Locate the valve as close to the pump as possible and ahead
of any other valves.
Adjust the pressure relief valve to no more than 10% over the
maximum working pressure of the system. Do not exceed the
manufacturer’s pressure rating for the pump or valve.
Route the bypass line to the supply tank.
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.
Minimum Discharge Pressure
To ensure proper capacity control, a minimum discharge
pressure of 50 psi (3.5 bar) is required.

7P400-991-2400B
P400 Installation
Initial Start-Up Procedure
Before you start the pump, be sure that:
• All shut-off 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.
1. Open the priming valve on the system back pressure valve
so the pump starts under minimum pressure.
2. Turn on power to the pump motor.
3. Check the inlet pressure or vacuum. To maintain maximum
flow, the pump inlet should be under flooded suction
conditions at all times. Inlet pressure must not exceed 250
psi (17 bar).
4. Listen for any erratic noise and look for unsteady flow.
• Jog the pump on and off until fluid coming from the
priming valve is air-free.
• Close the priming valve.
P400 Maintenance
NOTE: The numbers in parentheses are Reference Numbers
located in the Parts List exploded views of this manual.
Periodically
Change the oil according to the guidelines below. When changing,
remove the drain plug (34), Allow all oil and contaminant to drain
out. Catch the oil and dispose of it properly.
Hours Between Oil Changes @ Various
Process Fluid Temperatures
<90°F <139°F <180°F
Pressure (32°C) (60°C) (82°C)
Metallic Pump Head
<650 psi (45 bar) 6,000 4,500 3,000
<1000 psi (70 bar) 4,000 3,000 2,000
Non-Metallic Pump Head
<250 psi (17 bar) 4,000 3,000 —
NOTE: Minimum oil viscosity for proper hydraulic end
lubrication is 16-20 cST (80-100 SSU).
CAUTION: Do not turn the drive shaft while the oil reservoir
is empty.
Use the appropriate Hydra-Oil for the application.
Note: P Series replacement parts kits (complete kits and
diaphragm kits) include the appropriate oil for each specific
P Series pump configuration.
CAUTION: If you are losing oil but don’t see any external
leakage, or if the oil becomes discolored and contaminated,
the diaphragm (20) 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. Dispose of properly. Replace with clean oil.
Check the inlet pressure periodically with a gauge.
Calibration Procedure
Each individual metering pump put into service must be calibrated
in order to accurately determine required pump speed to achieve
the desired flow. The capacity curves shown on page 3 represent a
typical pump; individual pumps may vary slightly from these curves.
In order to achieve the best possible results, perform calibration
under actual process conditions. Follow these steps:
1. Run the pump for 20 minutes at actual process conditions. If
the process system cannot be used, circulate back to the supply
tank through a pressure relief valve (see Installation drawing on
page 5). If required system pressure is less than 50 PSI (3.5
bar) a back pressure valve must be installed and set to produce
a minimum of 50 PSI (3.5 bar) pressure at the pump head.
2. Determine maximum pump speed required for all system
conditions that need to be satisfied. Measure pump delivery
at this maximum speed using your system calibration cylinder,
flow meter, or some other means. This is considered to be the
“rated capacity” for your particular metering pump.
3. Measure pump delivery at 75%, 50%, 25%, and 10% of the
maximum speed just determined. Let the pump run for 5
minutes at each speed setting before taking the capacity
measurement.
4. Plot these values on linear graph paper using the horizontal
axis for RPM and the vertical axis for GPH, or any other unit of
measure you may be using for capacity.
5. Draw a best-fit straight line through the points just plotted. For
stable conditions, this line predicts pump speed required to
achieve desired flow over a 10:1 turndown ratio.
Note: as pump discharge pressure increases, capacity
decreases slightly. For any metering pump there are a
series of valid capacity curves that may apply. Use the
curve that depends on actual pump discharge pressure
and other system conditions. It is critically important to
develop a custom capacity curve for each pump and each
system.

8P400-991-2400B
P400 Fluid End Service
NOTE: The reference numbers in parentheses are shown
in the Fluid End Parts List.
This section explains how to disassemble and inspect all easily-
serviceable parts of the pump.
CAUTION: Do not disassemble the hydraulic end of the
pump. Contact Wanner Engineering (TEL [phone] or
FAX [phone]) or the distributor in your area.
1. Remove Manifold (6), Valve
Plate (16)
a. Remove six nuts (31) and six bolts (4) around manifold (6).
Do not remove bolt (25) or bolt (29) installed through back
of cylinder housing (24).
b. Use 3/8-in. (10-mm) hex Allen wrench to remove center bolt (1)
and washer (2).
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 manifold (6), and support plate (42) [non-metallic
pump head only]. Valve plate (16) will remain on cylinder
housing (24).
d. Inspect manifold (6) for warping or wear around inlet and
outlet ports. If wear is excessive, replace the manifold.
To check if manifold is warped, remove O-rings (7,8,9) and
place straightedge across it. If warped replace.
WRONG: Retainer
leg pointing toward
center of pump.
RIGHT
Installing Valve Retainers
Into Valve Plate
W0020
2. Inspect Valves (10-15, 39)
The three inlet and three outlet valve assemblies are
identical but face opposite directions. Inspect each valve
as follows:
a. Check the spring retainer (15), and replace if worn.
Note: if your pump has a non-metallic pump head there
will be a plastic dampening washer (39) at the bottom
of each seat. Inspect each one for wear or cracks and
replace if necessary.
b. Check valve spring (13). If shorter than new spring,
replace (do not stretch old spring).
c. Check valve (12). If worn excessively, replace.
NOTE: If your pump has plastic spring retainers, there
is a tetra seal (flat O-ring, 14) between retainer (15) and
valve seat (11).
d. Remove valve seat (11) and O-ring (10). A seat puller is
included in Wanner Tool Kit.
Inspect valve seat for wear, and replace if necessary. A new
O-ring should be installed.
e. Reinstall the inlet and outlet assemblies:
• Clean valve ports and shoulders with emery cloth, and
lubricate with lubricating gel or petroleum jelly.
• Install O-ring (10) on valve seat (11).
• Inlet Valves (3 center valves in illustration below). Insert
spring retainer (15) into valve plate (16). Then insert
spring (13), valve (12), and valve seat (11). If the pump
has plastic spring retainers, install flat Tetra seal O-ring
(14) between spring retainer (15) and valve seat (11).
Insert dampening washer (39), if included in your valve
assembly.
• Outlet Valves (3 outer valves in illustration below).
Insert dampening washer (39), if included in your valve
assembly. Insert valve seat (11), valve (12), spring (13),
and spring retainer (15). If the pump has plastic spring
retainers, install flat Tetra seal O-ring (14) between spring
retainer and valve seat. If the pump has metal spring
retainers in the outlet valves, position them so a leg does
not point toward the center of the pump (see illustration
below).

9P400-991-2400B
P400 Fluid End Service
4. Flush Contaminant from
Hydraulic End
(only if a diaphragm has ruptured)
a. Remove the brass cap (34) and allow all oil and
contaminate to drain out.
b. Fill reservoir with kerosene or solvent, manually turn
pump shaft to circulate kerosene, and drain.
CAUTION: If you have EPDM diaphragms, or if food
grade oil is in the reservoir, do not use kerosene or
solvents. Instead, flush with the same lubricant that is
in the reservoir.
c. Repeat flushing procedure (step b).
d. Fill reservoir with fresh oil, manually turn pump shaft to
circulate oil. Drain oil.
e. Refill reservoir with fresh oil. If oil appears milky, there is
still contaminant in reservoir. Repeat steps c and d until
oil appears clean.
3. Inspect and Replace
Diaphragms (20)
If necessary to service diaphragms, remove two socket-
head cap screws (41) that secure valve plate (16) to cylinder
casting (24). Inspect valve plate the same as manifold in
Section 1 step d.
a. Lift diaphragm (20) by one edge, and turn pump shaft
until diaphragm pulls up. This will expose machined
cross-holes in plunger shaft behind diaphragm.
b. Insert Allen wrench through one of the holes, to hold
diaphragm up. The proper size tool is included in the
Wanner Tool Kit. (Don’t remove tool until new diaphragm
is installed in step f below.)
c. Remove the screw (17), O-ring (18), and follower (19) in
center of diaphragm (20).
d. Remove diaphragm (20), and inspect carefully. A
damaged diaphragm generally indicates a pumping
system problem. Replacing diaphragm only, will not solve
the larger problem. Inspect diaphragm for following:
• Small puncture. Usually caused by sharp foreign object
in fluid.
• Diaphragm pulled away from center screw or from
cylinder sides. Usually caused by fluid being frozen in
pump, or by over-pressurization of pump.
• Diaphragm becoming stiff and losing flexibility. Usually
caused by pumping fluid that is incompatible with
diaphragm material.
• Diaphragm edge chewed away. Usually caused by
over-pressurizing system.
e. Inspect plunger (21) for any rough surfaces or edges.
Do not remove plunger from the plunger shaft. Smooth
the surfaces and edges as necessary with emery cloth
or fine file.
CAUTION: If a diaphragm has ruptured and foreign
material or water has entered the oil reservoir, do not
operate the pump. Check all diaphragms, then flush the
reservoir completely (as outlined below) and refill it with
fresh oil. Never let the pump stand with foreign material
or water in the reservoir, or with the reservoir empty.
f. Install new diaphragm (20) (or old one, if not damaged),
ridge side out.
g. Clean screw (17) and remove any oil from it. Apply
medium-strength thread locker to screw. Reinstall screw
and follower (19), and new O-ring (18). Tighten to 18
in-lbs (2.0 N-m).
h. Repeat above inspection procedure (and replacement,
as necessary) with other two diaphragms (20).

10 P400-991-2400B
P400 Fluid End Service
5. Priming Hydraulic Cells
for Kel-Cell Pumps
NOTE: Providing oil prime to Kel-Cell fitted pumps requires
pressure be applied to the diaphragms. This can be done
manually, with the system head pressure, or with pressurized
air if available. Review all methods below to determine the
procedure most suitable.
Method 1 (system head pressure less than 2
psi)
a. Install valve plate (16) but without the outlet valves
installed (or else remove outlet valves; leave seats
installed) onto cylinder housing (24). Tighten two socket-
head screws (41).
b. Fill reservoir with correct Hydra-oil to fill port.
Note: P Series replacement parts kits (complete kits and
diaphragm kits) include the correct oil for each specific
P Series pump configuration.
c. With blunt pointer (eraser end of pencil), reach in
through each outlet valve port and push diaphragm (20)
backwards. Note air bubbles coming out at oil fill port.
Now turn shaft about 1/2 turn.
d. Repeat depressing diaphragms (20) and rotating shaft
(approximately 4-6 times) until no more air bubbles
escape and oil has dropped about 1 inch (25 mm) from
top of fill port. Hydraulic cells are now primed. Replace
oil fill cap (27).
e. Install outlet valve assemblies in each outlet valve port.
See Parts List for correct assembly order. If necessary,
tip pump (head upward) in order to keep valve (12)
centered on valve seat (11) and allow valve retainer (15)
to fit into port flush.
f. Install manifold (6) and complete installation.
Alternative Method 1 (system head pressure
less than 2 psi)
a. With pump horizontal, and the fluid-end head removed,
fill reservoir with correct Hydra-oil to fill port.
Note: P Series replacement parts kits (complete kits and
diaphragm kits) include the correct oil for each specific
P Series pump configuration.
c. Have catch basin for oil that leaks from behind diaphragms
when priming. Catch oil and dispose of properly. Do not
reuse oil.
c. All air in oil within hydraulic piston behind diaphragms
(20) must be forced out by turning shaft (and pumping
piston). A shaft rotator is included in the Hydra-Cell
Tool Kit. Keep pressure on diaphragms while turning
shaft until bubble-free flow of oil comes from behind all
diaphragms. Maintain oil level in reservoir. Do not allow
oil level to be lower than reservoir.
d. Quickly attach loaded valve plate (16) (before oil runs
out past diaphragms (20)) with socket head screws (41),
but do not tighten completely. Leave gap between valve
plate and the cylinder housing (24). Turn shaft 2-3 turns
to finish forcing out air behind diaphragms. Hydraulic
cells are now primed. Finish tightening valve plate with
two socket head screws and add pump manifold (6).
e. Wipe excess oil from around pump head.
f. Check that oil level is 1 inch (25 mm) from top of fill
port.
g. Replace oil fill cap (27) and complete installation.

11 P400-991-2400B
P400 Fluid End Service
Method 2 (head pressure greater than 2 psi)
This simple and clean method of priming 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.
a. Completely assemble pump and fill reservoir with correct
Hydra-oil to fill port.
Note: P Series replacement parts kits (complete kits and
diaphragm kits) include the correct oil for each specific
P Series pump configuration.
b. When tank head pressure is being used to prime,
install pump back into system and connect tank supply
line to pump inlet. Pump discharge line may be connected
at this time, but end of line must be open to allow air to
pass out.
c. Slowly turn pump shaft by hand and watch for bubbles
exiting oil reservoir fill opening. This will take several
rotations; when no more bubbles come out and reservoir
level has dropped about 1” (25 mm), hydraulic cells are
primed.
d. Replace oil fill cap (27) and complete installation.
e. When compressed air is being used to prime, insert
clean air hose to pump inlet and restrict pump outlet.
Turn shaft quarter turn and then apply air pressure into
manifold to put pressure on diaphragms (20). This will
force air out from inside pistons. Observe see bubbles
at reservoir opening. Repeat for several rotations until
no more air bubbles come out and reservoir level has
dropped about 1” (25 mm). Hydraulic cells are now
primed.
f. Replace oil fill cap (27) and complete installation.
6. Reinstall Pumping Head
NOTE: Use the cap screw (29) protruding through the
cylinder casting at the 10 o’clock position to locate the
valve plate on the cylinder casting. Place the “blind
hole” on the valve plate over this bolt.
a. With valve assemblies installed as outlined above,
reinstall valve plate (16) onto cylinder housing (24).
Recheck that blind hole is over protruding bolt at 10
o’clock position. Install two socket-head cap screws (41)
and secure valve plate to cylinder casting.
b. Reinstall O-rings (7,8,9) on rear side of the manifold (6).
Use petroleum jelly or lubricating gel to hold them in
place.
c. Reinstall manifold (6) onto valve plate (16). Be sure drain
plug (3) is at bottom of manifold.
NOTE: on pumps with non-metallic head position
support plate (42) onto manifold with ports and bolt
holes aligned properly.
d. Insert bolts (4), washers (5), and nuts (31). Hand
tighten.
e. Reinstall center bolt (1) with washer (2), and torque to
45 ft-lbs (60 N-m).
f. Alternately tighten six perimeter bolts (4). Torque to 45
ft-lbs (60 N-m).
g. Recheck all bolts for tightness.

12 P400-991-2400B
P400 Fluid End Parts List
W0019
Valve Assembly
with Metal Retainer
Non-Metallic Pump Head
with Plastic Retainer
1
P400 with
Metallic Pump Head
Cylinder Housing Assembly includes cylinder housing (24),
bearing cup, adjusting plate (61), O-ring (60), and set
screws (22).
1
Valve Assembly
P400 with

13 P400-991-2400B
P400 Fluid End Parts List
1 D10-081-2020 Screw, cap, socket head, sst *...........1
D10-081-2021 Screw, cap, socket head, sst ** ..........1
2 D10-084-2010 Washer, flat, sst ..................................1
3 D10-038-2017 Plug, nickel alloy, Hastelloy
CW12MW, npt .....................................1
D10-038-2211 Plug, 316 SST, npt...............................1
G10-038-2017 Plug, nickel alloy, Hastelloy
CW12MW, bspt ...................................1
G10-038-2211 Plug, 316 SST, bspt.............................1
4 D10-024-2012 Screw, cap, hex-head, sst* .................6
H25-024-2041 Screw, cap, hex-head, sst **...............6
5 D10-048-2012 Washer, split lock, sst .......................14
6 D10-004-1002 Manifold, 316 SST, npt ........................1
D10-004-1017 Manifold, nickel alloy, Hastelloy
CW12MW, npt .....................................1
D10-004-1034 Manifold, cast iron, npt........................1
D10-004-1050 Manifold, polypropylene, npt...............1
D10-004-1053 Manifold, Kynar, npt ............................1
G10-004-1002 Manifold, 316 SST, bspt ......................1
G10-004-1017 Manifold, nickel alloy, Hastelloy
CW12MW, BSPT.................................1
G10-004-1034 Manifold, cast iron, bspt......................1
G10-004-1050 Manifold, polypropylene, bspt.............1
G10-004-1053 Manifold, Kynar, bspt ..........................1
7 D10-083-2110 O-ring, center bolt, Buna.....................1
D10-083-2111 O-ring, center bolt, Viton.....................1
D10-083-2112 O-ring, center bolt, neoprene..............1
D10-083-2113 O-ring, center bolt, EPDM...................1
D10-083-2118 O-ring, center bolt, PTFE....................1
8 D10-073-2110 O-ring, inner manifold, Buna...............1
D10-073-2111 O-ring, inner manifold, Viton...............1
D10-073-2112 O-ring, inner manifold, neoprene........1
D10-073-2113 O-ring, inner manifold, EPDM.............1
D10-073-2118 O-ring, inner manifold, PTFE..............1
9 D10-074-2110 O-ring, outer manifold, Buna* .............1
D10-074-2111 O-ring, outer manifold, Viton* .............1
D10-074-2112 O-ring, outer manifold, neoprene* ......1
D10-074-2113 O-ring, outer manifold, EPDM* ...........1
D10-074-2118 O-ring, outer manifold, PTFE* ............1
D10-109-2110 O-ring, outer manifold, Buna** ...........1
D10-109-2111 O-ring, outer manifold, Viton**............1
D10-109-2112 O-ring, outer manifold, Neoprene**....1
D10-109-2113 O-ring, outer manifold, EPDM** .........1
D10-109-2118 O-ring, outer manifold, PTFE** ..........1
10 D10-035-2110 O-ring, valve seat, Buna .....................6
D10-035-2111 O-ring, valve seat, Viton .....................6
D10-035-2112 O-ring, valve seat, neoprene ..............6
D10-035-2113 O-ring, valve seat, EPDM ...................6
D10-035-2118 O-ring valve seat, PTFE .....................6
11 D10-020-1011 Valve seat, 316 SST............................6
D10-020-1017 Valve seat, Hastelloy C.......................6
D10-020-3300 Valve seat, ceramic.............................6
12 D10-021-1011 Valve, Nitronic .....................................6
D10-021-1017 Valve, Hastelloy C...............................6
D10-021-3300 Valve, ceramic.....................................6
13 D10-022-3117 Valve Spring, Elgiloy ...........................6
D10-022-3123 Valve Spring, Hastelloy C ...................6
14 D10-092-2110 Tetra Seal, Buna .................................6
D10-092-2111 Tetra Seal, Viton..................................6
D10-092-2112 Tetra Seal, neoprene ..........................6
D10-092-2113 Tetra Seal, EPDM ...............................6
D10-092-2118 Tetra Seal, PTFE.................................6
15 D10-023-1017 Retainer, valve spring, Hastelloy C.....6
D10-023-2327 Retainer, valve spring, polypropylene 6
D10-023-2328 Retainer, valve spring, Kynar..............6
16 D10-003-1012 Valve Plate, 316 SST*.........................1
D10-003-1019 Valve Plate, cast iron* .........................1
D10-003-1027 Valve Plate, nickel alloy, Hastelloy
CW12MW*...........................................1
D10-003-1050 Valve Plate, polypropylene** ..............1
D10-003-1053 Valve Plate, Kynar**............................1
17 D10-030-2010 Screw, flat-head, sst ...........................3
D10-030-2011 Screw, flat-head, Hastelloy C .............3
18 D10-047-2110 O-ring, follower, Buna-N .....................3
D10-047-2111 O-ring, follower, Viton .........................3
D10-047-2112 O-ring, follower, neoprene ..................3
D10-047-2113 O-ring, follower, EPDM .......................3
D10-047-2118 O-ring, follower, PTFE ........................3
19 D10-017-1010 Follower, 316 SST ...............................3
D10-017-1011 Follower, Hastelloy C ..........................3
20 D10-018-2312 Diaphragm, neoprene .........................3
D10-018-2313 Diaphragm, EPDM ..............................3
D10-018-2315 Diaphragm, Viton XT ..........................3
D10-018-2318 Diaphragm, PTFE ...............................3
D10-018-2320 Diaphragm, Buna-N-XS ......................3
21 D10-016-1010 Plunger................................................3
22 D10-082-2010 Set Screw............................................3
24 K10-002-1010 Cylinder Housing, Kel-Cell .................1
K10-002-1210 Cylinder Housing Assembly, Kel-Cell1–
25 D10-029-2012 Screw, cap, hex-head, sst...................1
27 D03-039-1030 Cap with O-ring, oil fill.........................1
29 D10-087-2012 Screw, cap, hex-head, sst...................1
30 D10-001-1033 Pump Housing.....................................1
31 D10-028-2012 Nut, hex, sst ........................................6
32 D10-076-2210 Elbow, brass, 1/8” npt .........................1
33 D10-077-2210 Pipe, brass, 1/8” npt ............................1
34 D10-078-2210 Cap, brass, 1/8” npt.............................1
39 D10-125-2327 Washer, dampening, polypropylene** 6
D10-125-2328 Washer, dampening, Kynar** .............6
41 D10-088-2010 Screw, cap, socket head .....................2
42 D10-100-1033 Support, face plate**...........................1
44 D10-106-2310 Gasket, cover ......................................1
45 D10-105-1010 Cover/Nameplate ................................1
46 G10-090-2010 Screw, M4 x 12....................................4
* For use with Metallic Pump Head models only.
** For use with Non-Metallic Pump Head models only.
Cylinder Housing Assembly includes cylinder
housing (24), bearing cup, adjusting plate (61),
O-ring (60), and set screws (22).
1
Ref Quantity/
No. Part Number Description Pump
Ref Quantity/
No. Part Number Description Pump

14 P400-991-2400B
24
62
61
64
65
60
50
51
52
53
54
55
56
57
58
63
Qty per piston: 4
W0021
66
59
P400 Hydraulic End Parts List

15 P400-991-2400B
Hydraulic End Service
CAUTION: Do not disassemble or service the hydraulic
end.
For as sistanc e, c ont ac t Wa nner En gin eering at
[phone] for the distributor in your area.
1Piston Assembly includes cylinder, foot, valve plunger,
O-rings, spring retainer, and springs (50-59).
50 D10-019-3110 Spring, piston return............................3
51 K10-042-1010 Retainer, spring, Kel-Cell ...................3
52 C23-009-2110 O-ring, valve cylinder,
Buna, Kel-Cell ....................................3
53 K10-045-3110 Spring, sleeve valve, Kel-Cell ...........3
54 K10-044-1010 Valve Plunger, Kel-Cell .....................3
55 K10-043-1010 Cylinder, valve, Kel-Cell ...................3
56 D10-034-2110 O-ring, Buna........................................3
57 D10-041-1010 Washer, ball retainer ...........................3
58 D10-015-3010 Ball ...................................................12
59 D10-014-1209 Piston, with foot and retainer ..............3
K10-014-1210 Piston Assembly, Kel-Cell 1...............–
60 D10-075-2110 O-ring, bearing adjusting plate, Buna.1
61 D10-012-1010 Bearing Adjusting Plate.......................1
62 D10-007-1210 (X) Cam Assembly..............................1
63 D10-085-2210 Key, shaft ............................................1
64 D10-031-2210 Seal , Buna..........................................2
65 D10-037-2110 O-ring, pump housing, Buna...............1
66 D10-040-2421 Nameplate...........................................1
Ref Quantity/
No. Part Number Description Pump
Ref Quantity/
No. Part Number Description Pump
P400 Hydraulic End Parts List

16 P400-991-2400B
104
111
112
112
111
106
107
103
105
102
108
109
108
110
109
108
108
110
113
101
100
103
Key is included with P400 Pump Assembly.
P400 Pump Assembly
W0022A
126
127
126
125
124
120
123
122
121
128
128
P400 Reducer Parts List

17 P400-991-2400B
Ref Quantity/
No. Part Number Description Pump
100 112-200 Reducer, 5:1 ratio, 56C ......................1
Reducer, 5:1 ratio, 143/145TC
( requires 112-351 Motor Adapter Kit) ..1
112-201 Reducer, 7.5:1 ratio, 56C ...................1
Reducer, 7.5:1 ratio, 143/145TC
( requires 112-351 Motor Adapter Kit) ..1
112-202 Reducer, 10:1 ratio, 56C ....................1
112-203 Reducer, 15:1 ratio, 56C ....................1
112-204 Reducer, 20:1 ratio, 56C ....................1
112-205 Reducer, 25:1 ratio, 56C ....................1
112-206 Reducer, 30:1 ratio, 56C ....................1
112-207 Reducer, 40:1 ratio, 56C ....................1
112-208 Reducer, 50:1 ratio, 56C ....................1
112-209 Reducer, 60:1 ratio, 56C ....................1
112-210 Reducer, 80:1 ratio, 56C ....................1
112-211 Reducer, 100:1 ratio, 56C ..................1
101 112-212 Kit, Protective Cover ...........................1
102 112-213 Kit, Output Flange, FB ........................1
103 112-225 Kit, Single Output Shaft, P300 ...........1
104 A04-024-1205 Assembly, M24 Coupling 7/8” x 7/8” ...1
105 M10-127-1020 Adapter, P400 .....................................1
106 S1031-012 Screw, SHCS ......................................4
107 D10-048-2010 Washer, Lock ......................................4
108 S1156-100 Washer, flat .........................................6
109 100-938 Lock Nut ..............................................3
110 100-948 Screw, HHCS ......................................3
111 D10-087-2010 Screw, HHCS ......................................8
112 D11-048-2011 Washer, flat .........................................8
113 112-217 Metering Pump Base, Carbon Steel,
epoxy painted......................................1
112-218 Metering Pump Base, 304 SST ..........1
P400 Reducer Parts List
Ref Quantity/
No. Part Number Description Pump
The following parts are used on 112-200 and 112-201
Reducers with 143/145TC only
- 112-351 Motor Adapter Kit ................................1
(includes items 120 thru 128)
120 A04-032-1033 Adapter, Motor, NEMA 143/5TC .........1
121 A04-110-2200 Hub, 7/8” M28 .....................................1
122 A04-109-2200 Sleeve, M28, Nylon .............................1
123 A04-110-2205 Hub, 5/8”, M28.....................................1
124 112-025 Kit, Shaft .............................................1
125 G25-029-2011 Screw, M10 x 1.5 .................................4
126 100-037 Washer, flat .........................................8
127 D10-087-2012 Screw, HHCS ......................................4
128 A04-085-2210 Key, 0.187 square................................2

18 P400-991-2400B
P400 Troubleshooting
Problem Probable Cause Solution
Motor/Pump
Does Not
Operate:
No power. Supply correct power according to motor requirements.
Blown fuse/tripped circuit
breaker.
Replace/reset, eliminate circuit overload.
Shaft coupling to pump not in
place.
Install proper coupling hardware (see parts list).
Current overload - motor. Motor not rated for pump operating conditions - install proper motor.
Thermal overload - motor. Motor not rated for pump and/or ambient operating conditions - supply
cooling or install proper motor.
Faulty motor drive/controller. Repair/replace.
Faulty motor. Repair/replace.
Low liquid level in supply tank
(if low-level shut-off is used).
Fill tank.
No Delivery
Supply tank empty. Fill tank.
Inlet line or strainer clogged. Clear debris and flush, or replace.
Inadequate supply pressure at
pump inlet.
Increase supply pressure by raising fluid level in tank, raising tank, or
pressurizing suction tank.
Inlet line too restrictive. Increase inlet line diameter and/or decrease inlet line length.
Fluid viscosity too high. Reduce viscosity if possible (by heat or some other means). Increase inlet
line diameter and/or decrease inlet line length. Increase supply pressure.
Vapor lock/cavitation. Increase inlet pressure. Decrease fluid temperature.
Pump valves held open or
worn out.
Clear debris and flush, or replace (see Fluid End Service)
System relief valve actuating. Adjust relief valve, or repair, clean, or replace with new relief valve.
Delivery Too
Low and/or
Erratic
Review all Probable Causes and Solutions in Problem 2 No Delivery above.
Air leak(s) in inlet line. Locate all leaks and repair.
System back pressure too low. Adjust back pressure valve to higher setting. Install back pressure valve if
none in system.
Pumped fluid characteristics
changed.
Monitor supply tank temperature to determine if fluid is too hot (leading to
cavitation) or too cold (increasing fluid viscosity). Stabilize temperature
at suitable level to resolve problem. Check for entrapped air in the fluid
supply system.
Inlet supply pressure changed. Monitor inlet supply pressure (at the pump) to determine if it is too low,
causing a starved condition/cavitation. Stabilize pressure at suitable level
to resolve problem.
Pump OK - Calibration system
or flow meter error.
Evaluate components and repair/correct problem(s).
Oil condition in pump hydraulic
end changed.
Check oil level - if low evaluate for source of leakage. Consult factory for
hydraulic end service.
Change oil per recommended guidelines in maintenance section.
Delivery Too
High and/or
Erratic.
System back pressure too low. Adjust back pressure valve to higher setting. Install back pressure valve if
none in system.
Inlet supply pressure changed. Monitor inlet supply pressure (at the pump) to determine if it is too high,
causing a “flow-through” condition. Stabilize pressure at suitable level to
resolve problem.
Pump OK - Calibration system
or flow meter error.
Evaluate components and repair/correct problem(s).

19 P400-991-2400B
P400 Replacement Parts Kits
1-2 Pump Configuration
P4 For all P400 Pumps
3 Kit Designator
KComplete Fluid End Kit*
DDiaphragm Kit*
VValve Kit
4-5 Pump Head Version
52 Metallic Pump Head
55 Non-Metallic Pump Head
6 Spring Retainers/Dampening Washers
CFor Cast Iron pump head
MFor Kynar®pump head
PFor Polypropylene pump head
SFor 316 Stainless Steel pump head
TFor Hastelloy®C pump head
XNot included in Diaphragm Kit
7 Diaphragm & O-ring Material
EEPDM
GViton®-XT
SViton®-XT (Food Contact Oil)
XViton®-XT (Synthetic Oil)
JPTFE (Food Contact Oil)
WPTFE (Synthetic Oil)
PNeoprene
RNeoprene (Food Contact Oil)
ZNeoprene (Synthetic Oil)
T Buna-N-XS
F Buna-N-XS (Food Contact Oil)
Y Buna-N-XS (Synthetic Oil)
8-9 Check Valve Material
(Valve Spring / Valve & Seat)
SS 316 SST / 316 SST
TT Hastelloy®C / Hastelloy®C
SC 316 SST / Ceramic
TC Hastelloy®C / Ceramic
XX Not included in Diaphragm Kit
6 953
2
184
Kit Designator
Part Number* Description Qty K D V
D10-018-___ Diaphragm 3 ••
D10-047-___ O-ring, follower 3 ••
D10-074-___ O-ring, outer manifold 1 •••
D10-073-___ O-ring, inner manifold 1 •••
D10-083-___ O-ring, center bolt 1 •••
D10-035-___ O-ring, valve seat 6 ••
D10-020-___ Valve seat 6 ••
D10-021-___ Valve 6 ••
D10-022-___ Valve spring 6 ••
D10-023-___ Retainer, valve spring 6 ••
A01-113-3400 Thread locker 1 ••
Hydraulic End Oil (1.5 qt)
• •
7
Order
Digit Code Description
TO ORDER REPLACEMENT PARTS KIT: A Replacement Parts Kit contains 9 digits corresponding to customer-specified design options.
Metallic Pump Head
Kit Contents
* Last four digits of part numbers with –___ refer to specic material of
construction.
Kit Designator
Part Number* Description Qty K D V
D10-018-___ Diaphragm 3 ••
D10-047-___ O-ring, follower 3 ••
D10-109-___ O-ring, outer manifold 1 •••
D10-073-___ O-ring, inner manifold 1 •••
D10-083-___ O-ring, center bolt 1 •••
D10-035-___ O-ring, valve seat 6 ••
D10-020-___ Valve seat 6 ••
D10-021-___ Valve 6 ••
D10-022-___ Valve spring 6 ••
D10-092-___ Tetra seal 6 ••
D10-023-___ Retainer, valve spring 6 ••
D10-125-___ Washer, dampening 6 ••
A01-113-3400 Thread locker 1 ••
Hydraulic End Oil (1.5 qt)
• •
Non-Metallic Pump Head
Kit Contents
* Last four digits of part numbers with –___ refer to specic material of
construction.
* Includes Hydraulic End Oil

20
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 non-contractual 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.
© 2005 Wanner Engineering, Inc. Printed in USA
P400-991-2400B 8/2005, Revised 2/2007
1204 Chestnut Avenue, Minneapolis, MN 55403
TEL: [phone] FA X: (612) 332- 6937
TOLL-FREE FAX [US only]: [phone]
www.hydra-cell.com/metering
email: [e-mail]