Hydra-Cell P500 Owner's manual

W0303A
TM
P500 Metering Pump
P500-991-2400A
Installation, Operation & Maintenance
1204 Chestnut Avenue, Minneapolis, MN 55403
Tel: [phone] Fax: [phone]
Toll-free fax [US only]: [phone]
www.hydra-cell.com/metering
email: [e-mail]

2P500-991-2400A
P500 Contents
Component Identication
Oil Fill Cap ID Plate
Outlet
Reducer
Inlet
Pump Assembly
Fluid End
Pump Assembly
Hydraulic End
Oil Drain
Diaphragms per Liquid End 5 (non Kel-Cell pistons)
Flow Control Electronic variable speed drive
Steady State Accuracy ±1%
Linearity ±3%
Repeatability ±3%
Maximum Pressure
Metallic Head: 2500 psi (173 bar)
Maximum Inlet Pressure 500 psi (35 bar)
Fluid Operating Temperatures*
Metallic Head: 250°F (121°C)
* Consult factory for correct component selection for
 temperaturesfrom160˚F(71˚C)to250˚F(121˚C).
Inlet Port 1 1/4 inch NPT or BSPT
Discharge Port 3/4 inch NPT or BSPT
Maximum Solids 500 microns
Shaft Rotation Bi-directional
Materials Used See Replacement Parts Kits Section
 forindividualpumpmaterials.
Oil Capacity 2.2USquart(2.1liters)
Weight
 MetallicHead: 192.1lbs(87.1kg)
Page
Operation................................................................................2
Specications..........................................................................2
Dimensions.............................................................................4
Installation...............................................................................5
Calibration...............................................................................7
Maintenance............................................................................7
Fluid End Service ...................................................................8
Fluid End Parts List ..............................................................11
Hydraulic End Parts List .......................................................13
Hydraulic End Service ..........................................................14
Reducer Parts List.................................................................15
Troubleshooting.....................................................................17
Replacement Parts Kits........................................................18
Warranty................................................................................19
W0303A
P500 SpecicationsP500 Operation
Hydra-Cell Metering Solutions Pumps are hydraulically-
actuated, hydraulically-balanced diaphragm metering pumps
that exceed API 675 performance standards of ±1% steady state
accuracy,±3%linearityand±3%repeatability.
Due to their multiple diaphragm design, the P Series
meteringpumps,withtheexceptionoftheP100,providevirtually
“pulse-free”linearow.Unlikeconventionalsinglediaphragm
meteringpumps,thislinearowreducestheneedforpulsation
dampeners and increases the reliability, performance, and
safetyofthemeteringpumpsystem.
Pump operation and plunger activation are accomplished
throughacrankshaft(P100,P200andP300)orwobbleplate
(P400,P500andP600).Horizontaldiskcheckvalvesallowfor
the pumping of particulates that ordinarily collect on vertical
ball check valves common to conventional metering pumps.
P Series pumps utilize speed to adjust ow rate through a
motorandvariable-frequencydrive(VFD),eliminatingtheneed
formechanicaladjustment.

3P500-991-2400A
P500 Specications (Cont’d)
Performance Maximum Flow at Designated Pressure - Imperial *
*Capacity data shown is for pumps with elastomeric diaphragms. Consult factory for performance characteristics of pumps with PTFE diaphragms.
()RequiredMotorhp
Performance Maximum Flow at Designated Pressure - Metric *
*Capacity data shown is for pumps with elastomeric diaphragms. Consult factory for performance characteristics of pumps with PTFE diaphragms.
()RequiredMotorkW
Metallic Pump Heads (gph) Pump
rpm
Gear
Ratio
Motor
rpm
100 psi 500 psi 1500 psi 2500 psi
17.48(¼) 16.96(½) 15.74(1½) 14.47(1½) 30 60:1
1800
20.97(¼) 20.43(½) 19.11(1½) 17.71(2) 36 50:1
26.39(¼) 25.73(¾) 24.20(1½) 22.67(3) 45 40:1
35.27(¼) 34.47(¾) 32.63(2) 30.80(3) 60 30:1
42.37(¼) 41.47(¾) 39.37(2) 37.31(3) 72 25:1
53.03(¼) 51.97(¾) 49.49(2) 47.07(3) 90 20:1
70.78(½) 69.46(1) 66.35(3) 63.34(5) 120 15:1
106.3(½) 104.4(1½) 100.1(3) 95.88(5) 180 10:1
141.8(½) 139.4(1½) 133.8(5) 128.4(7½) 240 7.5:1
212.8(1) 209.4(2) 201.2(7½) 193.5(10) 360 5:1
283.9(1½) 279.4(3) 268.7(7½) 258.6(15) 480 7.5:1 3600
425.9(1½) 419.3(5) 403.6(15) 388.7(20) 720 5:1
Metallic Pump Heads (lph) Pump
rpm
Gear
Ratio
Motor
rpm
7 bar 34 bar 103 bar 172 bar
55.14(0.37) 53.50(0.75) 49.66(2.2) 45.641(3) 25 60:1
1500
66.16(0.37) 64.44(0.75) 60.28(2.2) 55.85(3) 30 50:1
83.25(0.37) 81.16(0.75) 76.32(2.2) 71.50(3) 37.5 40:1
111.26(0.37) 108.75(0.75) 102.92(2.2) 97.16(4) 50 30:1
133.66(0.37) 130.82(1.1) 124.19(2.2) 117.69(4) 60 25:1
167.27(0.37) 163.93(1.1) 156.11(2.2) 148.49(4) 75 20:1
223.28(0.55) 219.11(1.1) 209.29(3) 199.81(4) 100 15:1
335.31(0.75) 329.47(1.5) 315.67(4) 302.45(5.5) 150 10:1
447.33(1.1) 439.83(2.2) 422.05(4) 405.10(7.5) 200 7.5:1
671.4(1.5) 660.6(3) 634.8(7.5) 610.4(11) 300 5:1
895.4(3) 881.3(5.5) 847.6(7.5) 815.7(11) 400 7.5:1 3000
1343.5(4) 1322.7(7.5) 1273.1(11) 1226.3(11) 600 5:1

4P500-991-2400A
P500 Dimensions
P500 Models with Metallic Pumping Head
W0316A
1.50
(38.1)
13.90
(353.1)
13.00
(330.2)
14.50
(368.3)
24.00
(609.6)
22.00
(558.8)
Ø0.56
(14.3) 4X
G
D
C
E
A
B
H
1-1/4" NPT or
1-1/4" BSPT
3/4" NPT or
3/4" BSPT
F
10.13
(257.2)
4.84
(122.8)
I
Input Frame
Size A B C D E F
G
(Square
Key)
H I
NEMA 56C 21.76(552.6) 19.05(495.3) Ø6.54(Ø166) Ø4.50(Ø114.3) Ø0.62(Ø15.7) 13.22(335.9) 0.187(4.75) 13.53(343.7) 11.36(288.5)
NEMA
143/145 TC 21.76(552.6) 19.05(495.3) Ø6.54(Ø166) Ø4.50(Ø114.3) Ø0.87(Ø22.2) 13.22(335.9) 0.187(4.75) 13.53(343.7) 11.36(288.5)
NEMA
182/183TC 26.07(585) 20.36(517.1) Ø9.17(Ø233) Ø8.50(Ø218.9) Ø1.12(Ø26.6) 13.77(349.75) 0.25(6.35) 14.84(376.9) 12.68(322)
IEC 71 B5 21.64(549.7) 18.93(480.8) Ø6.54(Ø166) Ø4.33(Ø110) Ø0.55(Ø14) 13.42(340.7) 0.196(5) 13.41(340.6) 11.24(285.4)
IEC80B5 22.42(569.6) 19.71(500.6) Ø7.87(Ø200) Ø5.12(Ø130) Ø0.75(Ø19) 13.42(340.7) 0.236(6) 14.20(360.6) 12.02(305.3)
IEC 90 B5 22.42(569.6) 19.71(500.6) Ø7.87(Ø200) Ø5.12(Ø130) Ø0.94(Ø24) 13.42(340.7) 0.314(8) 14.20(360.6) 12.02(305.3)
IEC 100/112
B14 21.64(549.7) 18.93(480.8) Ø6.30(Ø160) Ø4.33(Ø110) Ø1.10(Ø28) 13.42(340.7) 0.314(8) 13.41(340.6) 11.24(285.4)
Dimensions in Inches (Millimeters)

5P500-991-2400A
P500 Installation
Location
Locatethepumpasclosetothesupplysourceaspossible.
Installthepumpsystem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.
Flow rateisdeterminedbymotorspeed,whichiscontrolled
using an inverterdutyconstant torquemotorand VFD. Flow
ratefunctionscanalsobeeasilycontrolledusingtheHydra-Cell
ControlFreakandappropriatemotor.
Accessories
Consult installation drawing below for typical metering uid
system components. Contact Wanner Engineering or the
distributorinyourareaformoredetails.
W0323A
(To process)
Pulsation
Dampener
(Optional)
Relief
Valve
Flanges & Manifolds
Ball Valve
Y-Strainer
Isolating
Valve
Calibration
Cylinder
Pressure
Gauge
Back Pressure
Valve
P-Series
Metering Pump
Typical Metering Installation
Controllers
& Motors
Important Precautions
Adequate Fluid Supply. To avoid cavitation and
prematurepumpfailure,besurethatthepumpwillhave
anadequateuidsupplyandthattheinletlinewillnotbe
obstructed.SeeInlet Piping.
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.
Safety Guards.Followallcodesandregulationsregarding
installationandoperationofthepumpingsystem.
Shut-O󰀨 Valves. Never installshut-o󰀨 valves between
thepumpandreliefvalve,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uidapplications
• Chemical compatibility problems
• Hot ambient temperatures (above 110°F)

6P500-991-2400A
P500 Installation (Cont’d)
Inlet Piping
Provide for permanent or temporary installation of a compound
pressure gauge to monitor the inlet pressure. To maintain
maximumow,thepumpinletshouldbeunderooded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uidtoescape.Thetanksizeshouldbeat
leasttwicethemaximumpumpow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ttings(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500psi(35bar).Forhigherpressures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 ow
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 shuto󰀨 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.
Safety Precautions
General remarks
These safety / installation instructions contain fundamental
informationandprecautionarynotesandmustbekeptavailable
toallassociatedwiththeoperationofthepump.Pleaseread
themthoroughlypriortoinstallation,electricalconnectionand
commissioningoftheunit.Itisimperativethatallotheroperating
instructionsrelatingtothecomponentsofindividualunitsare
followed.
These safety / installation instructions do not take local
regulationsintoaccount.Theoperatormustensurethatsuch
regulationsareobservedbyall,includingthepersonnelcarrying
outtheinstallation.
Each pumpmustbe labeled bythe end userto warnofany
hazardsthatthesystemprocessmayproduce;e.g.corrosive
chemicalsorhotprocessetc.
All personnel involved in the operation, maintenance, inspection
andinstallationofthepumpmustbefullyqualiedtocarryout
the work. The personnel’s responsibilities, competence and
supervisionmustbeclearlydenedbytheoperator.Totheextent
thatifthepersonnelinquestionisnotalreadyinpossession
oftherequisiteknowhow,appropriatetrainingandinstruction
mustbeprovided.Inaddition,theoperatorisresponsiblefor
ensuringthatthecontentsoftheoperatinginstructionsarefully
understoodbyalltheresponsiblepersonnel.
WheninstallingaHydra-Cellpumpinconjunctionwithamotor
ormotorandfrequencycontrollertherelevantmanualsmust
bereferredtoforelectromagneticcompatibility.Theinstallation
shouldconformtoEN61800andEN60204asapplicable.
All safety instructions in this manual and all relevant local health
andsafetyregulationsmustbefollowed.
Attention must be paid to the weight of the pump before
attemptingtolifteithermanuallyorselectingappropriatelifting
equipment.

7P500-991-2400A
P500 Installation (Cont’d)
P500 Maintenance
Note: The numbers in parentheses are Reference Numbers
located in the Parts List exploded views of this manual.
Periodically
CAUTION: Do not turn the drive shaft while the oil reser voir
is empty.
CAUTION: Do not leave contaminated oil in the pump
housing or leave the housing empty. Remove contaminated
oil as soon as discovered and replace with clean oil.
1. Checkinletpressureperiodicallywithgauge.
2. Changeoilaccordingtohoursguidelinesintable.
3. Changeoilasfollows:
a.Removebrasscap(26),andallowoiland 
contaminantstodraincompletely.Catchoil 
anddisposeofproperly.
b.UsesuitableHydra-Oilfortheapplicationand
pumpcomponents.
Pump Operation Hours Between Oil Changes
at Various Process Fluid Temperatures
<90°F <139°F <180°F
Pressure (32°C) (60°C) (82°C)
Metallic Pump Head
<1500 psi (104 bar) 4,000 3,000 2,000
<2500 psi (173 bar) 1,500 1,250 1,000
Note: Minimum oil viscosity for proper hydraulic end
lubricat ion is 16-20 cST (80-100 SSU). P- S eries replac ement
parts kits (complete kits and diaphragm kits) include
suitable oil for each P Series pump conguration.
CAUTION: If you are losing oil but don’t see any external
leakage, or if the oil becomes discolored and contaminated,
the diaphragm (21) may be damaged. Refer to the Fluid End
Service and Troubleshooting Sections. Do not operate the
pump with a damaged diaphragm.
Initial Start-Up Procedure
Before you start the pump, be sure that:
1. Allshut-o󰀨valvesareopen,andpumphasadequatesupply
ofuid.
2. Allconnectionsaretight.
3. The oil level is 1/4 inch (6 mm) above the cast surface in the
upperoilreservoir.
4. Openprimingvalveonsystembackpressurevalvesopump
starts under minimum pressure. See Typical Metering
Installationdrawing.
Turnonpowertopumpmotorand:
1. Checkinletpressureorvacuum.Tomaintainmaximumow,
pumpinletshouldbeunderoodedsuctionconditionsatall
times.Inletpressuremustnotexceed500psi(35bar).
2. Observeanyerraticnoiseorow.
3. Jogpumponando󰀨untiluidcomingfromprimingvalve
isair-free.
4. Closeprimingvalve.
5. Performpumpcalibration.SeeCalibrationProcedure.
Calibration
Note: Each metering pump or pump system must be calibrated
to deter mine the pump speed required for the desired ow rate.
Accurate calibration dependsonpumpdischargepressureand
systemconditions.Whencalibratingthepumporsystem,itis
usefultoplotcapacitycurvesforfuturereference.Observeon
thecurve,thatpumpcapacitydecreasesslightlyasdischarge
pressureincreases.
In order to achieve the best possible results, perform calibration
underactualprocessconditions.Followthesesteps:
1. Run pump for 20 minutes at actual process conditions.  If
processsystemcannotbeused,circulatebacktosupplytank
throughpressurereliefvalve(seeTypicalMeteringInstallation
drawing).Ifrequiredsystempressureislessthan50psi(3.5
bar)backpressurevalvemustbeinstalledandsettoproduce
minimumof50psi(3.5bar)pressureatpumphead.
2. Determine maximum pump speed required for all system
conditionsthatneedtobesatised.Measurepumpdelivery
atthismaximumspeedusingsystemcalibrationcylinder,ow
meter,orsimilarcontainer.Thisisthe“ratedcapacity”forpump.
3. Measurepumpdeliveryat100%,75%,50%,25%,and10%of
maximumspeedjustdetermined.Letpumprunfor5minutes
ateachspeedsettingbeforetakingcapacitymeasurement.

8P500-991-2400A
P500 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uidend.
Caution: Disassembly of the hydraulic end of the pump
should be performed only by a qualied technician. For
assistance, contact Wanner Engineering (612-332-5681) or
the distributor in your area.
CAUTION:  Do not remove the four socket-head capscrews
(29)thatgothroughthecylinderhousing(23),unlessyouare
repairingthehydraulicendofthepump.
1. Remove Manifold (4),
Valve Plate (24)
 a. Manifold (4.)Use8mmhexbitsocketincludedin
Wanner Tool Kit to remove 12 capscrews (2) and ve
capscrews(1)atfrontofmanifold.Removeandinspect
manifoldforwarpingorweararoundinletandoutletports
andowchannels.Ifwearisexcessivereplacemanifold.
Tocheckifmanifoldiswarped,placestraightedgeacross
it; check both sides.  A warped manifold should be
replaced.
 b. Valve Plate (24.)Using8mmhexbitsocketremove
capscrew(22).Removeandinspectvalveplate(inlike
manner as manifold) for excessive wear or warping.
Replaceifnecessary.
CAUTION: Don’t turn the pump drive shaft while the
manifold and valve plate are o󰀨 the pump, except when
removing diaphragms or repriming the hydraulic cells.
2. Remove and Inspect
Valves (9-20)
Note: Wanner Valve Kits include items and all O-rings for
sealing the manifold to the valve plate. The ve inlet and
ve outlet valve assemblies are di󰀨erent in size and face
in opposite directions.
 a. Remove inlet valve seat (10) using seat puller tool
includedinWannerToolKit.Inspectvalveseatforwear,
andreplaceifnecessary.
Note: Whenever any valve or seat is replaced it is
recommended to replace all valve assemblies to ensure
the most reliable operation.  All necessary parts are
includedinareplacementValveKit.
 b. Removeremaininginletvalvecomponents(11-14)and
outletvalvecomponents(17-20)byhandorwithsmall
needlenosepliers.
 c. Check spring retainers (14, 20) and replace if worn,
cracked,ordamaged.
 d. Checkvalvesprings(12,19)andreplaceifworn,broken,
orshorterthannewspring.Neverattempttostretchold
spring.
 e. Checkvalves(11,18)forwearordamageandreplace
if necessary.  Polishing of valves during operation is
normal.Ifyoucanfeelaridgeinvalvesurface,valve
shouldbereplaced.
  Note:Pumpswithplasticspringretainers(14,20)include
Tetra Seal (13, 17 - square section O-ring) between
springretainerandvalveseat.Pumpswithmetalspring
retainersdonotincludeTetraSeal.
 f. Reinstallvalveassemblies:
  • Cleanvalveportsandshouldersinvalveplate(24)with
Scotch-Britepadorneemerycloth.Washvalveplate
aftercleaning,andlubricatevalveportswithcompatible
grease,oil,orpetroleumjelly.
  • Install new O-rings (9, 15) on seats (10, 16) and
lubricateallO-rings.
  • InletValves(vecenter,largervalves).Insertspring
retainer(14)intovalveplate(24),followedbyTetraseal
(13)ifspring retaineris plastic. Insert spring(12) into
retainer,followedbyvalve(11)onspring.Finally,insert
seat(10)withnewO-ringintovalveborewithlargerI.D.
chamfer(seatingsurface)facingdown,towardsvalve.
  • OutletValves(veouter,smallervalves).Insertoutlet
seat(16)withnewO-ringintovalveborewithlargerI.D.
chamfer(seatingsurface)facingup.InsertTetraSeal
(17)ifvalvespringretainersareplastic.Insertvalve(18)
andspring(19)onseat.Finally,inser tspringretainer(20)
intovalvebore.
  • Makesurespringsareallproperlynestedintospring
retainerstoensurepropervalveperformance.

9P500-991-2400A
P500 Fluid End Service (Cont’d)
3. Inspect and Replace
Diaphragms (21)
 a.Lift diaphragm(21)byoneedge,and turnpump shaft
(use the shaft rotator from the Wanner Tool Kit) until
thediaphragmmovesupto“topdeadcenter”.This
willexposemachinedcross-holesinvalveplunger(51)
behinddiaphragm.
 b. Insertplungerholder(from the Wanner Tool Kit)through
oneofmachinedcrossholestoholddiaphragmup.Don’t
remove tool until new diaphragm is installed in step f
below.
 c. Unscrewdiaphragm(21).Usea5/16-in.(8-mm)open-
endwrench,andturncounterclockwise.
 d.Remove diaphragm 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:
• Puncture.Usuallycausedbysharpforeignobjectin
uid.
• Diaphragm pulled awayfromcenterscreworfrom
cylindersides.Usuallycausedbyuidbeingfrozenin
pump,orbyover-pressurizationofpump.
• Diaphragm becoming stiff and losing flexibility.
Usuallycausedbypumpinguidthatisincompatiblewith
diaphragmmaterial.
• Diaphragm edge chewed away.Usuallycausedby
over-pressurizingsystem.
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
ush the reservoir completely (as outlined below)
and rell it with fresh oil. Never let the pump stand
with foreign material or water in the reser voir, or with
the reservoir empty.
 e.Cleanawayanyspilledoil.
 f. Installnewdiaphragm(oroldone,ifnotdamaged),and
tightento10in.-lbs(110N-cm).
 g.Repeataboveinspectionprocedure(andreplacement,
ifnecessary)withotherfourdiaphragms.
4. Flush Contaminant from
Hydraulic End
(only if a diaphragm has ruptured)
 a.Withvalveplateandmanifoldstillremoved(seeabove),
removethebrasscap(26)allowalloilandcontaminant
todrainout.
 b. Fillreservoirwithcompatiblesolvent.Manuallyturnpump
shafttocirculatecompatiblesolventanddrain.Usethe
shaftrotatorprovidedinWannerToolKit(PartNo.A03-
175-1103).Disposeofcontaminateduidproperly.
CAUTION: If you have an EPDM diaphragm, or if food
grade oil is in the reservoir, do not use kerosene or
solvents. Instead, ush with the same lubricant that
is in the reservoir.
 c. Repeatstepbushingprocedure
 d.Fillreservoirwithfreshoilandmanuallyturnpumpshaft
tocirculateoil.Drainoil.
Note: P Series replacement parts kits (complete kits
and diaphragm kits) include the correct oil for each
specic P Series pump conguration.
 e.Rellreservoirwithfreshoil.Ifoilappearsmilky,thereis
stillcontaminantinreservoir.Repeatstepscandduntil
oilappearsclean.

10 P500-991-2400A
P500 Fluid End Service (Cont’d)
5. Prime Hydraulic Cells
 a. With pump horizontal and the fluid end head
removed, ll reservoir with appropriate Hydra oil for
application.  Have catch basin for oil that leaks from
behinddiaphragmswhenpriming.Catchoilanddispose
ofproperly;do not reuse.
 b. Allairinoilwithinhydrauliccell(behinddiaphragm)must
be forced out by turning shaft (thus pumping piston).
ShaftRotatorisincludedinWannerToolKit.Rotateshaft
tworevolutionsandrellreservoir.Rotateittwomore
revolutionsandrellagain.Continuetodothisuntiloil
thatisbeingpumpedfrombackofallvediaphragmsis
freeofair.
 c. Wipe excess oil from cylinder housing (23) and
diaphragms(21).
 d. Ensurethatoillevelis1/4in(6mm)abovecastsurface
inupperoilreservoir.
 e.Replaceoilllcap(28).
6. Reinstall Valve Plate (24),
Manifold (4)
 a.Reinstallvalveplate(24),withvalveassembliesinstalled
asoutlinedabove,oncylinderhousingcenterspudand
alignmentpin(8).
 b.Installcapscrew(22)withatwasher(3)throughcenter
holeinvalveplateandtorqueto45ft-lbs(60N-m).
 c.InstallnewO-rings(5,6,7)intogroovesinfrontsideof
valveplate.Usegreaseorpetroleumjellytoholdinplace.
 d.Reinstallmanifold(4)overalignmentpin(8),engaging
centerspudofmanifoldintocenterofvalveplate.
 e.Installcapscrews(1)with atwashers(3)throughve
centerholesinmanifold.Threadeachcapscrewin
severalturns,butdonottorque.
 f.Installcapscrews(2)withatwashers(3)throughtwelve
outer holes at perimeter of manifold.  Thread each
capscrewinseveralturns,butdonottorque.
 g.  Return to ve capscrews at center of manifold and
alternately tighten opposite bolts until all are secure.
Torqueto45ft-lbs(60N-m).
 h.Returntotwelvecapscrewsatperimeterofmanifoldand
alternately tighten opposite bolts until all are secure.
Torqueto45ft-lbs(60N-m).
 i.Recheckallcapscrewsfortightnessandpropertorque,
starting with ve at center of manifold, then twelve at
perimeter.