Wanner Engineering Hydra-Cell T100 Series Owner's manual

W0499D
1204 Chestnut Avenue, Minneapolis, MN 55403
Tel: [phone] Fax: [phone]
Toll-free fax [US only]: [phone]
www.hydra-cell.com
email: [email protected]
Models: T100K and T100M
T100 Series Medium Pressure
177-999H
Installation, Operation & Maintenance

2177-999H
Component Identication
Maximum Pressure T100K 3000 psi (207 bar)
T100M 3500 psi (241 bar)
Flow Capacities @ Maximum Pressure
rpm gpm I/min BPD
T100K 450 96.0 366.1 3292
T100M 450 76.5 289.6 2623
Delivery
Pressure psi (bar) gal/rev liters/rev
T100K 500 (34) 0.107 0.406
1500 (103) 0.105 0.397
3000 (207) 0.101 0.384
T100M 500 (34) 0.091 0.345
1750 (121) 0.089 0.338
3500 (241) 0.086 0.327
rpm 450 Maximum
200 M ini mu m (Consult factory for speeds less than 200 rpm)
Maximum Inlet Pressure 500 psi (34 bar)
Operating Temperature
Maximum: 180 F (82.2 C)
Minimum: 40 F (4.4 C)
(contact factory for temperatures outside this range)
Maximum Solids Size 800 microns
Input Shaft Left or Right Side
T100 Series Medium Pressure - Contents
T100 Series Medium - Specications
Page
Component Identication ........................................................2
Specications..........................................................................2
Dimensions .............................................................................4
Installation ...............................................................................8
Maintenance..........................................................................11
Service (Fluid End)................................................................12
Service (Hydraulic Section)...................................................13
Service (Power End) .............................................................18
Troubleshooting.....................................................................21
Torque Specications........................................................... 22
Oil Level Monitor .................................................................. 23
Fluid End Parts......................................................................24
Hydraulic Section Parts........................................................ 26
Power End Parts ...................................................................28
Tool Kit Parts........................................................................ 30
Pump Storage ...................................................................... 30
Replacement Parts Kits ........................................................31
Warranty................................................................................32
Inlet Ports 3-1/2 inch Class 300 RF ANSI Flange or
2-1/2 inch NPT
Discharge Ports 1-1/2 inch Class 2500 RTJ ANSI Flange or
1-1/2 inch NPT
Shaft Diameter 3 inch (76.2 mm)
Shaft Rotation Uni-directional (see rotation arrows)
Oil Capacity 18 US quarts (17 liters) - blank back cover
20.5 US quarts (19.4 liters) - oil level back cover
Weight (dry) Metallic Heads: 1100 lbs (499 kg)
Fluid End Materials
Diaphragm Following Screw: 316 Stainless Steel
Outlet Valve Retainer: 316 Stainless Steel
Plug-Outlet Valve Port: 316 Stainless Steel
Inlet Valve Retainer: 316 Stainless Steel
Power End Materials
Crankshaft: Forged Q&T Alloy Steel
Connecting Rods: Ductile Iron
Crossheads: 12L14 Steel
Crankcase: Ductile Iron
Bearings: Spherical Roller/Journal (main)
Steel Backed Babbit (crankpin)
Bronze (wristpin)
W0499D
Outlet
Oil Fill Cap
with Dipstick
Inlet
Crankshaft
Hydraulic Section
Fluid End
Power End
Oil Fill Cap
Oil Drain Plug
Float Switch &
Sight Glass

3177-999H
RPM
Liters Per Minute
Gallons Per Minute
W0504C
200 225 325 375 425 450
50.0
20.0
47.0
44.0
41.0
38.0
35.0
32.0
29.0
26.0
23.0
124.0
130.0
136.0
142.0
148.0
154.0
118.0
166.0
172.0
178.0
184.0
189.0
160.0
82.0
88.0
94.0
100.0
106.0
112.0
76.0
275 400350300250
17.0
70.0
64.4
500 psi (34 bar)
1500 psi (103 bar)
3000 psi (207 bar)
500 psi (34 bar)
1750 psi (121 bar)
3500 psi (241 bar)
T100M
T100K
Performance
RPM
12
NPSHr (feet of water)
NPSHr (meters of water)
13
14
15
16
17
18
3.75
4
4.25
4.5
4.75
5
5.25
W0505B
5.5
200 350 450300 400 500250
T100K, T100M
Net Positive Suction Head –
NPSHr
T100 Series Medium - Specications (Cont’d)
Attention!
When sizing motors with variable speed drives (VFDs), it is
very important to select a motor and a VFD rated for constant
torque inverter duty service and that the motor is rated to
meet the torque requirements of the pump throughout desired
speed range.
Calculating Required
Horsepower (kW)*
gpm x psi
1,460
= electric motor HP*
l/min x bar
511
= electric motor kW*
* HP/kW is required application power.

4177-999H
T100 Series Medium Pressure - Dimensions
W0543C
3.50
(89)
29.11
(739)
0.75 X 0.75 Keyway
(19.05 X 19.05)
Minimum full key
4.83
(123)
Center of mass
W0544D
Ø 3.00
(76.2)
18.54
(471)
2 X .06
(2)
Top View
Front View
inches
(mm)
Flange Version

5177-999H
T100 Series Medium - Dimensions (Cont’d)
Bottom View
Side View
8.20
(208)
ASME B16.5
1-1/2”CLASS 2500 RTJ
(4x 1 1/8-7 UNC-2B)
Outlet Both Sides
W0545C
13.55
(344)
10.25
(260)
13.39
(340)
19.44
(494)
43.00
(1092)
ASME B16.5
3-1/2”CLASS 300 RF
(8x 3/4-10 UNC-2B)
Outlet Both Sides
4.80
(122)
Center of mass
W0546D
20.80
(528)
8.27
(210)
12.06
(306)
4 X Ø 0.88
(22.23)
Mounting Holes
4.09
(104)
3.24
(82)
3/4-14 NPT
Center of mass
inches
(mm)
Flange Version

6177-999H
T100 Series Medium Pressure - Dimensions
W0507D
29.11
(739)
0.75 X 0.75 Keyway
(19.05 X 19.05)
3.50
(89) Minimum full key
4.83
(123)
Center of mass
Ø 3.00
(76.2)
15.65
(397)
16.00
(406)
W0508D
2 X .18
(4)
Top View
Front View
inches
(mm)
NPT Version

7177-999H
T100 Series Medium - Dimensions (Cont’d)
Bottom View
Side View
8.20
(208)
1-1/2 NPT Outlet Both Sides
W0509D
13.43
(341)
10.13
(257)
5.55
(141)
11.55
(293)
17.36
(441)
2-1/2 NPT Intlet Both Sides
40.14
(1019)
Center of mass
1/2-14 NPT
1/2-14 NPT
1/2-14 NPT
W0510D
20.80
(528)
8.27
(210)
12.06
(306)
4.09
(104)
4 X Ø0.88
(22)
Mounting Holes
1.85
(47)
Center of mass
3/4-14 NPT
inches
(mm)
NPT Version

8177-999H
T100 Series Medium Pressure - Installation
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” and consult
NPSH chart.
Positive Displacement. This is a positive-displacement pump. Install
a relief valve downstream from the pump. See “Discharge Piping”.
Safety Guards. Install adequate safety guards over all pulleys,
belts, and couplings. Follow all local codes and regulations regarding
installation and operation of the pumping system.
Shut-O󰀨 Valves. Never install shut-o󰀨 valves between the pump and
discharge pressure regulator, relief valve, or in the regulator bypass line.
Freezing Conditions. Protect the pump from freezing. See also the
Maintenance Section.
Vacuum at Outlet. Do not allow a vacuum at the pump outlet during
shutdown. A vacuum can damage the diaphragm at start-up. If there is a
vacuum at the pump outlet, allow atmospheric pressure at the outlet for
30 minutes before starting. Wanner Engineering recommends installing
an outlet check valve with a 65 psi (4.5 bar) cracking pressure to prevent
a vacuum condition during shutdown.
Consult the Factory for the following situations:
• Fluid temperature applications – above 180° F (82° C) or below 40° F (4.4°
C)
• Pressure feeding of pumps over 500 psig (34.5 bar)
• Viscous uid applications above 100 Cps
• 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 uid temperature,
and full horsepower load — an oil cooler may be required
• Pump rpm less than 200
Location
Locate the pump as close to the uid supply source as
possible.
Install it in a lighted clean space where it will be easy to
inspect and maintain. Allow room for checking the oil level,
changing the oil (drain plug on the bottom of pump), and
removing the pump head components (inlet and discharge
retainer plates, manifold, and related items).
Rigging Provisions and
Procedures
Lift pump by attaching rigging to all four eyebolts (14).
Adjust attachment lengths to keep pump level during lifting.
CAUTION: Eyebolts (14) are rated to lift the weight of
the pump only. Also see center of mass references in
the Dimension Drawings Section.
Mounting
CAUTION: The pump shaft rotation direction is
indicated by arrows on the pump housing.
To prevent vibration, mount the pump and motor securely
on a level rigid base.
On a belt-drive system, align the sheaves accurately; poor
alignment wastes horsepower and shortens the belt and
bearing life. Make sure the belts are properly tightened,
as specied by the belt manufacturer.
On a direct-drive system, align the shafts accurately.
Unless otherwise specied by the coupling manufacturer,
maximum parallel misalignment should not exceed 0.015
in. (0.4 mm) and angular misalignment should be held to 1°
maximum. Careful alignment extends life of the coupling,
pump, shafts, and support bearings. Consult coupling
manufacturer for exact alignment tolerances.
MINIMUM LIQUID LEVEL
VORTEX
BREAKER
WEIR
PLATE
FEED IN
LINE VELOCITY
5-15 FT/SEC.
LONG-RADIUS
ELBOW
SUCTION LINE
VELOCITY 1-3 FT/SEC.
FULL-OPENING
VALVE
ECCENTRIC REDUCER
W/ FLAT SIDE UP
(OPTIONAL)
SUCTION
STABILIZER
AMPLE NPSHA
PUMP FLUID
CYLINDER
LINE VELOCITY
3-10 FT/SEC.
MINIMUM NUMBER OF ELBOWS
WITH AMPLE PIPE SUPPORTS
(OPTIONAL)
PULSATION
DAMPENER
RELIEF VALVE W/
10 PERCENT MAX.
PRESSURE
ACCUMULATION
PRESSURE
GAUGE
PRESSURE
GAUGE
Typical Installation
START-UP AND
CAPACITY-CONTROL
VALVE
W0511A
CHECK VALVE
65 psi cracking pressure
OIL LEVEL
MONITOR

9177-999H
T100 Series Medium - Installation (Cont’d)
Do not use a line strainer or lter in the suction line unless
regular maintenance is assured. If used, choose a top loading
basket. It should have a free-ow area of at least three times
the free-ow area of the inlet.
Install piping supports where necessary to relieve strain on the
inlet line and to minimize vibration.
Inlet Piping (Pressure Feed)
Provide for permanent or temporary installation of a vacuum/
pressure gauge to monitor the inlet vacuum or pressure.
Pressure at the pump inlet should not exceed 500 psi (34.5 bar);
if it could get higher, install an inlet pressure reducing regulator.
Do not supply more than one pump from the same inlet line.
Inlet Calculations
Acceleration Head
Calculating the Acceleration Head
Use the following formula to calculate acceleration head losses.
Subtract this gure from the NPSHa, and compare the result to
the NPSHr of the Hydra-Cell pump.
Ha = (L x V x N x C) ÷ (K x G)
where:
Ha = Acceleration head (ft of liquid)
L = Actual length of suction line (ft) — not equivalent length
V = Velocity of liquid in suction line (ft/sec) [V = GPM x (0.408
÷ pipe ID2)]
N = rpm of crank shaft
C = Constant determined by type of pump — use 0.066 for
the T100K,M Hydra-Cell pumps
K = Constant to compensate for compressibility of the uid —
use: 1.4 for de-aerated or hot water; 1.5 for most liquids;
2.5 for hydrocarbons with high compressibility
G = Gravitational constant (32.2 ft/sec2)
Friction Losses
Calculating Friction Losses in Suction Piping
When following the above recommendations (under “Inlet
Piping”) for minimum hose/pipe I. D. and maximum length,
frictional losses in the suction piping are negligible (i.e., Hf = 0)
if you are pumping a water-like uid.
When pumping more-viscous uids such as lubricating oils,
sealants, adhesives, syrups, varnishes, etc.; frictional losses in
the suction piping may become signicant. As Hf increases, the
available NPSH (NPSHa) will decrease, and cavitation will occur.
In general, frictional losses increase with increasing viscosity,
increasing suction-line length, increasing pump ow rate, and
decreasing suction-line diameter. Changes in suction-line
diameter have the greatest impact on frictional losses: a 25%
increase in suction-line diameter cuts losses by more than two
times, and a 50% increase cuts losses by a factor of ve times.
Consult the factory before pumping viscous uids.
Minimizing Acceleration Head and Frictional Losses
To minimize the acceleration head and frictional losses:
• Keep inlet lines less than 6 ft (1.8 m) or as short as possible
Accessories
Consult installation drawing below for typical system components.
Contact Wanner Engineering or the distributor in your area for
more details.
Inlet Piping (Suction Feed)
Install drain cocks at any low points of the suction line, to permit
draining in freezing conditions.
Provide for permanent or temporary installation of a vacuum
gauge to monitor the inlet suction. To maintain maximum ow,
NPSHA must exceed NPSHR (See chart in Specications
Section). Do not supply more than one pump from the same
inlet line if possible.
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 ve times the maximum pump ow rate (in gpm or lpm).
For example: at a maximum rate of 96 gpm, since trapped air
takes ve minutes to escape from water, 5 x 96 = 480 gallons
for a recommended supply tank size.
Isolate the pump and motor stand from the supply tank, and
support them separately.
Install a separate inlet line from the supply tank to each pump.
Install the inlet and bypass lines so they empty into the supply
tank below the lowest water level, on the opposite side of the
ba󰀪e from the pump suction line.
If a line strainer is used in the system install it in the inlet line
to the supply tank.
To reduce aeration and turbulence, install a completely submerged
ba󰀪e plate to separate the incoming and outgoing liquids.
Install a vortex breaker in the supply tank, over the outlet port
to the pump.
Place a cover over the supply tank, to prevent foreign objects
from falling into it.
Hose and Routing
Size the suction line at least one size larger than the pump inlet,
and so that the velocity will be 1-3 ft/sec (0.3 to 0.9 m/s):
For pipe in inches: Velocity (ft/sec) = 0.408 x GPM/Pipe ID2
For pipe in mm: Velocity (m/sec) = 21.2 x LPM/Pipe ID2
Keep the suction line as short and direct as possible.
Use exible hose and/or expansion joints to absorb vibration,
expansion, or contraction.
If possible, keep suction line level. Do not have any high points
collecting vapor unless high points are vented.
To reduce turbulence and resistance, do not use 90° elbows.
If turns are necessary in the suction line, use 45° elbows or
arrange sweeping curves in the exible inlet hose.
If a block valve is used, be sure it is fully opened so that the ow
to the pump is not restricted. The opening should be at least the
same diameter as the inlet plumbing ID.

10 177-999H
T100 Series Medium - Installation (Cont’d)
Adjust the pressure relief valve to no more than 10% over the
maximum working pressure of the pump.
Route the bypass line to the supply tank. See the diagram showing
a typical installation at the beginning of the Installation Section.
If the pump may be run for a long time with the discharge closed
and uid bypassing, install a thermal protector in the bypass line
(to prevent severe temperature buildup in the bypassed uid).
CAUTION: Never install shuto󰀨 valves in the bypass line
or between the pump and pressure relief valve.
Install a pressure gauge in the discharge line.
Vacuum at Outlet. Do not allow a vacuum at the pump outlet
during shutdown. A vacuum can damage the diaphragm at start-up.
If there is a vacuum at the pump outlet, allow atmospheric pressure
at the outlet for 30 minutes before starting. Wanner Engineering
recommends installing an outlet check valve with a 65 psi cracking
pressure to prevent a vacuum condition during shutdown.
Oil Level Monitoring. Oil level is sensed by the back cover
oat switch (48) and can be used to control the pump system
operation.
Before Initial Start-Up
Before you start the pump, be sure that:
• Pump is stored at a temperature between 40-180 F (4.4-82.2 C)
for a minimum of 24 hours before start up.
• All shuto󰀨 valves are open, and the pump has an adequate
supply of uid.
• All connections are tight.
• The oil level is within the marking on the dipstick. Add oil as
needed. The oil level can also be viewed through the sight
glass (42) on the back cover (12). The oil level is OK when
the oat (48) is in the middle of the sight glass.
• Connect the oat switch (if used). See Float Switch Section.
• Test the oat switch by removing the side port plug (50) and
manipulating the oat up and down using a suitable tool
(screwdriver). Reinstall side port plug.
CAUTION: Take care not to drop tool inside pump.
• The relief valve on the pump outlet is adjusted so the pump
starts under minimum pressure.
• All shaft couplings or drive pulleys have adequate safety
guards.
Initial Start-Up
1. Pump must be at or above 40 F (4.4 C) for 24 hours prior to
starting.
2. Open the bypass line start-up and capacity-control valve so the
pump may be started against negligible discharge pressure.
3. Turn on power to the pump motor.
4. Check the inlet pressure or vacuum. To maintain maximum
ow, inlet vacuum must not exceed 7 in. Hg at 70° F (180 mm
Hg at 21° C). Inlet pressure must not exceed 500 psi (34 bar).
5. Listen for any erratic noise, and look for unsteady ow. If the
pump does not clear, refer to the Troubleshooting Section.
6. If the system has an air lock and the pump fails to prime:
a. Turn o󰀨 the power.
b. Remove the pressure gauge from the tee tting at the
pump outlet (see installation diagram).
• Use at least 4 in. (102 mm) I.D. inlet hose
• Use suction hose (low-pressure hose, non collapsing) for
the inlet lines
• Minimize ttings (elbows, valves, tees, etc.)
• Use a suction stabilizer on the inlet.
Net Positive Suction Head
NPSHa must be equal to or greater than NPSHr. If not, the
pressure in the pump inlet will be lower than the vapor pressure
of the uid — and cavitation will occur.
Calculating the NPSHa
Use the following formula to calculate the NPSHa:
NPSHa = Pt + Hz - Hf - Ha - Pvp
where:
Pt = Atmospheric pressure
Hz = Vertical distance from liquid surface to pump center line
(if liquid is below pump center line, the Hz is negative)
Hf = Friction losses in suction piping
Ha = Acceleration head at pump suction
Pvp = Absolute vapor pressure of liquid at pumping temperature
Notes:
• In good practice, NPSHa should be 2 ft greater than NPSHr
• All values must be expressed in feet of liquid
Atmospheric Pressure at Various Altitudes
Altitude Pressure Altitude Pressure
(ft) (ft of H2O) (ft) (ft of H2O)
0 33.9 1500 32.1
500 33.3 2000 31.5
1000 32.8 5000 28.2
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 W.P.-rated hose for systems to be operated at 1000
psi-gauge pressure.
Use exible hose between the pump and rigid piping to absorb
vibration, expansion or contraction.
Support the pump and piping independently. Size the discharge line
so that the velocity of the uid will be 3-10 ft/sec (1-3 m/sec):
For pipe in inches: Velocity (ft/sec) = 0.408 x GPM/Pipe ID2
For pipe in mm: Velocity (m/sec) = 21.2 x LPM/Pipe ID2
Pressure Relief
Install a pressure relief valve in the discharge line. Bypass
pressure must not exceed the pressure limit of the pump.
Size the relief valve so that, when fully open, it will be large
enough to relieve the full capacity of the pump without
overpressurizing the pump.
Locate the valve as close to the pump as possible and ahead
of any other valves.

11 177-999H
T100 Series Medium - Installation/Maintenance
Note: Fluid may come out of this port when the plug
is removed. Provide an adequate catch basin for uid
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 uid will
not be sprayed or lost. Use high-pressure-rated hose
and ttings from this port. Take all safety precautions
to assure safe handling of the uid being pumped.
Initial Start-Up (Cont’d)
c. Jog the system on and o󰀨 until the uid coming from this
port is air-free.
d. Turn o󰀨 the power.
e. Remove the plumbing that was temporarily installed, and
reinstall the pressure gauge or plug.
7. Adjust the bypass line valve to the desired operating pressure.
Do not exceed the maximum pressure rating of the pump.
8. After the system pressure is adjusted, verify the safety relief
valve setting by closing the bypass line valve until the relief
valve opens.
Note: Fluid may come out of the safety relief valve.
Provide an adequate catch basin for uid spillage. Take
all safety precautions to assure safe handling of the
spillage.
9. Reset the bypass line valve to obtain the desired system pressure.
10.Provide a return line from the relief valve to the supply tank,
similar to the bypass line.
Maintenance
Note: Minimum oil viscosity for proper hydraulic end
lubrication is 16-20 cST (80-100 SSU) at 212°F (100°C).
Use of an oil cooler is recommended when process uid
and/or hydraulic end oil exceeds 180°F (82.2°C).
When changing oil, remove drain plug (40) at the bottom of the
pump so all oil and accumulated sediment will drain out.
Check the inlet pressure or vacuum periodically with a gauge. If
vacuum at the pump inlet exceeds NPSHR, check the inlet piping
system for blockages. If the pump inlet is located above the
supply tank, check the uid supply level and replenish if too low.
Inspect pump for hydraulic oil or process uid leaks.
Shutdown Procedure During
Freezing Temperatures
Take all safety precautions to assure safe handling of the
uid being pumped. Provide adequate catch basins for uid
drainage and use appropriate plumbing from drain ports,
etc., when ushing the pump and system with a compatible
antifreeze. Drain ports are located in the manifold.
Note: The numbers in parentheses are the Reference
Numbers shown in the Parts Section of the manual.
Daily
Check the oil level and the condition of the oil with the pump
turned o󰀨. The oil level should be within the marking on the
dipstick or with the oat in the middle of the sight glass. Add oil
as needed or use continuous monitor.
Use the appropriate Hydra-Oil for the application (contact
Wanner Engineering if in doubt).
CAUTION: If you are losing oil but don’t see any external
leakage, or if the oil becomes discolored and contaminated,
one of the diaphragms (78) may be damaged. Refer to the
Fluid-End Service Section. Do not operate the pump with
a damaged diaphragm.
Do not leave contaminated oil in the pump housing or leave
the housing empty. Remove contaminated oil as soon as
discovered, and replace it with clean oil.
Periodically
Change the oil after the rst 500 hours of operation;
and then every 2000 hours or six months, whichever
comes rst.
Note: Hydra-Cell T100 Series Pumps come standard with
10W30 motor oil.
Recommended Tools and
Supplies
The following tools and supplies are recommended for servicing
the T100K,M Pump:
10 mm hex socket with extension
30 mm hex socket
46 mm hex socket
3/4 in. hex socket
8 mm box-end wrench
13 mm open-end wrench
9/16 in. box-end wrench
3 mm hex wrench
4 mm hex wrench
8 mm hex wrench
3/8 in. hex wrench
Torx T30
Tor x T45
Flathead screwdriver
No. 3 Phillips-head screwdriver
Internal retaining ring pliers
8 in. adjustable wrench
Torque wrench, adjustable from 250 to 450 ft-lbs (339 to 610 N-m)
Pipe wrench
Loctite 242
New Hydra-Oil
Wanner T100 Medium Pressure Tool Kit (see T100 Medium
Pressure Tool Kit Parts)

12 177-999H
This section explains how to disassemble and inspect all easily-
serviceable parts of the pump.
Note: The numbers in parentheses are the Reference
Numbers shown in the Parts Section of the manual.
Fluid End Service
Inlet Check Valve Disassembly
a. See Fluid End Parts View. Remove eight bolts (92) around
inlet retainer plate (87).
b. Remove inlet retainer plate and three inlet retainer plugs (85)
with assembled O-rings (86).
c. Check O-rings and inlet retainer plugs for wear. Replace
if worn. Lubricate new O-rings with petroleum jelly or
lubricating gel. Each inlet retainer plug is attached to inlet
retainer plate with two screws (88).
d. Inspect inlet retainer plate for warping or wear around
inlet ports. Look for corrosion, scale and wear. If wear is
excessive, replace inlet retainer plate. Clean inlet retainer
plate of any scale and corrosion with Scotch-Brite™ pad
or ne emery cloth. Wash after cleaning. To check if inlet
retainer plate is warped, place a straightedge across it. A
warped inlet retainer plate should be replaced.
e. Remove three inlet check valve cartridges (99,101-103,100)
with check valve extraction tool. Tool is included in Wanner
Tool Kit.
CAUTION - For Inlet Carbide Valve Assemblies (when used).
Inlet Carbide Valve Assemblies are a matched set
(consisting of items 102 and 103) and must be installed
together. Failure to install Inlet Carbide Valve Assemblies
as a matched set will cause pump damage.
f. Inspect each of three check valve cartridges for wear and
leakage at seat. Replace inlet check valve cartridges as
needed.
g. Using a light, visually inspect diaphragms through inlet ports.
If diaphragms appear abnormal or damaged, remove and
replace as instructed in Diaphragm Parts Disassembly.
Outlet Check Valve Disassembly
Note: Removal of Inlet Check Valves rst will make removal
of Outlet Check Valves easier.
a. Remove two eyebolts (14) and six cap screws (92) around
discharge retainer plate (89).
b. Remove discharge retainer plate with assembled outlet
valve port plugs (89), backup rings (93), O-rings (94), and
outlet valve retainers (95).
c. Check outlet valve port plugs, backup rings, O-rings, and
outlet valve retainers for wear. Replace if worn. Lubricate
new O-rings with petroleum jelly or lubricating gel. Outlet
valve port plugs are attached to discharge retainers plate
with two screws (88).
d. Inspect discharge retainer plates for warping or wear around
T100 Series Medium - Fluid End Service
discharge ports. Look for corrosion, scale and wear. If
wear is excessive, replace discharge retainer plate. Clean
discharge retainer plates of any scale and corrosion with
Scotch-Brite™ pad or ne emery cloth. Wash after cleaning.
To check if discharge retainer plate is warped, place a
straightedge across it. A warped discharge retainer plate
should be replaced.
e. Remove three outlet check valve cartridges (98,99,101-
103,100) with check valve extraction tool. Tool is included
in Wanner Tool Kit.
CAUTION - For Inlet Carbide Valve Assemblies (when used).
Inlet Carbide Valve Assemblies are a matched set
(consisting of items 102 and 103) and must be installed
together. Failure to install Inlet Carbide Valve Assemblies
as a matched set will cause pump damage.
f. Inspect each of three check valve cartridges for wear and
leakage at seat. Replace outlet check valve cartridges as
needed.
Outlet Check Valve Assembly
a. Reinstall three outlet check valve cartridges (98,99,101-
103,100).
b. Reinstall discharge retainer plate (89) with assembled outlet
valve port plugs (89) with two screws (88) [Torque to 75
in-lbs (8 N-m)], backup rings (93), O-rings (94), and outlet
valve retainers (95); using six cap screws (92) and two
eyebolts (14). (Check illustration) Hand thread cap screws
and eyebolts.
c. Tighten cap screws from opposing corners to opposing
corners of discharge retainer plates. Torque to 300 ft-lbs
(407 N-m).
d. Tighten eyebolts with crow bar or hammer.
Inlet Check Valve Assembly
a. Reinstall three inlet check valve cartridges (99,101-103,100).
b. Reinstall inlet retainer plate (87) and inlet retainer
plugs (85) with two screws (88) and assembled O-rings (86).
Use eight bolts (92) to fasten inlet retainer plate. Hand
thread bolts, then tighten from inner to outer. See Manifold
Assembly Torque Sequence Diagram. Torque to 300 ft-lbs
(407 N-m).
Drain Plug
a. Remove and replace drain plug (96) and O-ring (97) as
needed. Torque drain plug with O-ring to 40 ft-lbs (54 N-m).
Apply Loctite nickel anti-seize lubricant to thread and chamfer
of plug, with coverage on O-ring.

13 177-999H
T100 Medium - Hydraulic Section Service
Note: The numbers in parentheses are the Reference
Numbers shown in the Parts Section of the manual.
Hydraulic Section
Disassembly
Manifold Disassembly
a. See Power End Parts Illustration in Parts List. Remove drain
plug (40) from bottom of pump and drain oil into container
(capable of holding 20.5 qts [19.4 liters] of oil). Dispose of
old oil in an approved way.
b. Replace drain plugs.
c. See Fluid End Parts View. Remove eight bolts (92) around
inlet retainer plate (87).
d. Remove eight hex nuts (26) from uid end of pump. Install
four 177-393 Extender Studs from T100 Tool Kit on studs (20).
Carefully slide manifold (84) forward along extender studs
to allow access to diaphragm plate (52).
a. See Diaphragm Parts View. Remove two screws (79), two
O-rings (83) and follower (82).
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 and rell it with fresh oil. Never
let the pump stand with foreign material or water in the
reservoir, or with the reservoir empty.
b. Remove the diaphragm (78) and diaphragm back-up
ring (81). Inspect diaphragm carefully for any abnormal
conditions. A ruptured diaphragm generally indicates a
pumping system problem, and replacing only the diaphragm
will not solve the larger problem. Inspect the diaphragm for
the following:
• Small puncture. Usually caused by a sharp foreign object
in the uid.
• Diaphragm pulled away from the center screw or from
the cylinder sides. Usually caused by uid being frozen
in the pump, or by overpressurization of the pump.
• Diaphragm becoming sti󰀨 and losing exibility. Usually
caused by pumping a uid that is incompatible with the
diaphragm material.
• Slice in ridge of diaphragm. Occurs when diaphragm
is operated at cold temperatures.
• Diaphragm torn concentrically in the mid convolute
area. Usually an indication of an outlet vacuum condition.
c. If needed replace diaphragm.
d. Replace diaphragm back-up ring if needed.
81
78
82
83
79
W0547B
W0547B
75
74
73
71
72
54
77
69
76
80
Note: Make sure back up ring (81) orientation
arrow points towards the diaphragm (78).
Diaphragm Parts
Diaphragm Disassembly
a. See Bias Rod Parts and Diaphragm Parts Views. Remove
diaphragm parts as in steps a. through d. above.
b. Remove screw (80) and diaphragm clamp (76) with valve
arm (69) and two attaching screws (77).
c. Remove valve spool (54) from diaphragm plate (52).
d. Check diaphragm clamp for any rough surfaces, edges, or
corrosion. Replace if necessary.
e. Unscrew bias tube cap (72).
f. Remove bias rod parts: bias spring (71), bias rod (73), spring
guide (74), and screw (75).
g. Inspect rod parts. Smooth surfaces and edges as necessary
with emery cloth or ne le. Replace parts as necessary.
81
78
82
83
79
W0547B
W0547B
75
74
73
71
72
54
77
69
76
80
Note: Make sure back up ring (81) orientation
arrow points towards the diaphragm (78).
Bias Rod Parts
Bias Rod Disassembly
WARNING: Manifold (84) and assembled par ts weigh
over 200 pounds (91 kg) and are a two man lift. Use
care in handling to prevent personal injury or damage
to equipment.

14 177-999H
T100 Medium - Hydraulic Section Service (Cont’d)
Hydraulic Section
Disassembly (Cont’d)
Diaphragm Plate Disassembly
WARNING: Manifold (84) and assembled par ts weigh
over 200 pounds (91 kg) and are a two man lift. Use
care in handling to prevent personal injury or damage
to equipment.
a. Slide manifold (84) away from diaphragm plate (52),
following steps a. through d. in the Remove Manifold
Assembly Section.
WARNING: Diaphragm plate (52) and assembled
parts weigh over 100 pounds (45 kg) and are a two
man lift. Use care in handling to prevent personal
injury or damage to equipment.
Note: To ease handling of diaphragm plate, install
two Eyebolts (177-058) from T100 Medium Pressure
Tool Kit in place of two Setscrews (55) on top of
diaphragm plate.
b. See Hydraulic Section Parts view. Remove two cap
screws (56) from diaphragm plate (52).
c. Carefully slide diaphragm plate and assembled parts away
from pump along pump studs.
d. Replace diaphragm plate gasket (24) if damaged.
Check/Replace Airbleed Valve
a. See Valve Parts View. Unthread airbleed valve (61) from
diaphragm plate (52). Inspect valve and replace if needed.
b. Reinstall airbleed valve. Torque to 75 ft-lbs (102 N-m).
Check/Replace Underll Valve
a. See Valve Parts View. Unthread underll valve (65) from
bottom of diaphragm plate (52). Inspect valve and replace if
needed.
b. Reinstall underll valve. Torque to 30 ft-lbs (41 N-m).
Check/Replace Overll Valve Assembly
a. See Valve Parts View. Unthread overll valve (57) from
bottom of diaphragm plate (52). Inspect overll valve and
replace if needed.
b. Reinstall overll valve. Torque to 105 in-lbs (12 N-m).

15 177-999H
57
W0514B
52
24
61
65
Airbleed Valve
Overll Valve
Underll Valve
T100 Medium - Hydraulic Section Service (Cont’d)
Valve Parts View

16 177-999H
Diaphragm Assembly
a. See Diaphragm Parts View.
CAUTION: It is important to observe the following steps d.
and e. to ensure proper assembly.
b. Install the diaphragm (78) and back-up ring (81) into
diaphragm plate (52). Seat diaphragm edge with ngers.
Make sure diaphragm bead is fully seated into the square
groove of diaphragm plate.
Note: Refer to Diaphragm Parts View for correct installation
orientation of diaphragm and back-up ring.
c. Install two O-rings (83) into follower (82).
d. Attach following to diaphragm clamp with two screws (80).
Use Loctite 242 and torque to 60 in-lbs (7 N-m).
e. Repeat steps a. through e. for three diaphragms.
Manifold Assembly
a. See Fluid End Parts View. Prior to manifold assembly, inspect
mating surfaces of pump and manifold. Make sure they are
clean and free of any foreign material. Ensure diaphragm
beads are seated.
b. Carefully slide manifold (84) onto pump studs. If used,
remove four 177-393 Extender Studs from pump and install
eight bolts (92) around inlet retainer plate (87) and hand
tighten.
CAUTION: The manifold should slide cleanly onto the
pump and the back-up rings should be engaged into
the mating grooves in the manifold prior to tightening.
Failure to slide the manifold all the way on engaging the
back-up rings prior to tightening can cause the back-
up ring to be pinched and cause the pump to leak. If
the manifold does not slide easily onto the pump, use
scotch-brite or ne abrasive paper to clean the outer
edge of the groove where the back-up ring ts.
c. Thread on eight hex nuts (26) and hand tighten.
d. Tighten hex nuts in torque sequence shown in illustration
following to 450 ft-lbs (610 N-m).
e. Thread on eight bolts (92) and hand tighten.
f. Tighten bolts in torque sequence shown in illustration
following to 300 ft-lbs (407 N-m).
g. Fill pump with oil to cover marks on dipstick. Approximately
18 qts (17 liters) with at back cover or 20.5 US quarts (19.4
liters) with oil monitor back cover.
h. Follow instructions in Before Initial Start-Up and Initial
Start-Up Section to start pump.
WARNING: Manifold (84) and assembled par ts weigh
over 200 pounds (91 kg) and are a two man lift. Use
care in handling to prevent personal injury or damage
to equipment.
Hydraulic Section Assembly
T100 Medium - Hydraulic Section Service (Cont’d)
Diaphragm Plate Assembly
a. Replace diaphragm plate gasket (24) if damaged.
CAUTION: Ensure plungers (51) are lubricated with oil
before assembly. Dry plungers and cylinders can bind
on start-up.
b. See Hydraulic Section Parts Illustration. Carefully slide
diaphragm plate (52) and assembled parts along pump studs
ush with Power End of pump.
c. Screw two cap screws (56) into diaphragm plate. Torque to
50 ft-lbs (68 N-m).
d. Hand rotate to assure smooth operation.
Bias Rod Assembly
CAUTION: It is important to observe the following steps a.
and b. to insure proper assembly.
a. See Bias Rod Parts View. Clean internal threads of bias rod (73)
and threads of screw (75). Make sure threads are dry and
oil free. Prime threads with Loctite Primer N.
b. Apply a small amout of No. 271 Loctite to internal threads of
bias rod and screw. Insert screw through spring guide (74)
and thread into bias rod.
c. Install bias rod assembly parts into diaphragm plate (52).
Thread bias tube cap (72) into bias tube with: bias spring (71),
bias rod, spring guide, and screw. Make sure spring tangs
mate with spring guide and bias tube cap. Use Loctite 242 on
bias tube cap and torque to 50 ft-lbs (68 N-m).
d. Insert valve spool (54) into diaphragm plate (52).
e. Thread screw (80) through diaphragm clamp (76) with valve
arm (69) and two attaching screws (77) into bias rod. Use
Loctite 242 on screw (80) and torque to 20 ft-lbs (27 N-m).
CAUTION: Use care not to over-tighten as that can cause
the rod to rotate and bind the bias spring. Verify the bias
spring is not bound by pulling the diaphragm clamp out
and verifying that the clamp has full range of motion.
f. Repeat for three rod assemblies.
WARNING: Diaphragm plate (52) and assembled
parts weigh over 100 pounds (45 kg) and are a two
man lift. Use care in handling to prevent personal
injury or damage to equipment.
Note: To ease handling of diaphragm plate, install t wo
Eyebolts (177- 058) from T100 Tool Kit in place of two
Setscrews (55) on top of diaphragm plate.

17 177-999H
T100 Medium - Hydraulic Section Service (Cont’d)
Torque sequence:
- Snug eight hex nuts (26) in order indicated,
then torque to 450 ft-lbs (610 N-m) in order
indicated.
- Repeat same snug and torque sequence for
corresponding bolts (92) to 300 ft-lbs (407 N-m).
735
6 82
4
W0516D
Eight hex nuts (26)
Eight bolts (92)
1
Hydraulic Section Assembly
(Cont’d)

18 177-999H
T100 Series Medium - Power End Service
Power End Disassembly
WARNING: Crankcase (2) and assembled par ts weigh
over 400 pounds (181 kg) and are a two man lift. Use
care in handling to prevent personal injury or damage
to equipment.
Float Switch Back Cover Disassembly
Note: The numbers in parentheses are the Reference
Numbers shown in the Parts Section of the manual.
a. Disconnect oat switch (48).
b. Remove oat switch adapter (47) with oat switch and
O-ring (46) from back cover (12).
c. Remove oat switch from oat switch adapter.
d. Remove twelve screws (16) from crankcase (2).
e. Remove back cover and ba󰀪e (13).
f. Remove eight screws (45) from assembled frame (44)
and back cover.
g. Disassemble frame, gasket (43), sight glass (42),
and thick gasket (41).
Crankcase Disassembly
a. Remove Fluid End and Hydraulic plate as outlined in two
preceding sections.
b. See Power End Parts Illustration. Remove drain plug (40),
cap with o-ring (25), dipstick (32), and crankshaft key (31)
and drain lubricating uid into a suitable container.
c. Remove 12 cap screws (16) and remove back cover (12)
and back cover ba󰀪e (13).
Connecting Rod Removal
Note: Each of three Connecting rod assemblies (3*)
consists of: connecting rod, connecting rod end cap,
sleeve, and two bolts.
a. Remove connecting rod assembly bolts (3*) and remove
connecting rod end cap (3*) with split shell bearing. Make
sure numbers on connecting rod and end cap are 'top-up'
in the assembly and match.
Note: Make sure to note 'top-up' orientation of numbers
on connecting rod and end cap when removing. These
are matched parts and must be stored together as one
assembly and not mixed with any other connecting rod
assemblies or parts.
b. Set aside connecting rod assembly bolts, end cap, and one
half split shell bearing (8) for use in reassembly.
c. Remove connecting rod assembly from crankshaft by
reaching into rear of crankcase (2) around crankshaft (1).
Push connecting rod assembly away from journal on the
crankshaft. Move as far forward as possible.
d. Repeat removal for three sets.
Crankshaft Removal
a. Remove six cap screws (15) from one side of pump attaching
seal and bearing assembly (assembled items 6, 7, 9, 11, 15,
17, and 18) to the crankcase (2).
b. Carefully remove crankshaft (1) with seal and bearing
assembly from crankcase.
c. Remove seal and bearing assembly from end of crankshaft.
d. Remove six screws (15) and remaining seal and bearing
assembly from crankcase.
Seal and Bearing Disassembly
a. Separate seal and bearing assemblies by removing six cap
screws (15).
b. Remove O-ring (17) from bearing cover (6). Remove roller
bearing (7) from bearing cover.
c. Remove O-ring (18) from seal cover (9). Remove two
crankshaft seals (11) from seal cover.
d. Disassemble two sets.
Connecting Rod Disassembly
Note: Make sure to note 'top-up' orientation of numbers
on connecting rod and end cap when storing. These are
matched parts and must not be mixed with par ts from other
connecting rod assemblies.
a. Pull out connecting rod/plunger assembly and remove from
crankcase.
b. Remove remaining one half of split shell bearing (8) from
connecting rod (3*). Match with shell bearing already
removed in Connecting Rod Removal.
c. Retrieve bolts (3*), and end cap (3*) from previous step in
Connecting Rod Removal. Be careful not to mix with parts
from other connecting rod assemblies.
d. Loosely assemble two bolts, and connecting rod end cap
with connecting rod assembly and set aside. Note proper
orientation of numbers on connecting rod and end cap.
e. Remove setscrew (23) to unlock wrist pin (5). Remove wrist
pin, assembled plunger and slider from connecting rod.
Note alignment marks on wrist pin and alignment mark on
crosshead (4).
f. Disassemble and remove three sets.
Plunger Disassembly
a. Remove shoulder screw (29) from plunger assembly to
remove plunger (51), spherical washer (27), slider (4), and
belleville spring (28).
b. Disassemble three sets as in step a.
c. Clean crankcase for later reassembly.

19 177-999H
T100 Series Medium - Power End Service (Cont’d)
Power End Assembly
Plunger Assembly
Note: The numbers in parentheses are the Reference
Numbers shown in the Parts Section of the manual.
a. Start with crankcase (2) clean and ready to assemble.
b. Assemble plunger (51), spherical washer (27), slider (4),
belleville spring (28), with shoulder screw (29). Use Loctite 242
and torque to 50 ft-lbs (68 N-m).
Note: One concave side of spherical washer assembly (27)
mates with plunger (51) and the other convex side of
spherical washer assembly mates with slider (4).
c. Assemble three sets.
Connecting Rod Assembly
Note: Each of three Connecting rod assemblies (3*)
consists of: connecting rod, connecting rod end cap,
sleeve, and two bolts.
a. Attach assembled plunger and slider to connecting rod (3*)
using wrist pin (5). Align marks on wrist pin with marks on
slider (4). Lock wrist pin in place with setscrew (23). Use
Loctite 271 and torque to 60 in-lbs (7 N-m).
Note: Make sure to note 'top-up' orientation of numbers
on connecting rod and end cap when taking apart. These
are matched parts and must not be mixed with parts from
other connecting rod assemblies.
b. Remove two bolts (3*) and connecting rod end cap (3*)
from connecting rod assembly. Note orientation numbers
on connecting rod and end cap.
c. Set aside bolts and end cap for later installation. Do not mix
with parts from other connecting rod assemblies.
d. Install one half of split shell bearing (8) on connecting rod.
Remaining one half of split shell bearing will be installed later.
e. Insert connecting rod/plunger assembly into crankcase and
push all the way forward. Ensure numbers are "top-up."
f. Assemble and install three sets.
Seal and Bearing Assembly
a. Press two crankshaft seals (11) into seal cover (9). Install
O-ring (18) onto seal cover.
b. Install roller bearing (7) into bearing cover (6). Install O-ring
(17) onto bearing cover.
c. Bolt seal and bearing assemblies together using six cap
screws (15).
d. Assemble two sets.
WARNING: Crankcase (2) and assembled par ts weigh
over 400 pounds (181 kg) and are a two man lift. Use
care in handling to prevent personal injury or damage
to equipment.
Crankshaft Installation
a. Install one seal and bearing assembly to either side of
crankcase (2) using six screws (15). Crankshaft (1) will be
installed on opposite side.
b. Place remaining seal and bearing assembly on following end
of crankshaft.
Note: No shimming of crankshaft is necessary. End play
of crankshaft should be between 0.010 in. minimum to
0.200 in. maximum when installed.
c. Insert crankshaft with seal and bearing assembly into
crankcase and insert into installed seal and bearing
assembly on opposite end of crankcase. Align ange of seal
and bearing assembly with ange on crankcase.
d. Bolt ange of seal and bearing assembly to crankcase with
six cap screws (15).
Connecting Rod Installation
Note: Each of three Connecting rod assemblies (3*)
consists of: connecting rod, connecting rod end cap,
sleeve, and two bolts.
a. Attach connecting rod assembly to crankshaft (1) by reaching
into rear of crankcase around crankshaft and pulling
connecting rod assembly until it reaches its journal on the
crankshaft.
Note: Make sure to note 'top-up' orientation of numbers
on connecting rod and end cap when installing. These are
matched par ts and must not be taken from other connect ing
rod assemblies.
b. Retrieve connecting rod assembly bolts, end cap, and
remaining split shell bearing (8) set aside in previous steps.
c. Reinstall connecting rod end cap with remaining split shell
bearing using connecting rod assembly bolts. Make sure
numbers on connecting rod and end cap are 'top-up' in the
assembly and match. Torque two bolts to 100 ft-lbs (136 N-m).
d. Repeat installation for three sets.
Crankcase Assembly
Note: for torque values refer to the table following the Parts
List Section.
a. Install back cover (12) and back cover ba󰀪e (13) using 12
cap screws (16).
b. Install crankshaft cover (10) on crankshaft end not used
with six cap screws (15) used to attach seal and bearing
assembly.
c. If removed, reinstall four studs (20), with four set screws (21),
four studs (19), and two eyebolts (14).
d. Install plug (40), cap with o-ring (25), dipstick (32), and
crankshaft key (31) and add lubricating uid.

20 177-999H
Float Switch Back Cover Assembly
a. Align and assemble frame (44), gasket (43), sight glass (42),
and thick gasket (41).
Float Switch Back Cover Assembly
b. Install eight screws (45) alternately through assembled
frame into back cover (12) until snug.
c. Assemble ba󰀪e (13) and back cover.
d. Attach ba󰀪e and back cover to crankcase (2) with twelve
screws (16)
e. Assemble oat switch (48) to oat switch adapter (47)
nger tight plus one half turn.
f. Assemble oat switch adapter with oat switch and O-ring (46)
into back cover until seated.
g. Reconnect oat switch.
T100 Series Medium - Power End Service (Cont’d)
Power End Assembly (Cont’d)