TM

P500 Metering Pump

Installation & Service
P500-991-2400

W0303

1204 Chestnut Avenue, Minneapolis, MN 55403

TEL: (612) 332- 5681 FA X: (612) 332- 6937
TOLL-FREE FAX [US only]: (800) 332-6812
www.hydra-cell.com/metering
email: [email protected]
P500 Contents
Page Component Identification
Specifications...........................................................................2
Dimensions..............................................................................3 Oil Fill Cap ID Plate Reducer
Installation................................................................................6
Maintenance.............................................................................8
Fluid End Service . ..................................................................9
Troubleshooting.....................................................................11 Outlet

Fluid End Parts List . .............................................................12

Hydraulic End Parts List .......................................................14
Hydraulic End Service ..........................................................15
Reducer Parts List.................................................................16
W0303

Replacement Parts Kits.........................................................19

Inlet
Warranty................................................................................ 20
Oil Drain
Pump Assembly Pump Assembly
Fluid End Hydraulic End

P500 Specifications
Steady State Accuracy ±1%
Linearity ±3% Inlet Port 1 1/4 inch NPT or BSPT
Repeatability ±3% Discharge Port 3/4 inch NPT or BSPT
Maximum Pressure Shaft Rotation Bi-directional
Metallic Head: 2500 psi (173 bar) Oil Capacity 2.2 US quart (2.1 liters)
Maximum Inlet Pressure 500 psi (35 bar) Weight
Maximum Temperature Metallic Head: 160 lbs (72.6 kg)
Metallic Head: 250°F (121°C) – consult factory for
temperatures above 160°F (71°C)
Gallons Per Hour (GPH) Maximum Flow at Designated Pressure
GPH Metallic Pump Heads Only Pump Gear Motor
100 PSI (*) 500 PSI (*) 1500 PSI (*) 2500 PSI (*) RPM Ratio RPM
11.74 (¼) 11.26 (¼) 10.25 (¼) 9.47 (½) 18 100:1
14.39 (¼) 13.89 (¼) 12.79 (½) 11.89 (½) 22.5 80:1
18.82 (¼) 18.27 (¼) 17.02 (½) 15.92 (¾) 30 60:1
22.36 (¼) 21.78 (¼) 20.41 (½) 19.15 (¾) 36 50:1
27.67 (¼) 27.03 (¼) 25.49 (¾) 23.99 (1) 45 40:1
36.52 (¼) 35.80 (½) 33.95 (¾) 32.06 (1½) 60 30:1
1800
43.60 (¼) 42.81 (½) 40.73 (1) 38.52 (1½) 72 25:1
54.22 (¼) 53.32 (½) 50.89 (1) 48.20 (2) 90 20:1
71.93 (¼) 70.84 (½) 67.82 (1½) 64.34 (3) 120 15:1
107.3 (¼) 105.9 (¾) 101.7 (2) 96.62 (5) 180 10:1
142.7 (¼) 140.9 (1) 135.5 (3) 128.9 (5) 240 7.5:1
213.6 (½) 211.0 (1½) 203.3 (5) 193.5 (7½) 360 5:1
284.4 (½) 281.1 (2) 271.0 (7½) 258.0 (10) 480 7.5:1
3600
426.0 (¾) 421.3 (5) 406.5 (10) 387.1 (15) 720 5:1
*Required Motor HP

 P500-991-2400
P500 Dimensions
P500 Models with Metallic Pumping Head Inches (mm)
316 Stainless Steel
Cast Iron
Hastelloy ® C

P500 Model
1.25 7.50
NEMA 143/145TC Ø0.875 (22.2) (31.8) (190.5)
0.187 (4.7) Square Key
NEMA 143/145TC Flange/Shaft
2.15
NEMA 143/145TC Flange (54.6)
(Ø4.500 (114.3) Pilot) Ø6.5
(Ø5.875 (149.2) B.C.) (165)
4.50
(114.3) 10.0
(254)
NEMA 56C 0.625 (15.9)
0.187 (4.7) Square Key NEMA 56C Flange/Shaft
Ø0.656 X 1.3
(16.7) (330) FRONT

NEMA 56C Flange Ø6.5 Long Slots 10.0

(Ø4.500 (114.3) Pilot) (165) (254)
(Ø5.875 (149.2) B.C.)
Oil Fill 3/4" NPT or
3/4" BSPT

12.4
(315) 3.0 2.3 OUT
3/8" NPT or
(76.2) (58.4) 3/8" BSPT
(Drain Ports)
9.8
(248.9)
5.62 IN 1-1/4" NPT or
(142.7) 1-1/4" BSPT
Note: 1
1 Oil Drain
Worm Gear Reducer available 0.656
(16.7) W0316 3.75 1.3 Slot 4X
in the following ratios: (33)
- With NEMA 56C Flange/Shaft Slot (95.3)
(20:1, 25:1, 30:1, 40:1, 50:1, 6.7 2.15 4.50 3.35 2.5 5.0
60:1, 80:1, 100:1) (170.2) (54.6) (114) (85.1) (63.5) (127)
10.0
- With NEMA 143/145TC 10.0 (254)
Flange/Shaft (7.5:1, 10:1, 15:1, 19.2 (254) 10.7
20:1, 25:1, 30:1, 40:1) (487.7) (271.8)
2. Weight = 160 lbs (73 kg) -
does not include motor.

 P500-991-2400
P500 Dimensions
P500 Models with Metallic Pumping Head Inches (mm) 316 Stainless Steel
Cast Iron
Hastelloy ® C
P500 Model FB75 with 56C or 140TC Flange Adapter
NEMA 143/5TC Flange
(Ø4.500 (114.3) Pilot)
(Ø5.875 (149.2) B.C.)
1.25 7.50
(31.8) (190.5)
NEMA 143/5TC Ø0.875 (22.2)
0.187 (4.7) Square Key
2.15
NEMA 56C Flange (54.6)
(Ø4.500 (114.3) Pilot)
(Ø5.875 (149.2) B.C.)
4.50
(114.3) 10.0
NEMA 56C Ø0.625 (15.9) (254)
0.187 (4.7) Square Key

Ø0.656 X 1.3
(16.7) (330) FRONT

Long Slots 10.0

(254)
1
Oil Fill

3/4" NPT or
3/4" BSPT
12.4
(315) 3.0 2.3 OUT
3/8" NPT or
(76.2) (58.4) 3/8" BSPT
11.7 (Drain Ports)
(297.2)

5.62 IN 1-1/4" NPT or

(142.7) 1-1/4" BSPT
Notes:
Oil Drain
1
0.656 Slot 1.3 Slot 4X
Worm Gear Reducer available (16.7) W0355 3.75
in the following ratios: (95.3) (33)
7.0 2.15 4.50 3.35 2.5
(5:1) (177.8) 5.0
(54.6) (114) (85.1) (63.5)
2. Weight = 180 lbs (82 kg) - (127)
10.0 10.0
does not include motor. (254) (254)
19.5 11.2
(495.3) (284.5)

P500 Model FB75 with 180TC Flange Adapter and Base

NEMA 182/4TC Flange

(Ø8.500 (215.9) Pilot)
(Ø7.25 (184.2) B.C.)

NEMA 182/4TC Ø1.125 (28.6)

0.250 (6.35) Square Key

Oil Fill

3/4" NPT or
3/4" BSPT
12.4
(315) 3.0 2.3 OUT
3/8" NPT or
(76.2) (58.4) 3/8" BSPT
13.8 (Drain Ports)
(350.5)

5.62 IN
1-1/4" NPT or
Notes: 1 (142.7) 1-1/4" BSPT
1 W0334
Worm Gear Reducer available Oil Drain
in the following ratios:
(5:1, 7.5:1, 10:1, 15:1)
2. Weight = 200 lbs (91 kg) - 24.0 1.5 0.188 14.5
does not include motor. (609.6) (38.1) (4.78) (368.3)

 P500-991-2400
P500 Dimensions
P500 Models with Metallic Pumping Head Inches (mm)
316 Stainless Steel
Cast Iron
P500 Model FL232 with 210TC Flange Adapter and Base Hastelloy ® C
38.8
(985.5)
36.8
(934.7)

7.8
(198.1)

16.1
(408.9)
19.1

FRONT
(485.1)

10.2
(259.1)

8.1
Notes: (205.7)
1
Worm Gear Reducer available 3/4" NPT or
3.0 3/4" BSPT
in the following ratios: (76.2)
(5:1, 7.5:1)
3/8" NPT or
2.3
OUT
2. Weight = 312 lbs (142 kg) - 3/8" BSPT
does not include motor. 18.3 12.4 (58.4) (Drain Ports)
(464.8) (315)
1 5.62 1-1/4" NPT or
2.5
IN
(142.7) 1-1/4" BSPT
(63.5)

Oil Drain
W0335

P500 Model FL242 with 250TC Flange Adapter and Base

38.8
(985.5)
36.8
(934.7)

6.8
(172.7)

16.1
(408.9)
19.1
FRONT

(485.1)

9.1
(231.1)

8.1
(205.7)
Notes:
1 3/4" NPT or
3.0 3/4" BSPT
Worm Gear Reducer available (76.2)
in the following ratios: 22.7
(5:1) (576.6) 3/8" NPT or
2.3
OUT

3/8" BSPT
2. Weight = 377 lbs (171 kg) - 12.4 (58.4) (Drain Ports)
does not include motor. (315)

1 5.62 IN
1-1/4" NPT or
(142.7) 1-1/4" BSPT
2.5
(63.5)

Oil Drain
W0336

 P500-991-2400
P500 Installation
Location
NOTE: The numbers in parentheses are Reference Numbers
Important Precautions
located in the Parts List exploded views of this manual. Adequate Fluid Supply. To avoid cavitation and
premature pump failure, be sure that the pump will have
Locate the pump as close to the supply source as possible.
an adequate fluid supply and that the inlet line will not be
Install it in a lighted clean space where it will be easy to inspect obstructed. See Inlet Piping on page 6.
and maintain.
Positive Displacement. This is a positive-displacement
pump. To avoid severe system damage if the discharge line
Motor and Controller ever becomes blocked, install a relief valve downstream
The P Series pump shaft can rotate in either direction, therefore from the pump. See Discharge Piping on page 6.
direction of motor shaft rotation is not critical. Safety Guards. Follow all codes and regulations regarding
installation and operation of the pumping system.
Accessories Shut-Off Valves. Never install shut-off valves between
the pump and discharge pressure regulator, or in the
Consult installation drawing below for typical precision metering
regulator bypass line.
fluid system components. Contact Wanner Engineering or the
distributor in your area for more details. 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)

PULSATION
DAMPENER
(OPTIONAL)

BACK PRESSURE
VALVE

RELIEF
VALVE
(To process)

P500
METERING PUMP

PRESSURE
CALIBRATION GAUGE
CYLINDER

ISOLATING VALVE

W0327

BALL VALVE FLANGES & MANIFOLDS

Y-STRAINER

 P500-991-2400
P500 Installation
Inlet Piping Discharge Piping
Provide for permanent or temporary installation of a compound
pressure gauge to monitor the inlet pressure. To maintain
Hose and Routing
maximum flow, the pump inlet should be under flooded suction Use the shortest, most-direct route for the discharge line.
conditions at all times. Do not supply more than one pump Select pipe or hose with a working pressure rating of at least
from the same inlet line. 1.5 times the maximum system pressure. EXAMPLE: Select a
1500 psi (103 bar) W.P.-rated hose for systems to be operated
Supply Tank at 1000 psi (69 bar) gauge pressure.
Use a supply tank that is large enough to provide time for any Support the pump and piping independently.
trapped air in the fluid to escape. The tank size should be at
least twice the maximum pump flow rate. Pressure Regulation
Install a separate inlet line from the supply tank to each Install a pressure relief valve in the discharge line. Bypass
pump. pressure must not exceed the pressure limit of the pump.
Place a cover over the supply tank, to prevent foreign objects Size the valve so that, when fully open, it will be large enough
from falling into it. to relieve the full capacity of the pump without over-pressurizing
the system.
Hose Sizing and Routing
Locate the valve as close to the pump as possible and ahead
To minimize acceleration head and frictional losses, size the of any other valves.
suction line at least one size larger than the pump inlet, and
keep the suction line as short and direct as possible. Adjust the pressure relief valve to no more than 10% over the
maximum working pressure of the system. Do not exceed the
Recommendations:
manufacturer’s pressure rating for the pump or valve.
• Keep inlet lines less than 3 ft. (1 m) long
Route the bypass line to the supply tank.
• Use at least 1-1/2” (38 mm) I.D. inlet hose
• Minimize fittings (elbows, valves, tees, etc.) CAUTION: Never install shutoff valves in the bypass line or
between the pump and pressure regulator or relief valve.
Inlet Piping (Pressure Feed) Provide for permanent or temporary installation of a pressure
gauge to monitor the discharge pressure at the pump.
Provide for permanent or temporary installation of a pressure
gauge to monitor the inlet pressure. Pressure at the pump inlet Minimum Discharge Pressure
should not exceed 500 psi (35 bar); if it could get higher, install a
pressure reducing valve. Do not supply more than one pump To ensure proper capacity control, a minimum discharge
from the same inlet line. pressure of 50 psi (3.5 bar) is required.

Note: System back pressure must exceed the pump inlet

pressure by at least 15 psi (1 bar) in order to prevent flow
thru.

 P500-991-2400
P500 Installation
Initial Start-Up Procedure Calibration Procedure
Before you start pump, be sure that: Each individual metering pump put into service must be calibrated
in order to accurately determine required pump speed to achieve
• All shut-off valves are open, and the pump has an adequate
the desired flow. The capacity curves shown on page 3 represent a
supply of fluid.
typical pump; individual pumps may vary slightly from these curves.
• All connections are tight.
In order to achieve the best possible results, perform calibration
• The oil level is 1/4 inch (6 mm) above the cast surface in the under actual process conditions. Follow these steps:
upper oil reservoir.
1. Run pump for 20 minutes at actual process conditions. If
1. Open priming valve on system back pressure valve so pump
process system cannot be used, circulate back to supply tank
starts under minimum pressure.
through pressure relief valve (see Installation drawing on page
2. Turn on power to pump motor. 5). If required system pressure is less than 50 PSI (3.5 bar) back
3. Check inlet pressure or vacuum. To maintain maximum flow, pressure valve must be installed and set to produce minimum
pump inlet should be under flooded suction conditions at all of 50 PSI (3.5 bar) pressure at pump head.
times. Inlet pressure must not exceed 500 psi (35 bar). 2. Determine maximum pump speed required for all system
4. Listen for any erratic noise and look for unsteady flow. conditions that need to be satisfied. Measure pump delivery
• Jog pump on and off until fluid coming from priming valve at this maximum speed using your system calibration cylinder,
is air-free. flow meter, or some other means. This is considered to be
• Close priming valve. “rated capacity” for your particular metering pump.
3. Measure pump delivery at 75%, 50%, 25%, and 10% of
maximum speed just determined. Let pump run for 5 minutes
at each speed setting before taking capacity measurement.
4. Plot these values on linear graph paper using horizontal axis
for RPM and vertical axis for GPH, or any other unit of measure
you may be using for capacity.
5. Draw best-fit straight line through points just plotted. For stable
conditions, this line predicts pump speed required to achieve
desired flow over 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.

P500 Maintenance
NOTE: The numbers in parentheses are Reference Numbers CAUTION: Do not turn the drive shaft while the oil reservoir
located in the Parts List exploded views of this manual. is empty.
Use the appropriate Hydra-Oil for the application.
Periodically Note: P Series replacement parts kits (complete kits and
Change the oil according to the guidelines below. When changing, diaphragm kits) include the appropriate oil for each specific
remove the drain plug (34), Allow all oil and contaminant to drain P Series pump configuration.
out. Catch the oil and dispose of it properly. CAUTION: If you are losing oil but don’t see any external
leakage, or if the oil becomes discolored and contaminated,
Hours Between Oil Changes @ Various the diaphragm (20) may be damaged. Refer to the Fluid-End
Process Fluid Temperatures Service Section. Do not operate the pump with a damaged
<90°F <139°F <180°F diaphragm.
Pressure (32°C) (60°C) (82°C) CAUTION: Do not leave contaminated oil in the pump
Metallic Pump Head housing or leave the housing empty. Remove contaminated
<1500 psi (104 bar) 4,000 3,000 2,000 oil. Dispose of properly. Replace with clean oil.
<2500 psi (173 bar) 1,500 1,250 1,000
Check the inlet pressure periodically with a gauge.
NOTE: Minimum oil viscosity for proper hydraulic end
lubrication is 16-20 cST (80-100 SSU).

 P500-991-2400
P500 Fluid End Service
NOTE: The number in parentheses are the Reference b. Valve Plate (24.) Using 8 mm hex bit socket remove
numbers on the illustration on the preceding page and in capscrew (22). Remove and inspect valve plate (in like
the Parts Manual. manner as manifold) for excessive wear or warping.
This section explains how to disassemble and inspect all easily Replace if necessary.
serviceable parts of the pump. Repair procedures for the CAUTION: Don’t turn the pump drive shaft while the
hydraulic end (oil reservoir) of the pump are included in a later manifold and valve plate are off the pump, except
section of the manual. when removing diaphragms or repriming the hydraulic
cells.
CAUTION: Do not disassemble the hydraulic end unless
you are a skilled mechanic. For assistance, contact Wanner
Engineering (TEL 612-332-5681 or FAX 612-332-6937) or the
distributor in your area. 2. Remove and Inspect
CAUTION: Do not remove the four socket-head capscrews
(29) that go through the cylinder housing (23), unless you are
Valves (9-20)
repairing the hydraulic end of the pump. NOTE: Wanner Valve Kits include items and all O-rings for
sealing the manifold to the valve plate. The five inlet and
five outlet valve assemblies are different in size and face
in opposite directions.
Tools and Supplies a. Remove inlet valve seat (10) using seat puller tool
The following tools and supplies are recommended for servicing
included in Wanner D-15 Tool Kit. Inspect valve seat for
the pump:
wear, and replace if necessary.
• Straightedge (at least 8 in. long) NOTE: Whenever any valve or seat is replaced it is
• Grease or petroleum jelly recommended to replace all valve assemblies to ensure
• 1/2” drive torque wrench, rated to at least 50 ft-lbs (70 N-m) the most reliable operation. All necessary parts are
• Emery cloth and Scotch-Britetm pad included in a replacement Valve Kit.
• 11/16” socket (3/8” or 1/2” drive) b. Remove remaining inlet valve components (11-14) and
• 19 mm socket (1/2” drive) outlet valve components (17-20) by hand or with small
• 3/8” drive socket wrench with extensions needle nose pliers.
• 1/2” drive socket wrench with extensions c. Check spring retainers (14, 20) and replace if worn,
cracked, or damaged.
• 5/16” (8 mm) open-end wrench
d. Check valve springs (12, 19) and replace if worn, broken,
• Wanner Hydra-Oil (appropriate Grade, as determined by
or shorter than new spring. Never attempt to stretch old
digit 12 of your pump model number).
spring.
• Anaerobic seal sealant (for shaft seals if servicing Hydraulic
e. Check valves (11, 18) for wear or damage and replace
End)
if necessary. Polishing of valves during operation is
• Wanner D-15 Tool Kit, which includes the following: normal. If you can feel a ridge in valve surface, valve
– Valve seat puller should be replaced.
– Plunger guide lifter NOTE: Pumps with plastic spring retainers (14, 20)
– 3/32 x 6 in. T-handle hex wrench include Tetra Seal (13, 17 - square section O-ring)
– 8 mm hex bit socket (1/2” drive) between spring retainer and valve seat. Pumps with
– Shaft rotator metal spring retainers do not include Tetra Seal.
– Seal protector f. Reinstall valve assemblies:
– Seal inserter • Clean valve ports and shoulders in valve plate (24) with
– 5/16” hex Allen wrench Scotch-Brite pad or fine emery cloth. Wash valve plate
after cleaning, and lubricate valve ports with compatible
– 7/16” 8-point socket (3/8” drive)
grease, oil, or petroleum jelly.
– 6 mm hex Allen wrench
• Install new O-rings (9, 15) on seats (10, 16) and
lubricate all O-rings.
1. Remove Manifold (4), • Inlet Valves (five center, larger valves). Insert spring
retainer (14) into valve plate (24), followed by Tetra seal
Valve Plate (24) (13) if spring retainer is plastic. Insert spring (12) into
a. Manifold (4.) Use 8 mm hex bit socket included in retainer, followed by valve (11) on spring. Finally, insert
Wanner D-15 Tool Kit to remove 12 capscrews (2) and seat (10) with new O-ring into valve bore with larger I.D.
five capscrews (1) at front of manifold. Remove and chamfer (seating surface) facing down, towards valve.
inspect manifold for warping or wear around inlet and • Outlet Valves (five outer, smaller valves). Insert outlet
outlet ports and flow channels. If wear is excessive seat (16) with new O-ring into valve bore with larger I.D.
replace manifold. To check if manifold is warped, place chamfer (seating surface) facing up. Insert Tetra Seal
straightedge across it; check both sides. A warped (17) if valve spring retainers are plastic. Insert valve (18)
manifold should be replaced. and spring (19) on seat. Finally, insert spring retainer

 P500-991-2400
P500 Fluid End Service
(20) into valve bore. b. Fill reservoir with kerosene or solvent, manually turn
• Make sure springs are all properly nested into spring pump shaft to circulate kerosene, and drain. Dispose
retainers to ensure proper valve performance. of this contaminated fluid properly.
c. Repeat flushing procedure (step “b” above).
d. Fill reservoir with fresh oil, manually turn pump shaft to
3. Inspect and Replace circulate oil, and drain again.
e. Refill reservoir. If oil appears milky, there is still
Diaphragms (21) contaminant in reservoir. Repeat flushing procedure
a. Lift diaphragm by one edge, and turn pump shaft until until oil appears clean.
the diaphragm moves up to “top dead center”. This
will expose machined cross-holes in valve plunger (51)
behind diaphragm. 5. Prime Hydraulic Cells
b. Insert a 3/32 x 6 in. hex wrench through one of machined a. With pump horizontal and the fluid end head
cross-holes, to hold diaphragm up and to keep valve removed, fill reservoir with appropriate Hydra oil for
plunger from rotating. Proper size tool is included in application. Have catch basin for oil that leaks from
Wanner Tool Kit. (Don’t remove tool until new diaphragm behind diaphragms when priming. Catch oil and dispose
is installed in step “f” below.) of properly; do not reuse.
c. Unscrew diaphragm. Use a 5/16-in. (8-mm) open-end b. All air in oil within hydraulic cell (behind diaphragm) must
wrench, and turn counterclockwise. be forced out by turning shaft (thus pumping piston).
d. Remove diaphragm and inspect diaphragm carefully. A Shaft Rotator is included in Wanner D-15 Tool Kit. Rotate
damaged diaphragm generally indicates pumping system shaft two revolutions and refill reservoir. Rotate it two
problems and replacing diaphragm will not solve overall more revolutions and refill again. Continue to do this until
problem. Inspect diaphragm for the following: oil that is being pumped from back of all five diaphragms
• Small puncture. Usually caused by a sharp foreign is free of air.
object in the fluid, or by an ice particle. c. Wipe excess oil from cylinder housing (23) and
• Diaphragm pulled away from the metal insert. diaphragms (21).
Usually caused by excessive inlet vacuum, or by over d. Ensure that oil level is 1/4 in (6 mm) above cast surface
pressurization of the pump inlet. in upper oil reservoir.
• Outer diaphragm bead extruded. Usually caused e. Replace oil fill cap (28).
by over pressurization of the pump or by extremely high
temperatures.
• Diaphragm becoming stiff and losing flexibility. 6. Reinstall Valve Plate (24),
Usually caused by pumping a fluid that is incompatible
with the diaphragm material. Manifold (4)
a. Reinstall valve plate (24), with valve assemblies installed
• Cut diaphragm convolute. Usually caused by
as outlined above, on cylinder housing center spud and
excessive inlet vacuum.
alignment pin (8).
CAUTION: If a diaphragm has ruptured and foreign
b. Install capscrew (22) with flat washer (3) through center
material or water has entered the oil reservoir, do
hole in valve plate and torque to 45 ft-lbs (60 N-m).
not operate the pump. Check all diaphragms, then
flush the reservoir completely (as outlined below) c. Install new O-rings (5, 6, 7) into grooves in front side
and refill it with fresh oil. Never let the pump stand of valve plate. Use grease or petroleum jelly to hold in
with foreign material or water in the reservoir, or with place.
the reservoir empty. d. Reinstall manifold (4) over alignment pin (8), engaging
e. Clean away any spilled oil. center spud of manifold into center of valve plate.
f. Install good or new diaphragm and tighten to 10 in.-lbs e. Install capscrews (1) with flat washers (3) through five
(110 N-cm). center holes in manifold. Thread each capscrew in
several turns, but do not torque.
g. Repeat above inspection procedure (and replacement,
if necessary) with other four diaphragms. f. Install capscrews (2) with flat washers (3) through twelve
outer holes at perimeter of manifold. Thread each
capscrew in several turns, but do not torque.

4. Flush Contaminant from g. Return to five capscrews at center of manifold and

alternately tighten opposite bolts until all are secure.
Hydraulic End (only if diaphragm Torque to 45 ft-lbs (60 N-m).
h. Return to twelve capscrews at perimeter of manifold and
has ruptured) alternately tighten opposite bolts until all are secure.
a. With valve plate and manifold still removed (see above), Torque to 45 ft-lbs (60 N-m).
remove oil drain cap (26) allow all oil and contaminant to i. Recheck all capscrews for tightness and proper torque,
drain out. starting with five at center of manifold, then twelve at
perimeter.

10 P500-991-2400
P500 Troubleshooting
Problem Probable Cause Solution
No power. Supply correct power according to motor requirements.

Blown fuse/tripped circuit Replace/reset, eliminate circuit overload.

breaker.
Shaft coupling to pump not in Install proper coupling hardware (see parts list).
place.
Motor/Pump Current overload - motor. Motor not rated for pump operating conditions - install proper motor.
Does Not
Operate: 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 Fill tank.
(if low-level shut-off is used).
Supply tank empty. Fill tank.
Inlet line or strainer clogged. Clear debris and flush, or replace.
Inadequate supply pressure at Increase supply pressure by raising fluid level in tank, raising tank, or
pump inlet. pressurizing suction tank.
Inlet line too restrictive. Increase inlet line diameter and/or decrease inlet line length.

No Delivery 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 Clear debris and flush, or replace (see Fluid End Service)
worn out.
System relief valve actuating. Adjust relief valve, or repair, clean, or replace with new relief valve.

Review all Probable Causes and Solutions in Problem 2 No Delivery above.

Air leak 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 Monitor supply tank temperature to determine if fluid is too hot (leading to
changed. cavitation) or too cold (increasing fluid viscosity). Stabilize temperature
at suitable level to resolve problem. Check for entrapped air in the fluid
Delivery Too supply system.
Low and/or
Erratic 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 Evaluate components and repair/correct problem.
or flow meter error.
Oil condition in pump hydraulic Check oil level - if low evaluate for source of leakage. Consult factory for
end changed. hydraulic end service.
Change oil per recommended guidelines in maintenance section.

System back pressure too low. Adjust back pressure valve to higher setting. Install back pressure valve if
none in system.
Delivery Too Inlet supply pressure changed. Monitor inlet supply pressure (at the pump) to determine if it is too high,
High and/or causing a “flow-through” condition. Stabilize pressure at suitable level to
Erratic. resolve problem.
Pump OK - Calibration system Evaluate components and repair/correct problem.
or flow meter error.

11 P500-991-2400
P500 Fluid End Parts List
Bolt Torque Specifications
Ref. No. Assembly Torque
1 45 ft-lbs (60 N-m)
2 45 ft-lbs (60 N-m)
22 45 ft-lbs (60 N-m)
29 15 ft-lbs (20 N-m)
32 45 ft-lbs (60 N-m)

0
1 2

3
3

4 DETAIL "A"
(Valve Assemblies)

7 OUTLET VALVE INLET VALVE

5 Metal Retainer Metal Retainer
Valve
20 9
6 Assemblies
(see Detail A)
19 10

18 11
22
3 16 12

15 14

24

29 21

33 30
8

32

25 26 31

23

34

28
37

W0317
27
35

36 34

12 P500-991-2400
P500 Fluid End Parts List
Ref. Quantity/ Ref. Quantity/
No. Part Number Description Pump No. Part Number Description Pump
0 D25-038-2017 Plug, Hastelloy C, NPT........................2 16 D15-020-2011 Valve Seat, outlet, Nitronic 50.............5
D25-038-2211 Plug, 316 SST, NPT.............................2 D15-020-2017 Valve Seat, outlet, Hastelloy C............5
G25-038-2017 Plug, Hastelloy C, BSPT......................2
17 D03-092-2110 Tetra Seal, outlet, Buna.......................5
G25-038-2211 Plug, 316 SST, BSPT...........................2
D03-092-2111 Tetra Seal, outlet, Viton.......................5
1 G15-081-2012 Screw, cap, socket head, sst..............5
18 D03-021-1011 Valve, outlet, Nitronic 50......................5
2 G10-024-2012 Screw, cap, socket head, sst ............12 D03-021-1017 Valve, outlet, Hastelloy C.....................5
3 100-037 Washer, flat, sst.................................17 19 D15-022-3113 Valve Spring, outlet, Hastelloy C.........5
4 D15-004-1012 Manifold, 316L SST, NPT.....................1 D15-022-3114 Valve Spring, outlet, Elgiloy.................5
D15-004-1018 Manifold, Hastelloy C, NPT..................1 20 D03-023-1017 Retainer, outlet valve spring,
G15-004-1012 Manifold, 316L SST, BSPT..................1 Hastelloy C...........................................5
G15-004-1018 Manifold, Hastelloy C, BSPT...............1
21 D15-018-1220 Diaphragm, Buna-N-XS.......................5
5 D40-073-2110 O-ring, outer manifold, Buna...............1 D15-018-1215 Diaphragm, Viton-XT...........................5
D40-073-2111 O-ring, outer manifold, Viton................1
22 G10-087-2010 Screw, cap soc hd................................1
6 D15-073-2110 O-ring, middle manifold, Buna.............1
23 G15-002-1010 Cylinder Housing..................................1
D15-073-2111 O-ring, middle manifold, Viton.............1
24 D15-003-1012 Valve Plate, 316L SST.........................1
7 D35-080-2120 O-ring, inner manifold, Buna................1
D15-003-1018 Valve Plate, Hastelloy C.......................1
D35-080-2121 O-ring, inner manifold, Viton................1
25 D25-077-2210 Pipe, Brass...........................................1
8 D15-026-2210 Pin, dowel.............................................1
26 D25-078-2210 Pipe Cap, Brass...................................1
9 D10-035-2110 O-ring, inlet valve seat, Buna..............5
D10-035-2111 O-ring, inlet valve seat, Viton...............5 27 D10-080-2110 O-ring, Buna.........................................1
10 D15-020-1011 Valve Seat, inlet, Nitronic 50................5 28 D03-039-1030 Cap with O-ring, oil fill..........................1
D15-020-1017 Valve Seat, inlet, Hastelloy C..............5 29 C22-015-2014 Screw, cap soc hd.................................4
11 D10-021-1011 Valve, inlet, Nitronic 50........................5 30 D15-025-1033 Base Plate............................................1
D10-021-1017 Valve, inlet, Hastelloy C.......................5
31 G35-084-2010 Lockwasher..........................................4
12 D10-022-3117 Valve Spring, inlet, Elgiloy...................5
32 G35-087-2010 Screw, cap hex hd...............................................4
D10-022-3123 Valve Spring, inlet, Hastelloy C...........5
33 D35-111-2010 Plug, magnetic.....................................1
13 D10-092-2110 Tetra Seal, inlet, Buna..........................5
D10-092-2111 Tetra Seal, inlet, Viton..........................5 34 D25-038-2210 Plug, Brass...........................................2
14 D10-023-1017 Retainer, inlet valve spring, .................. 35 D10-040-2420 Nameplate............................................1
Hastelloy C...........................................5 36 D10-112-2200 Rivet.....................................................4
15 D25-046-2110 O-ring, outlet valve seat, Buna............5 37 G15-001-1033 Pump Housing......................................1
D25-046-2111 O-ring, outlet valve seat, Viton............5

13 P500-991-2400
P500 Hydraulic End Parts List
Bolt Torque Specifications
Ref. No. Assembly Torque
40 15 ft-lbs (20 N-m)

23
38

39 47

40

48
41

42 49

Cross-Section 50
Assembly

43 A 57
51

43
52
43

53

54
44 43 B
55 *

56

45

* Qty per piston: 4

46

37

W0086

14 P500-991-2400
P500 Hydraulic End Parts List
Ref.
No. Part Number Description
Quantity/
Pump Hydraulic End Service
38 D15-075-3110 Spring, disk..........................................6 CAUTION: Do not disassemble or service the
hydraulic end.
39 D15-112-1010 Guide, disk spring................................1
40 G15-115-2010 Screw, cap, soc hd...............................1
For assistance, contact Wanner Engineering at
(612)332-5681 for the distributor in your area.
41 D15-012-1010 Plate, bearing adjustment....................1
42 D15-110-2210 Pin, dowel.............................................1
43 D15-007-1210 (X) Cam Assembly 1............................1
44 D25-085-2211 Key, shaft.............................................1
45 H25-031-2112 Seal shaft.............................................2
46 D15-037-2110 O-ring, Buna.........................................1
47 D10-019-3110 Spring, piston return.............................5
48 D10-042-1010 Retainer, spring....................................5
49 D10-046-2110 O-ring, Buna.........................................5
50 D10-045-3110 Spring, sleeve valve.............................5
51 D15-044-1010 Plunger, valve.......................................5
52 D10-043-1010 Cylinder, valve......................................5
53 D10-034-2110 O-ring, Buna.........................................5
54 D10-041-1010 Washer, retaining.................................5
55 D10-015-3010 Ball, steel........................................... 20
56 D15-014-1209 Piston (with foot, retainer and balls)....5
57 D15-014-1210 Piston Assembly, Buna 2......................5

1
Cam Assembly includes cam, shaft, wobble plate, bearings,
and cups. It is only available as an assembly.
2
Piston Assembly includes items 47 through 55.

15 P500-991-2400
P500 Reducer Parts List (1 of 3)
Ref Quantity/ Ref Quantity/
No. Part Number Description Pump No. Part Number Description Pump
100 112-331 Reducer, 7.5:1 ratio, 56C 101 112-312 Kit, Protective Cover............................1
(requires item 111)................................1
102 112-313 Kit, Output Flange, FC.........................1
112-332 Reducer, 10:1 ratio, 56C
(requires item 111)................................1 103 112-320 Shaft Key Retainer...............................1
Reducer, 10:1 ratio, 143/145TC ..........1 106 A04-046-2012 Screw, hex hd.......................................4
112-333 Reducer, 15:1 ratio, 56C
107 D40-048-2010 Washer, flat..........................................4
(requires item 111) . .............................1
Reducer, 15:1 ratio, 143/145TC ..........1 111 112-350 Motor Adapter......................................1
112-304 Reducer, 20:1 ratio, 56C .....................1 44 D25-085-2211 Key, shaft.........................................Ref
112-334 Reducer, 20:1 ratio, 143/145TC ..........1
112-305 Reducer, 25:1 ratio, 56C .....................1
112-335 Reducer, 25:1 ratio, 143/145TC ..........1
112-306 Reducer, 30:1 ratio, 56C .....................1
112-336 Reducer, 30:1 ratio, 143/145TC ..........1
112-307 Reducer, 40:1 ratio, 56C .....................1
112-337 Reducer, 40:1 ratio, 143/145TC ..........1
112-308 Reducer, 50:1 ratio, 56C .....................1
112-309 Reducer, 60:1 ratio, 56C .....................1
112-310 Reducer, 80:1 ratio, 56C .....................1
112-311 Reducer, 100:1 ratio, 56C ...................1

102
44

111
W0318

P500 Pump Assembly

101

107
106
100
103

16 P500-991-2400
P500 Reducer Parts List (2 of 3)
Ref Quantity/ Ref Quantity/
No. Part Number Description Pump No. Part Number Description Pump
110 112-500 Reducer, 5:1 ratio, 56C .......................1 117 112-520 Flange, input, 56C................................1
Reducer, 5:1 ratio, 143/145TC ............1 112-521 Flange, input, 143/145TC.....................1
Reducer, 5:1 ratio, 182/184TC ............1 112-522 Flange, input, 182/184TC.....................1
112-501 Reducer, 7.5:1 ratio, 143/145TC .........1 Screw, cap, ½ in. (part of 117).............4
Reducer, 7.5:1 ratio, 182/184TC .........1 Screw, cap, M8 (part of 117)................4
112-502 Reducer, 10:1 ratio, 182/184TC ..........1 118 112-525 Shaft.....................................................1
112-503 Reducer, 15:1 ratio, 182/184TC ..........1
119 D25-085-2211 Key, 2 inch............................................1
111* 112-517 Base, 182/184TC.................................1
112* S1256-014 Screw, SST, 182/184TC.....................12
113* 100-657 Washer, flat, SST, 182/184TC............12
114* 112-519 Support, SST, 182/184TC....................2
115* D10-048-2012 Washer, lock, SST, 182/184TC............4
116* 100-036 Nut, lock, SST, 182/184TC...................4
* Used with 182/184TC reducers only.

115-522 Flange Shown

P500 Pump Assembly

119
W0352

117

112

118

110
112

112
111
115

113

116

113

116
114

17 P500-991-2400
P500 Reducer Parts List (3 of 3)
Ref Quantity/ Ref Quantity/
No. Part Number Description Pump No. Part Number Description Pump
110 112-700 Reducer, 5:1 ratio, 213/215TC.............1 119 A04-116-2201 Hub, coupling, 213/215TC....................1
112-701 Reducer, 7.5:1 ratio, 213/215TC..........1 A04-118-2201 Hub, coupling, 254/256TC....................1
112-800 Reducer, 5:1 ratio, 254/256TC.............1 120 100-989 Screw, SST...........................................4
111 112-717 Base.....................................................1 121 C22-018-3102 Washer, flat, SST..................................4
112 100-913 Screw, SST...........................................8
113 D10-048-2012 Washer, flat, SST..................................8
114 112-821 Guard, 213/215TC................................1
112-822 Guard, 254/256TC............................... 1
117 A04-116-2205 Hub, coupling, 213/215TC....................1
A04-118-2203 Hub, coupling, 254/256TC....................1
118 A04-115-2200 Sleeve, coupling, 213/215TC...............1
A04-117-2200 Sleeve, coupling, 254/256TC...............1

P500 Pump Assembly

114

112
Ref W0359

113

120

121

119
118
117

112

113

111

110

18 P500-991-2400
P500 Replacement Parts Kits
TO ORDER REPLACEMENT PARTS KIT: A Replacement Parts Kit contains 9 digits corresponding to customer-specified design options.

1 2 3 4 5 6 7 8 9

Order
Digit Code Description Kit Contents
1-2 Pump Configuration
P5 For all P500 Pumps Kit Designator
3 Kit Designator Part Number* Description Qty K D V
K Complete Fluid End Kit* D15-018-___ Diaphragm 5 • •
D Diaphragm Kit*
V Valve Kit
D40-073-___ O-ring, outer manifold 1 • • •
4-5 Pump Head Version
D15-073-___ O-ring, middle manifold 1 • • •
51 Standard D35-080-___ O-ring, inner manifold 1 • • •
6 Spring Retainers/Dampening Washers D10-035-___ O-ring, valve seat, inlet 5 • •
S For 316 Stainless Steel pump head D15-020-___ Valve seat, inlet 5 • •
T For Hastelloy ® C pump head
X Not included in Diaphragm Kit
D10-021-___ Valve, inlet 5 • •
7 Diaphragm & O-ring Material
D10-022-___ Valve spring, inlet 5 • •
G Viton® -XT
D10-023-___ Retainer, valve spring, inlet 5 • •
S Viton® -XT (Food Contact Oil) D25-046-___ O-ring, valve seat, outlet 5 • •
X Viton® -XT (Synthetic Oil) D15-020-___ Valve seat, outlet 5 • •
T Buna-N-XS
F Buna-N-XS (Food Contact Oil)
D03-021-___ Valve, outlet 5 • •
Y Buna-N-XS (Synthetic Oil) D03-022-___ Valve spring, outlet 5 • •
8-9 Check Valve Material D10-023-___ Retainer, valve spring, outlet 5 • •
(Valve Spring / Valve & Seat) A01-113-3400 Threadlocker 1 • •
SS 316 SST / 316 SST Hydraulic End Oil (2.5 qt)
TT Hastelloy ® C / Hastelloy ® C
XX Not included in Diaphragm Kit * Last four digits of part numbers with –___ refer to specific material
of construction.
* K&D Kits include hydraulic end oil: oil not included in V Kit.

19 P500-991-2400
 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.

1204 Chestnut Avenue, Minneapolis, MN 55403

TEL: (612) 332- 5681 FA X: (612) 332- 6937
TOLL-FREE FAX [US only]: (800) 332-6812
www.hydra-cell.com/metering
email: [email protected]
© 2007 Wanner Engineering, Inc. Printed in USA
20 P500-991-2400 3/2007