Wheeler-Rex 465210 Operating Instructions Manual

WEIGHT: 105 lbs. 48 kg PUMP: Triple Diaphragm: Positive Displacement Ports: 3/4” inlet ; 1/2” NPT outlet Capacity: 10gpm, 38lpm Pressure: 0-500psi Operating Speed: 550rpm (max) 400rpm (min) Lubrication: Pump 30W Non-Detergent Gear 80/90W Gear Oil Shaft Size: 1” Female ENGINE: Honda 5.5hp, 4 cycle, gasoline CONTROL: 50 – 500psi adjustable pressure relief GAUGE: Glycerin filled, 0 – 1000psi, 0-69bar DISCHARGE HOSE: 1/2” x 10’ (3m) 2000psi rated INLET HOSE: ¾” x 10’ (3m) with strainer 465230 Operating Instructions Models 46521, 465210, 46523, 465230 Hydrostatic Test Pumps DIMENSIONS: 23” (57cm) L x 20” (51cm) W x 19.5” (50cm) H WEIGHT: 105 lbs. 48 kg PUMP: Triple Diaphragm: Positive Displacement Ports: 3/4” inlet ; 1/2” NPT outlet Capacity: 10gpm, 38lpm Pressure: 0-500psi Operating Speed: 550rpm (max) 400rpm (min) Lubrication: Pump 30W Non-Detergent Gear 80/90W Gear Oil Shaft Size: 1” Female ENGINE: 6.5hp Briggs & Stratton Intek Pro, 4 cycle, gasoline CONTROL: 50 – 500psi adjustable pressure relief valve GAUGE: Glycerin filled, 0 – 1000psi, 0-69bar DISCHARGE HOSE: 1/2” x 10’ (3m) 2000psi rated INLET HOSE: ¾” x 10’ (3m) with strainer 46523

WEIGHT: 111 lbs. 50.5 kg PUMP: Triple Diaphragm: Positive Displacement Ports: 1” inlet ; ¾” NPT outlet Capacity: 10gpm, 38lpm Pressure: 0-500psi Operating Speed: 550rpm Lubrication: Pump 30W Non-detergent Gear 80/90W Gear Oil Shaft Size: 1” Female ENGINE: Honda 5.5hp, 4 cycle, gasoline CONTROL: 0 – 500psi adjustable pressure relief GAUGE: Glycerin filled, 0 – 600psi, 0-42kg DISCHARGE HOSE: ¾” x 10’ (3m) 1000psi rated INLET HOSE: ¾” x 10’ (3m) with strainer 465210 Operating Instructions Models 46521, 465210, 46523, 465230 Hydrostatic Test Pumps DIMENSIONS: 28” (71cm) L x 20” (51cm) W x 19.5” (49.5cm) H WEIGHT: 111 lbs. 50.5 kg PUMP: Triple Diaphragm: Positive Displacement Ports: 1” inlet ; ¾” NPT outlet Capacity: 10gpm, 38lpm Pressure: 0-500psi Operating Speed: 550rpm Lubrication: Pump 30W Non-detergent Gear 80/90W Gear Oil Shaft Size: 1” Female ENGINE: 6.5hp Briggs & Stratton Intek Pro, 4 cycle, gasoline CONTROL: 0 – 500psi adjustable pressure relief valve GAUGE: Glycerin filled, 0 – 600psi, 0-42kg DISCHARGE HOSE: ¾” x 10’ (3m) 1000psi rated INLET HOSE: ¾” x 10’ (3m) with strainer 46521

Hydrostatic Test Pumps A Engine Controls (throttle, choke, gas ON/OFF) B Pull Start C Power Switch ON/OFF D Dipstick / Engine oil fill 465210 / 465230 A B D C

Hydrostatic Test Pumps E Pump gear lube vent cap / fill F Relief valve adjustment G Relief valve jam nut H Isolation valve I Gauge J Outlet connection K Dump Valve L K J I H G F E O N M L Dump port M` Inlet connection N Strainer bowl O Pump diaphragm oil reservoir

This method requires a tank with a water outlet at the bottom. The water tank’s outlet should be level with or above the level of the water inlet connection on the pump. This allows water to flow naturally into the test pump. Connecting a pressure fed water line is harmful to the diaphragms in the pump. 1. Fill the water line (or test vessel) to be tested prior to pump connection. 2. Connect water supply hose to the garden hose inlet connection (M) on the pump. 3. Open valve and turn water supply on. 4. Purge the pump and pressure hose of all air. 5. Connect output (pressure) hose connection (J) between pump and water line (or vessel) being tested. 6. Turn pump on. 7. Purge water line (or vessel) of all air at the highest point of the system. 8. Bring water line (or vessel) to pressure. Watch the gauge (I) while pumping. When the desired pressure is achieved, turn the isolation valve (H) to the “off” position. The engine can now be turned off. If pressure drops, there is a leak in the line. Siphon Method Use a clean water source 1. Fill the water line to be tested. 2. Fill the intake hose with water, then quickly place the hose into a bucket and turn pump on. (Unit is self-priming once primed). Continue to run pump until you see the water coming out of the outlet hose, with little or no air mixed with it. 3. Connect the output hose to the water line. Continue on with steps 6 through 8 in Gravity Feed Method. Operating Instructions Models 46521, 465210, 46523, 465230 Hydrostatic Test Pumps

Your pump can be pre-set to a specific pressure easily by adjusting the pressure relief valve. 1. Loosen the jam nut (G) on pressure relief valve. Then unscrew (counterclockwise direction) the pressure relief valve knob (F) a few turns . Be sure not to unscrew the knob too far as the knob and nut can easily be lost. 2. Add a ball valve (not supplied with pump) to the end of the high pressure hose. 3. Follow steps 2 through 4 from the ‘Gravity Feed Method’. 4. As water is flowing out of the high pressure hose, turn the ball valve to the off position. 5. Slowly start turning pressure relief valve knob (F) in the clockwise direction by ¼ turn increments, until you reach the desired pressure. Tighten jam nut (G) to hold at this desired pressure. 6. Your test pump is now pre-set. This eliminates over-pressurizing the water line (or the vessel). Operating Instructions Models 46521, 465210, 46523, 465230 Hydrostatic Test Pumps

Test pressure not being reached: Possible air in line (or vessel) Air needs to be purged from system. Remove pump from system and follow steps 1 through 6 of the “Pre-setting Your Pump” section. If using the Siphon Method and not getting pressure, try the ‘‘Gravity Feed Method’ to ensure water is getting into the pump. Check strainer (F) O-Ring for cracks.  Oil Reservoir is milky in color  Diaphragm is cracked, causing water to mix with oil. Diaphragm needs replaced. Pressure relief valve not adjusted properly. Turn relief valve counterclockwise and watch gauge (C) for change in pressure. Pump Maintenance Pump 50/50 antifreeze/water solution through pump after each use to avoid freezing and to lubricate pump. Check strainer (F) O-Ring for cracks prior to each use. Check and change engine oil per manufacturers specifications. Gear reduction Gear Lube. Check and change per manufacturers specifications. Pump repair kit (Wheeler Rex PN 36345) Suction Hose (Wheeler Rex PN 34550) Pump Oil Reservoir - Check and change per manufacturers specs. Use 30W Non-detergent oil Dump Valve Dump valve is designed to dump off pressure when the test is complete.. Operating Instructions Models 46521, 465210, 46523, 465230 Hydrostatic Test Pumps CAUTION !!! This pump is designed for water only!! The pump is equipped with an adjustable pressure relief valve (A), which helps protect the system from being over pressurized. It can be preset by plugging the end of the hose. Turn the adjusting knob clockwise to increase pressure and counterclockwise to decrease.

1 3 275857 5/16-18 HEX NYLON-INSERT LOCKNUTS 7 4 275638 5/16 x 1 1/2" HEX HEAD CAP SCREW 4 5 275685 5/16" FLAT WASHER 2 6 277303 COMET PUMP ASSEMBLY 1 7 220874 NAME PLATE 1 8 275543 POP RIVET, STAR 4-2AAD 4 9 701542 PUMP BRACE (COMET) 1 10 701543 MANIFOLD BLOCK (COMET) 2 11 275697 1/2" 3000LB FS SCRD 90 ELL 1 12 276341 RELIEF VALVE 1 13 277302 1/2" MNPT x 1/2 HB 90 ELBOW 1 14 275788 GAGE 0-1000 PSI 1 15 275670 1/2 x 1/4 FS SCRD HX BUSH 1 16 275368 HEX SOCKET 1/2" NPT PIPE PLUG 1 17 275689 1/2 NPT x 1/2 SWIVEL ADAPTER 2 18 275675 1/2" VALVE 2 19 275669 1/2 x CLOSE PIPE NIPPLE 3 20 275666 1/2" FS SCRD STREET ELL 2 21 277220 U-BOLT 1 22 729 1/4-20 THIN ESNA NUT 2 23 1020 5/16-18 x 1" HEX HEAD CAP SCREW 1 24 275932 STRAINER, HYPRO 3350-0040P 1 25 276102 3/4" BRASS CLOSE NIPPLE 1 26 275644 3/4" TEE 1 27 275874 3/4" FH x 3/4" FP ADAPTER 1 28 701544 INLET BRACE 1 29 276184 3/4 NPTx 1/2 90 DEG HOSE BARB 1 30 276185 HOSE CLAMP 2 31 276099 3/4" HOSE QUICK DISCONNECT 1 32 560081 1/4-20 x 3/4" HHCS 2 33 276540 1/4" FLAT WASHER 16 34 701547 CONNECTION HOSE 1 35 277304 3/4 MP x 1" MH 90 DEG HOSE BARB 1 36 277200 SMALL U-BOLT 1 37 700641 HIGH PRESSURE HOSE 22" 1 38 701546 BY-PASS HOSE 1 39 277305 5/16" x 3 3/4" LONG HHCS 2 40 275426 1/4-20 ESNA STOP NUT 2 41 275335 HOSE CLAMP 2 42 277322 3/4" x 2 1/2" LONG BRASS NIPPLE 1 43 277181 WARNING TAG ***NOT SHOWN*** 1 44 34550 SUCTION HOSE ASSEMBLY ***NOT SHOWN*** 1 45 221065 PRESSURE HOSE ***NOT SHOWN*** 1

1 2 275857 5/16-18 HEX NYLON-IINSERT LOCKNUTS 11 3 275638 5/16 x 1 1/2" HEX HEAD CAP SCREW 4 4 277303 COMET PUMP ASSEMBLY 1 5 220874 NAME PLATE 1 6 275543 POP RIVET, STAR 4-2AAD 4 7 701542 PUMP BRACE (COMET) 1 8 701543 MANIFOLD BLOCK (COMET) 2 9 275697 1/2" 3000LB FS SCRD 90 ELL 1 10 276341 RELIEF VALVE 1 11 277302 1/2" MNPT x 1/2 HB 90 ELBOW 1 12 275788 GAGE 0-1000 PSI 1 13 275670 1/2 x 1/4 FS SCRD HX BUSH 1 14 275368 HEX SOCKET 1/2" NPT PIPE PLUG 1 15 275689 1/2 NPT x 1/2 SWIVEL ADAPTER 2 16 275675 1/2" VALVE 2 17 275669 1/2 x CLOSE PIPE NIPPLE 3 18 275666 1/2" FS SCRD STREET ELL 2 19 729 1/4-20 THIN ESNA NUT 2 20 1020 5/16-18 x 1" HEX HEAD CAP SCREW 1 21 275932 STRAINER, HYPRO 3350-0040P 1 22 276102 3/4" BRASS CLOSE NIPPLE 1 23 275644 3/4" TEE 1 24 275874 3/4" FH x 3/4" FP ADAPTER 1 25 701544 INLET BRACE 1 26 276184 3/4 NPTx 1/2 90 DEG HOSE BARB 1 27 276185 HOSE CLAMP 2 28 276099 3/4" HOSE QUICK DISCONNECT 1 29 560081 1/4-20 x 3/4" HHCS 2 30 276540 1/4" FLAT WASHER 21 31 701547 CONNECTION HOSE 1 32 277304 3/4 MP x 1" MH 90 DEG HOSE BARB 1 33 277220 U-BOLT 1 34 700641 HIGH PRESSURE HOSE 22" 1 35 701546 BYPASS HOSE 1 36 277305 5/16" x 3 3/4" Long HHCS 2 37 701549 ROLL CAGE (XL) 1 38 701548 BASE PLATE (COMET) 1 39 276443 RUBBER FOOT 4 40 275639 5/16-18 x 1 3/4" HHCS 4 41 275426 1/4-20 ESNA STOP NUT 2 42 275335 HOSE CLAMP 2 43 277322 3/4" x 2 1/2" LONG BRASS NIPPLE 1 44 221065 PRESSURE HOSE ***NOT SHOWN*** 1 45 277181 WARNING TAG ***NOT SHOWN*** 1 46 34550 SUCTION HOSE ASSEMBLY***NOT SHOWN*** 1 47 277200 SMALL U-BOLT 1

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