Gardner Denver GD-3000 Operating And Service Manual

GARDNER DENVER®

WELL SERVICING PUMP

MODEL

3-1-618 Revision D

April 2011

GD-3000

OPERATING AND
SERVICE MANUAL

ECN 1058968

GD-3000

WELL SERVICING PUMP

MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITH

GENUINE GARDNER DENVER

PARTS AND SUPPORT SERVICES

Gardner Denver® genuine pump parts are manufactured to design tolerances and are developed for
optimum dependability. Design and material innovations are the result of years of experience with
hundreds of different pump applications. Reliability in materials and quality assurance is incorporated in
our genuine replacement parts.

Your authorized Gardner Denver Sales Office offers all the backup you’ll need. The Tulsa
Manufacturing Facility maintains a large inventory of genuine parts.

Gardner Denver supports your needs with these services:

1. Trained parts specialists to assist you in selecting the correct replacement parts.

2. Repair and maintenance kits designed with the necessary parts to simplify servicing your pump.
Authorized service technicians are factory trained and skilled in pump maintenance and repair. They

are ready to respond and assist you by providing fast, expert maintenance and repair services.

For the location of your local authorized Gardner Denver distributor, refer to the yellow
pages of your phone directory or contact:

Factory
(Tulsa)

Gardner Denver Well Servicing Pumps
4747 South 83rd East Avenue
Tulsa, Oklahoma 74145

Phone: [phone]
[phone]

Fax: [phone] Fax: [phone] Fax: [phone]

INSTRUCTIONS FOR ORDERING REPAIR PARTS

When ordering parts, specify Pump MODEL and SERIAL NUMBER (see nameplate on unit).
The Serial Number is also stamped on top of the cylinder end of the frame (cradle area).

All orders for Parts should be placed with the Tulsa or Ft. Worth facility.

Where NOT specified, quantity of parts required per pump or unit is one (1); where more than
one is required per unit, quantity is indicated in parenthesis. SPECIFY EXACTLY THE

NUMBER OF PARTS REQUIRED.

Service Center
(Odessa)

Chaparral
2121 West 44th Street
Odessa, Texas 79768

Phone: [phone]
[phone]

Service Center
(Ft. Worth)

Geoquip
7533 Kathy Lane
Ft. Worth, Texas 76126

Phone: [phone]
[phone]

3-1-618 Page i

FOREWORD

Gardner Denver® pumps are the result of advanced engineering and skilled manufacturing. To
be assured of receiving maximum service from this pump the owner must exercise care in its
operation and maintenance. This book is written to give the operator and maintenance personnel
essential information for day-to-day operation, maintenance and adjustment. Careful adherence
to these instructions will result in economical operation and minimal downtime.

DANGER

Danger is used to indicate the presence of a hazard, which will cause severe
personal injury, death or substantial property damage if the warning is ignored.

WARNING

Warning is used to indicate the presence of a hazard, which can cause severe
personal injury, death or substantial property damage if the warning is ignored.

Caution is used to indicate the presence of a hazard, which will or can
cause minor personal injury or property damage if the warning is ignored.

CAUTION

NOTICE

Notice is used to notify people of installation, operation or maintenance
information which is important but not hazard related.

3-1-618 Page ii

TABLE OF CONTENTS

Maintain Pump Reliability and Performance with Genuine Gardner Denver Parts and

Support Services...........................................................................................................i

Instructions For Ordering Repair Parts..................................................................................i

Foreword...............................................................................................................................ii

Index.....................................................................................................................................iv

List of Illustrations.................................................................................................................v

Section 1, Danger Notices.....................................................................................................1

Section 2, Design, Description and Specifications.................................................................9

Section 3, Preparation, Operation and Maintenance..............................................................15

Section 4, Service Procedures..............................................................................................21

Section 5, Trouble-Shooting..................................................................................................28

Section 6, Rebuilding Data, Recommended Running Clearances and Torques.....................34

Warranty.......................................................................................................................... Last Page

3-1-618 Page iii

Crankshaft Assembly.................................. 26

Crosshead Assembly ….............................. 24

Crosshead Guide and Tie Rods ….............. 25

Daily Routine Maintenance Schedule.......... 19

DANGER NOTICES, SECTION 1................. 1

Covers and Guards............................... 2

Equipment Moving and Lifting............... 2

Flammable, Hot, Cold or Corrosive

Fluid Pumping............................... 5

Hammer Lug Fasteners………………... 1
High Pressure Liquid Jetting,

Blasting and Cleaning................... 6

Pressurized Pump Systems.................. 3

Valve Seat Pulling ................................ 2

DESIGN DESCRIPTION AND

SPECIFICATIONS, SECTION 2 ........... 9

Fluid End Description.................................. 13

Fluid End Removal and Installation ............ 21

Fluid End Service....................................... 21

Foreword …………………………………..…...ii

Gear Reduction Unit...............................11,26

General Requirements and Safety Rules.... 21

General Specifications................................ 14

Introduction................................................... 9

Lube Pump Suction Piping Sizing and

Requirements..................................... 16

Lube System Pump.................................... 16

Lubrication, Plunger / Packing .................... 17

Monthly Routine Maintenance Schedule..... 19

Oil Stop Head Seal Retainer and Crosshead

Guide End Plate ................................. 24

Ordering Instructions, Repair Parts................ i

INDEX

Performance Rating....................................... 14

Periodic Routine Maintenance Schedule........ 18

Plunger / Packing Lubrication........................ 17

Plunger Packing Lubrication Recommendation

Chart....................................................... 20

Plungers and Packing Replacement .............. 22

Power End.................................................10,24

Power End and Gear Reduction

Unit Lube System.................................... 12

Power End Lubrication System...................... 16

Preparation after Shipping and Storage......... 15

PREPARATION, OPERATION AND

MAINTENANCE, SECTION 3.................. 15

Pump Design................................................. 10

Pump Mounting Instructions........................... 15

Quarterly Routine Maintenance Schedule...... 19

Rebuilding Data............................................. 34

REBUILDING DATA, RECOMMENDED
RUNNING CLEARANCES AND

TORQUES, SECTION 6.......................... 34

Recommended Running Clearances – Actual 34

Repair Parts, Ordering Instructions................... i

SERVICE PROCEDURES, SECTION 4 ........ 21

Specifications, General.................................. 14

Startup and New Pump Run-In Procedure..... 17

Torques......................................................... 35

TROUBLE-SHOOTING, SECTION 5............. 28

Warranty ................................................ Last Page

Valve and Seat Replacement ........................ 22

3-1-618 Page iv

LIST OF ILLUSTRATIONS

Figure #

Figure 2-1 GD 3000 Pump...................................................................................... 9

Figure 2-2 GD 3000 Power End..............................................................................10

Figure 2-3 GD 3000 Power End Top View...............................................................11

Figure 2-4 GD 3000 Gear Reduction Unit ............................................................... 12

Figure 2-5 GD 3000 Fluid End................................................................................ 13

Figure 3-1 Lubricant Recommendations ................................................................. 17

Figure 4-1 Tightening Sequence for Fluid End Nuts................................................ 22

Figure 4-2 Packing Assembly ................................................................................. 22

Figure 4-3 Crosshead Assembly............................................................................. 25

Description Page

3-1-618 Page v

SECTION 1
DANGER NOTICES

DANGER

Read and understand the following
DANGER NOTICES before moving or
operating the pump or any pump package
unit equipment.

Reciprocating pumps are machines capable
of producing high fluid pressures and flow
rates and are designed to be used with
proper care and caution by trained,
experienced operators. TO AVOID

PERSONAL INJURY, DEATH AND/OR
EQUIPMENT DAMAGE, READ AND
THOROUGHLY UNDERSTAND THE
FOLLOWING DANGER NOTICES PLUS
THE ENTIRE OPERATING AND SERVICE
MANUAL BEFORE ATTEMPTING TO
MOVE OR OPERATE THE PUMP. Contact

a Gardner Denver service representative if
you are unable to comply with any of the
danger notices or procedures described in
these documents.

Closely examine the pump performance
data upon pump delivery to become
thoroughly familiar with the operating limits
for this pump model. The pump must

never

be operated at speeds, pressures
or horsepower exceeding the maximum
values or at speeds below the minimum.
Failure to observe the operating limits
could result in personal injury, death,
and/or equipment damage and will void
the warranty. Alterations to the pump, or

application of the pump outside the limits,
must not be made without Gardner Denver
written approval, together with a new set of
performance data, as dangerous operating
conditions could result.

Keep in mind that full operator attention and
alertness are required when operating high
pressure pumping equipment. Operators
should not begin or continue operations
when tired, distracted or under the influence
of alcohol or any type of prescription or
nonprescription drugs.

The timely replacement of expendable parts
and any other worn or damaged parts can

prevent equipment damage and possible
injury. The original parts used in Gardner
Denver pumps are designed and tested to
exacting standards to provide high quality
performance and durability. Your best
insurance in maintaining these
characteristics is to use genuine Gardner
Denver replacement parts.

A broad range of danger notices are
covered on these pages, however, they
cannot substitute for training, experience
and common sense in the safe operation of
high pressure pumping equipment.

HAMMER LUG FASTENERS

DANGER

On pumps equipped with hammer lug
unions and/or hammer lug valve covers the
following precautions must be observed to
avoid personal injury, death and/or
equipment damage due to contact with the
hammer, broken parts from the hammer,
lugs or other objects propelled by hammer
blows. When tightening or loosening
hammer lug unions and valve covers,
operators or maintenance personnel should:

• Inspect the hammer and hammer lugs
to insure they are all in good condition.
Replace any of these parts which are
cracked, damaged or badly worn.

• Wear safety shoes and safety glasses.

• Alert other personnel to move away

from the area.

• Check to insure they have safe footing.

• Fully engage the hammer bar, if one is

used, to prevent it from disengaging
violently from the cover as a blow is
struck.

• Wipe their hands and the hammer
handle and maintain a firm grip on the
handle to avoid losing control of the
hammer while swinging and striking.

3-1-618 Page 1

• Carefully swing the hammer to avoid
striking themselves, another person and
objects other than the targeted lugs or
hammer bar.

• Avoid swinging the hammer above
shoulder height.

VALVE SEAT PULLING

DANGER

The following precautions must be observed
by operators and maintenance personnel to
avoid personal injury, death and/or
equipment damage from contact with the
puller, hammer, wedge or broken parts from
these components when using either a
hydraulic or wedge valve seat puller.
Operators or maintenance personnel
should:

Hydraulic Seat Puller

• Wear safety shoes and glasses.

• Chain or tie the jack down as it will jump

violently when the valve seat
disengages from the valve deck.

• Check to insure the pressure applied by
the hydraulic pump does not exceed the
hydraulic ram maximum pressure
rating.

Wedge Seat Puller

• Grind off any mushroomed material
from the wedge before use.

• Inspect the hammer and wedge to
insure they are in good condition.
Replace any of those parts which are
cracked, damaged or badly worn.

• Wear safety shoes and goggles.

• Check to insure they have safe footing.

• Fully engage the wedge to prevent it

from disengaging violently from the
cover as a blow is struck.

• Wipe their hands and the hammer
handle and maintain a firm grip on the
handle to avoid losing control of the
hammer while swinging and striking.

• Carefully swing the hammer to avoid
striking themselves, another person and
objects other than the targeted wedge.

• Avoid swinging the hammer above
shoulder height.

COVERS AND GUARDS

DANGER

Personal injury, death and /or
equipment damage can result from
contact with moving parts. All moving
parts must be equipped with covers
and guards. All covers and guards
must be securely positioned at all
times when the unit is in operation.

Covers and guards are intended to not only
protect against personal injury or death, but
to also protect the equipment from foreign
object damage

EQUIPMENT MOVING AND LIFTING

DANGER

Heavy equipment including pumps, pump
packages and components should only be
moved or lifted by trained, experienced
operators, who are physically and mentally
prepared to devote full attention and
alertness to the moving and lifting
operations. An operator should be fully
aware of the use, capability, and condition
of both the equipment being moved and the
equipment being used to move it

3-1-618 Page 2

DANGER

Failure to follow safe and proper
pump, pump package or component
lifting or moving procedures can lead
to personal injury, death and /or
equipment damage from shifting,
falling or other unexpected or
uncontrolled equipment movements.

Make sure the hoist, lift truck, ropes, slings,
spreader bar or other lifting equipment you
are using is in good condition and has a
rated lifting capacity equal to or greater than
the weight being lifted. Lifting devices must
be checked frequently for condition and
continued conformance to rated load
capacity. They should then be tagged with
the rated capacity together with the date of
inspection.

Fully assembled pumps and pump
packages are heavy and should only be
moved using the specified lifting lugs or
attachments.

Many individual components have lifting
eyes or lugs which must not be used to
lift assemblies, as they are designed to
bear the weight of the component only

Before lifting the individual component
check to insure the lifting attachment is
firmly secured to the component with
undamaged, properly torqued fasteners,
sound welds, or other secure attachments.
Examine the lifting eyes, lugs, slots, holes
or other projections to insure they are not
cracked, otherwise damaged or badly worn.
The repair of existing or addition of new
welded lifting eyes, lugs or other projections
should only be performed by experienced,
qualified welders.

Package units should be lifted with
spreaders connected to the lifting
attachments normally built into the package
unit support skid. Packages too large to lift

.

as fully assembled should be separated into
smaller loads.
For these smaller loads the lifting devices
should be fastened to the lifting attachments
normally built into the individual motor,
engine, pump or transmission / torque
converter, or their separate support skids.

When lifting subassembled components, for
example a suction stabilizer attached to
suction piping or a discharge pulsation
damper attached to a strainer cross and
piping, use special lifting slings designed to
safely support the combined weight of the
components.

If a crane or hoist is being used to lift large
components or assemblies, one or more
persons should assist the operator from the
ground with guide lines attached to the
equipment being moved to properly position
it and prevent uncontrolled movement.

When you start to lift a pump, package unit,
subassemblies or individual components
and you observe the equipment is tilting, or
appears unbalanced, lower the equipment
and adjust the lifting device to eliminate
these improper lifting conditions before
proceeding to move the equipment.

It is poor practice and dangerous to allow
the equipment to pass over or close to your
body or limbs. Be prepared to move quickly
out of danger if equipment starts to fall, slip
or move unexpectedly toward you.

PRESSURIZED PUMP SYSTEMS

DANGER

Fluids under high pressure can
possess sufficient energy to cause
personal injury, death and/or
equipment damage either through
direct contact with escaping fluid
streams or by contact with loose
objects the pressurized fluid propels

3-1-618 Page 3

Operating a pump against a blocked or
restricted discharge line can produce
excessive pressures in the entire discharge
system, which can damage or burst
discharge system components.

DANGER

Never operate a pump without a
properly sized pressure relief valve or
working overpressure shutdown in
the discharge line immediately
adjacent to the pump discharge.

The relief valve should be placed in the
flowing discharge line and not at the
opposite end of the discharge manifold in a
dead end connection. The dead end may
become clogged with solid material carried
in the fluid, which could prevent proper
relief valve operation.

DANGER

Never place a shut-off valve or any
other component between the pump
discharge connection and the
pressure relief valve.

Make sure the pressure relief valve is
installed so any pressurized relief discharge
from the valve is directed away from
possible contact with people or equipment.
The relief valve must be set to relieve at a
pressure equal to or below the maximum
pressure values shown on the pump data
plate. However, if a component is used in
the discharge system with a lower rated
pressure capability than that listed on the
pump data plate, the pressure relief valve
must be set to relieve at a pressure equal to
or below the rated capability of the lowest
rated component.

Before starting the pump every time,
check to insure:

• The pressure relief valve is in good
operating condition and has been set to
the proper relief pressure.

• Any pipe line used to direct pressurized
relief flow to another location, such as a
collecting tank, is not blocked.

• The discharge system is not blocked
and all the discharge line valves are
open.

Check all fluid end discharge system
components including pipes, elbows
connections, threads, fasteners, hoses,
etc., at least once every six months to
confirm their structural adequacy. With

time, wear, corrosion and fatigue can
reduce the strength of all components.
Magnetic iron and steel components should
be checked with magnetic particle or dye
penetrant crack detection equipment.
Nonmagnetic materials should be checked
for cracks with dye penetrants. All metallic
components should also be visually
checked during these inspections for signs
of corrosion. If a component shows
evidence of cracking or loss of material due
to corrosion it must be replaced with a new
part.

Continually monitor suction and discharge
hose assemblies when the pump is
operating for leakage, kinking, abrasion,
corrosion or any other signs of wear or
damage.

Worn or damaged hose assemblies
should be replaced immediately. At least

every six months examine hose assemblies
internally for cut or bulged tube,
obstructions and cleanliness. For segment
style fittings, be sure that the hose butts up
against the nipple shoulder, the band and
retaining ring are properly set and tight and
the segments are properly spaced. Check
for proper gap between nut and socket or
hex and socket. Nuts should swivel freely.
Check the layline of the hose to be sure that
the assembly is not twisted. Cap the ends of
the hose with plastic covers to keep them
clean until they are tested or reinstalled on
the pump unit.

3-1-618 Page 4

Following this visual examination, the hose
assembly should be hydrostatically tested,
on test stands having adequate guards to
protect the operator, per the hose
manufacturer's proof test procedure.

Fluid end component inspections should
be performed more frequently than every
six months if pressures above 2500 psi
are used in the discharge system or if
corrosive, abrasive, flammable or hot
(over 110º F) fluids are being pumped.

Proper stuffing box packing selection is
important for safe pump operation. Contact
a Gardner Denver service representative for
assistance in selecting the proper packing
before beginning operation.

Before starting the pump the first time, and
periodically thereafter check the pump,
suction and discharge system fastener
torques versus the values listed on page 35
to insure proper tightness. Over and under
torquing can damage threaded pipes,
connections and fasteners, which may lead
to component damage and/or failure.
Replace all components found to be
damaged or defective. On pumps equipped
with stuffing boxes, the gland must be
engaged by at least three (3) threads to hold
the discharge pressure of the pump.

DANGER

Do not attempt to service, repair or
adjust the plunger packing or other­wise work on the pump while the unit
is operating. Shut off the pump drive
engine and relieve the fluid pressure
in the suction and discharge systems
before any work or investigation is
performed on the pump or pump
systems.

Block the crankshaft from turning and make
certain that all pump drive motor or engine
start switches or starter controls are clearly
tagged with warnings not to start the pump
while repair work is in process.

Whenever the pump is operating,
continually monitor the entire suction,
discharge and pump lubricating systems for
leaks. Thoroughly investigate the cause for
leakage and do not operate the pump until
the cause of the leak has been corrected.
Replace any parts which are found to be
damaged or defective. When a gasketed
joint is disassembled for any reason, discard
the used gasket and replace it with a new,
genuine Gardner Denver gasket before
reassembling the joint.

Due to the high working pressures contained
by the fluid end, discharge manifold and
discharge piping, welding on these
components is not recommended. If
welding on the discharge system cannot be
avoided, only experienced, qualified welders
should be used. In addition, the welded part
should be hydrostatically proof tested in the
shop with water or hydraulic fluid to one and
one half times maximum discharge system
working pressure, with no observable fluid
leakage, before the part is reinstalled in the
pump system.

In summary, high pressure fluid streams can
possess sufficient energy to cause personal
injury, death and/or equipment damage.
These results can occur either through
direct contact with the fluid stream or by
contact with loose objects the fluid stream
has propelled, if the pump system is
improperly used, or if the fluid is
misdirected, or allowed to escape from
defective or improperly maintained
equipment.

FLAMMABLE, HOT, COLD OR
CORROSIVE FLUID PUMPING

DANGER

Extreme caution must be exercised
by trained and experienced operators
when flammable, hot, cold or
corrosive fluids are being pumped to
avoid personal injury, death an/or
equipment damage due to explosion,
fire, extreme cold or chemical attack.

3-1-618 Page 5

Never operate a pump which is pumping
hydrocarbons or other flammable, hot, cold,
or corrosive fluids when any part of the
pump, suction system or discharge system
is leaking. Stop the pump immediately if
any leakage, other than a few drops per
minute of packing weepage, is observed.
Keep all flame, sparks, or hot objects away
from any part of the pump, suction system,
or discharge system. Shield the pump,
suction system and discharge system to
prevent any flammable, hot, cold or
corrosive fluid leakage from dripping or
spraying on any components, flame, sparks,
hot objects or people. Inspect the plungers,
packing, gaskets and seals for fluid leakage
frequently and replace all worn or leaking
parts.

Selection of the proper gaskets, seals and
stuffing box packing is even more critical
when flammable, hot, cold or corrosive
fluids are being pumped than when other,
inherently less dangerous fluids are used.
Contact a Gardner Denver service
representative for assistance in selecting
the proper gaskets, seals and packing
before beginning operation.

Since some packing weepage into the
cradle area is inevitable, the drain at the
bottom of the cradle must be connected to a
drain line which conducts the fluid leakage
to a collection container located in a
protected area. The entire drain system and
container must be constructed of materials
resistant to attack from the pumped fluid or
from explosion or fire of the pumped fluid.

Before beginning pumping operations or
starting the pump power source (whether an
engine or electric motor) check the
atmosphere all around the pumping site for
the presence of flammable or explosive
vapors. Do not begin operation and stop
ongoing operation if flammable or explosive
vapors are detected. Hot surfaces, sparks,
electric current or engine exhaust could
ignite flammable or explosive vapors. Each
engine used as a power source on pumping
units where flammable or explosive vapors
could form should be equipped with an air
inlet shut-off. If flammable or explosive
vapors are present in the pumping site
atmosphere, an engine could continue to
run

on these vapors even after the engine fuel
line is shut-off if an air inlet shut-off is not
used.

In addition, on pumping units used where
flammable or explosive vapors could form,
all electric motors used as power sources
must be of explosion proof construction and
all electrical components and wiring must
meet the current National Electrical Code
for explosive atmospheres.

These precautions must be taken to avoid
possible personal injury, death and/or
equipment damage from explosion, fire or
burns.

HIGH PRESSURE LIQUID JETTING,
BLASTING AND CLEANING

DANGER

Extreme caution must be exercised if
any type of wand, gun, nozzle or any
other pressure and flow directing
device is attached to the pump
discharge system for use in jetting,
blasting, cleaning, etc. This type of
equipment must be used by trained,
experienced operators with the
utmost care. High pressure fluid
streams can either by direct contact
or by propelling loose objects, cause
serious personal injury or death to
operators and/or other persons.

Pressure or flow directing devices often
receive pressurized flow through flexible
hoses, which can burst if they are kinked,
cut, abraded or are otherwise worn,
damaged or pressured above their rated
capacity. Protect the hose and connections
from damage by people, objects and
vehicles. A broken, cut or otherwise burst
hose can release pressurized fluid which
may cause personal injury, death and/or
equipment damage.

3-1-618 Page 6

High pressure fluid from hand held or hand
directed pressure and flow directing devices
may overpower an operator’s ability to
control or direct the device, which could
lead to personal injury, death and/or
equipment damage. The operator must
brace against the backward thrust of a hand
held device. In addition, a safety harness or
safety net must be used when working in an
area where the operator could be injured in
a fall. Stand to the side of any tubing or
container being sprayed to avoid back spray
and never operate a hand held device
above shoulder level.

Never direct the pressurized fluid stream at
yourself or any other person, control valves,
the pump, pump drive, suction or discharge
systems. The pressurized stream can
cause serious personal injury or death and
can also change valve or control settings
which could dangerously increase the
delivery pressure to the pressure and flow
directing device.

When operating a pressure and flow
directing device, use only equipment which
automatically shuts off flow when an
operator releases hand or foot pressure on
the pressurized flow trigger control to
prevent injury if the operator is overpowered
or becomes disabled.

Check to insure this automatic shut-off
equipment is operating properly before
every use and never

circumvent the
automatic shut-off for any reason or by any
means when operating the equipment.

When operating any type of high pressure
liquid jetting, blasting or cleaning devices,
the operators must always wear protective
clothing including, but not limited to, a hard
hat with full face visor, heavy duty rain coat
and pants, boots with nonskid sole and
safety toe, rubber gloves with rough grip
surface and ear noise protection.

Full operator attention and alertness are
required when operating this equipment to
avoid personal injury, death and/or
equipment damage. The operators should
take frequent rest breaks and cease
operations when they become tired or
distracted.

Before the equipment is started, the work
area must be inspected and properly
prepared to avoid personal injury, death,
and/or damage to equipment. Make sure
the work area is checked for hazardous
fumes, has adequate ventilation for engine
exhaust and sufficient drainage for released
fluid. Check the work area for electrical
equipment, connections, outlets, fixtures, or
lines. If any are present they must be made
water tight and the electrical power to these
devices must be shut off to avoid electrical
shocks from fluid contact. The work area
should be clearly marked and roped off to
keep unauthorized people and vehicles from
entering. Remove all loose parts, tools and
equipment from the work area before
beginning operation.

All pressure containing devices including
wands, nozzles, guns, hoses, connections,
etc., should be regularly checked for
condition. These components should all be
tagged with their tested pressure capabilities
together with the date testing was
performed. Always be aware of the

pressure level in the system and never
connect any equipment to the system
which has a rated or tested pressure
capability below the system operating
pressure. The equipment must be shut

down and the system pressure released
before changing or disconnecting wands,
nozzles, guns, hoses, connections or any
other pressurized system components.

All pressure containing devices including
wands, nozzles, guns, connections, etc.,
plus all automatic shut-off, pressure and
control equipment should be treated with
care. Protect them from damage by people,
objects and vehicles. Never

lay them in
dirt, mud, ice or other loose material which
could plug the fluid opening or interfere with
their operation. Never

use the wand,
nozzle, gun, etc. to pry loose material off
items being cleaned.

Before starting operation in a cold
environment, check to make sure there is
no ice in the fluid system and repeat this
inspection each time before operation is
restarted.

3-1-618 Page 7

Before purchasing wands, nozzles, guns,
connections, hoses, etc., manufacturers of
these components should be contacted for
detailed information on the design and
safety features incorporated in their
products. After careful study of various
manufacturers products, we recommend
that only
connections and hose, etc., be considered
for purchase that you judge to offer the
highest quality of design, construction and
safety, since these components are among
the most critical to the safe operation of
high pressure liquid jetting, blasting and
cleaning equipment.

After you have selected and purchased
these components, follow the
manufacturer’s instructions completely in
their use.

In summary, high pressure jetting,
blasting and cleaning are inherently
dangerous, as the pressures and flow
rates needed to remove scale, clean, etc.
are sufficient to cause personal injury,
death, and/or equipment damage
resulting from, but not limited to, any of
the conditions described in the above
Danger Notices.

those wands, nozzles, guns,

3-1-618 Page 8

SECTION 2
DESIGN, DESCRIPTION AND SPECIFICATIONS

INTRODUCTION

The new Gardner Denver GD 3000 is a high
horsepower, high rod load multi-purpose
pump for various applications such as oil
and gas well fracturing and acidizing and
potentially as a light weight drilling pump.
The pump was designed using modern
analytical and engineering methods and
techniques. The gear drive was designed in
accordance with the most recent standards,
procedures, and computer software
developed by American Gear Manufacturers
Association.

The issue of personnel safety is the most
important topic covered in this manual.

FIGURE 2-1 GD 3000 Pump

Therefore, in the beginning of this manual
the user is introduced to dangers inherent in
the operation of a high pressure pump. To
avoid accidents and injuries, all safety rules
listed in this section and also all other
applicable safety rules and regulations must
be carefully observed.

The sections on Pump Design, Description,
and Specifications, describe the pump
design, list the pump specifications, and
present drawings depicting the pump
external views and all essential cross­sectional drawings.

3-1-618 Page 9

Section 3, "Pump Preparation, Operation,
and Maintenance," addresses the issues of
preparing the pump for operation after
shipping or storage, the lubrication system
design and specifications, the new pump
run-in procedures, and the periodic routine
maintenance schedule. The recommended
oils, viscosity data, and crankcase oil
temperature requirements are also
presented in this section.

Section 4, "Service Procedures," describes
the various assembly / disassembly
procedures.

Section 5, “Trouble–Shooting,” describes
possible problems, causes and solutions
related to pump performance.

Section 6, “Rebuilding Data, Recommended
Running Clearances and Torques,” presents
information useful for pump rebuilding and
assembly, including dimensional and
tolerance data, running clearances for all

bearings, and recommended fastener
torques.

PUMP DESIGN

The GD 3000 pump uses three major
assemblies: power end, fluid end, and gear
reduction unit. The pump is designed with a
modular concept. Each assembly is a
module that can be assembled, handled,
installed, fixed, or transported separately
from the rest of the pump (See FIGURE 2­1, page 9). The following is a brief
description of the essential design features
for each modular assembly.

POWER END (FIGURE 2-2,FIGURE 2-3)
The power end was designed utilizing cast

frame members joined by welded sections
to provide stiffness and strength. By
combining cast components with
weldments, the GD 3000 provides
maximum durability with minimum weight.

FIGURE 2-2 GD 3000 Power End

3-1-618 Page 10

FIGURE 2-3 GD 3000 Power End Top View

NOTICE

The direction of rotation must be
such that the top side of the
crankshaft is moving towrd the fluid
end.

The cast crosshead guide connects the
pump power frame and the fluid cylinder
and the whole assembly is held together by
eight (8) tie rods with sleeves. This
approach is weight efficient and allows for
convenient service and disassembly after
the fluid end is removed. The connecting
rods and the crossheads are easily
accessible through the front of the guide.
The long tie rods tend to elongate under
load substantially, thus reducing the
stresses under dynamic rod load. If the fluid
cylinder nut tightening procedure is
performed properly, the tie rods will last
indefinitely.

The connecting rod is 27.25” long (center to
center) providing a smaller pressure angle,
increasing component life significantly. The
knuckle joint design is essentially standard

but utilizes a large knuckle (7”) and
crosshead (13.5”), thus allowing extremely
high rod load (350,000 lbf.). (See FIGURE
2-3).

Also, the pump has a drain pan to collect
the oil and other liquids from the
reciprocating plungers and pony rods. A
cover, hinged to the crosshead guide,
encloses the reciprocating parts to provide
for personnel safety.

GEAR REDUCTION UNIT (FIGURE 2-4)
A light weight, highly efficient pump gear

box consists of a planetary drive with an
offset parallel gear drive bolted to the
planetary. The overall ratio of the reduction
gear unit is 7.842:1. This arrangement
offers the best power to weight ratio and
flexibility in using different prime movers
such as diesel engines as well as electric
motors. The installation and removal of the
gear reduction unit is easy and convenient
due to a splined gear coupling between the
planetary carrier and the pump crankshaft.
All gears are carburized, case hardened,
heat treated and precision made of aircraft
quality steel to ensure the highest reliability
and long life of the gear box.

3-1-618 Page 11

POWER END AND GEAR REDUCTION
UNIT LUBE SYSTEM (FIGURE 2-2,

FIGURE 2-3, and FIGURE 2-4,)
Both the gear reduction unit and power end

have individual lube oil inlets. The power
end inlet is located at the rear of the pump.
The inlet is a 1-1/2” NPTF tee which divides
the lube flow between the lube manifold for
the crosshead guide and the rotary union.
Pressurized lubrication for each crosshead
is delivered from the lube manifold through
the underside of the crosshead guide. An
aluminum cover houses the rotary union,
which is attached to the crankshaft.
Lubrication for the power end components
comes from forced lube through the
crankshaft. Lube oil enters the crankshaft
and first lubricates the #4 main bearing. Oil
from the main bearing also lubes the thrust
bearing. As oil reaches the first crankshaft
journal, oil exits the journal oil hole and
lubes the journal and journal bearings,
passes through the center of the connecting
rod to the wrist pin and bushing. It then
reaches the knuckle bearing and then to the
crosshead. This is repeated for the rest of
the main bearing cylinder components. Oil
is removed from the power end through a
primary 4” drain in the bottom of the frame
in the center cylinder. Oil passages at the
forward part of the frame members allow
the end cylinders to drain to the center. Oil
is also drained from three 1” crosshead
drains located at

FIGURE 2-4 GD 3000 Gear Reduction Unit

the forward end of each cylinder in the
bottom of the crosshead guide. These three
drains are combined together and empty
into the main drain external to the frame.

The gear reduction unit has one inlet
located on the upper input side of the offset
section. This is a 1-1/2” NPTF on a bronze
“Y-type” strainer mounted on a distribution
block. From the distribution block the input
and output gears and bearings and
planetary section are lubricated through a
spray bar, nozzle, and orifices.

The lube oil is drained from the gear
reduction unit through two SAE 2” 4 bolt
split flange drains located on the offset
section housing and one 1-1/2” NPTF drain
on the transition section connected to the
power frame. It is important that these drain
hose sizes are maintained to the primary
drain and include as few restrictions and
direction changes as is practical. Gear unit
heating problems are most often related to
drain restrictions causing buildup of oil
inside the unit, thus generating excessive
heat.

NOTICE

It is also extremely important to
maintain some downward slope in the
entire drain system back to the lube
reservoir.

3-1-618 Page 12

FLUID END (FIGURE 2-5)

This fluid end incorporates a modern
through stud design, which eliminates the
weight of the traditional flange fluid ends
and simplifies installation and removal of tie
bolt nuts. HYTORC turbine style nuts are
used to provide much improved method of
fastening. These nuts eliminate the use of
hammer wrenches and galling problems
associated with old style tie bolt nuts.

The conventional valve over valve
configuration offers field proven arrange-

ment in terms of valve and spring
performance. Improvements in the fluid end
life come from increasing fluid cylinder
cross sections in areas of maximum
stresses and new high quality low sulfur,
higher nickel and molybdenum content
steels. New sophisticated methods of
metallurgical control allow us to obtain
steels with very consistent chemical
compositions and mechanical properties.
This forging has higher tensile, yield,
hardness and impacts than conventional
frac service forgings.

FIGURE 2-5 GD 3000 Fluid End

3-1-618 Page 13

Medium Pressure Fluid End Plunger Sizes (Requires Fluid End Part Number 304TLS029)

High Pressure Fluid End Plunger Sizes (Requires Fluid End Part Number 305TLS029)

Low Pressure Fluid End Plunger Sizes (Requires Fluid End Part Number 306TLS029)

Medium High Pressure Fluid End Plunger Sizes (Requires Fluid End Part Number 307TLS029)

Pump Rate (bpm) @ 1950 Engine rpm

Transmission Gear

GENERAL SPECIFICATIONS

This section presents the pump basic specifications. The first set of specifications deals with the
pump's power, rod load, plunger stroke, and overall dimensions. The other table presents
allowable pressures and flows for various pump speeds along with data on power requirements.

GD 3000 PERFORMANCE RATING

Rated Brake Horsepower 3000 bhp
Stroke Length 11.0 inches
Maximum Rod Load 350,000 pounds
Gear Box Ratio 7.842 : 1
Overall Length 94.04 inches
Overall Width 96.57 inches
Overall Height 40.53 inches
Weight (system dry) 18,550 pounds

Plunger Stroke Plunger Vol/rev Calculated

Size Length Area 97% V.E. 1 2 3 4 5 6 7 8 Max. Press.

(inches) (inches) (sq. in.) (bbl/rev) (@ 350,000 lbf.)

4.5 11 15.904 0.052 2.93 3.67 4.60 5.44 6.83 8.52 10.49 13.12 22,007
5 11 19.635 0.065 3.62 4.54 5.68 6.72 8.44 10.52 12.96 16.20 17,825

5.5 11 23.758 0.078 4.38 5.49 6.88 8.13 10.21 12.73 15.68 19.60 15,000

5.75 11 25.967 0.086 4.79 6.00 7.52 8.89 11.16 13.91 17.13 21.42 13,479
6 11 28.274 0.093 5.22 6.53 8.18 9.68 12.15 15.14 18.66 23.32 12,379

5 11 19.635 0.065 3.62 4.54 5.68 6.72 8.44 10.52 12.96 16.20 17,825

5.5 11 23.758 0.078 4.38 5.49 6.88 8.13 10.21 12.73 15.68 19.60 15,000

6.5 11 33.183 0.109 6.12 7.67 9.60 11.36 14.26 17.77 21.90 27.37 10,548
7 11 38.485 0.127 7.10 8.89 11.14 13.17 16.53 20.61 25.39 31.74 9,095

3-1-618 Page 14

SECTION 3
PREPARATION, OPERATION AND MAINTENANCE

DANGER

Read and understand clearly all
safety rules and precautions before
attempting to operate the pump.

This section deals with pump preparation
after shipping and storage of the pump, user
built lubrication system and its
specifications, pump break in procedures,
recommended oils, allowable crankcase
operating tempera-tures, viscosity
conversion tables, and routine maintenance
schedule.

PREPARATION AFTER SHIPPING AND
STORAGE

All pumps are shipped dry and therefore
must be flushed with light weight oil before
operating. The flushing must be performed
regardless of method or duration of the
shipment or type of container the pump was
shipped in.

Pumps are not prepared for storage and
should be put in service as soon as
possible.

If for any reason the pump has to be put into
storage after prior use, the following
procedure should be followed:

1. Clean and flush the fluid end with a
rust preventative.

2. Plug all discharge and suction

openings.

3. Drain oil from the power end and the
gear reduction unit.

4. Flush the power end with a rust

preventative (before flushing make
sure that the rust preventative will not
clog the oil passages).

5. Remove the breather and either plug or

tape the opening.

6. Coat the gear reducer input shaft and
all extension rods with a heavy rust
preventive.

7. Plug drain holes at the bottom of the

pump frame, crosshead guide, gear
reducer transition and offset.

8. Plug the lube inlets.

9. Store the pump inside in a warm dry
place.

10. If the pump is shipped ocean cargo, it

must be crated in a water-tight contain­ er placed below the deck to prevent
rusting and salt water contamination.

PUMP MOUNTING INSTRUCTIONS

Follow this procedure to shim the feet of the
pump. This will require the use of (8) grade
8, 1”-8 hex head screws with lock washers
and nuts to secure the pump frame, and (4)
grade 8, 3/4”-10 hex head screws with lock
washers and nuts to secure the fluid end
supports.

1. Set the pump in its location.

2. Install one bolt in each of the two feet
at the rear corners of the power frame.
Snug but do not tighten these bolts.

3. The fluid end support brackets should
be in their uppermost position, against
the bottom of the fluid end.

4. Using a feeler gauge, check under the

two center feet at the rear of the frame
and the four at the front of the frame.

5. Select the proper number and

thickness of shims to fill the gap under
the high foot.

6. With shims in place (if required), install

bolts in the remaining six power frame
mounting feet.

7. Tighten all eight bolts. Use the appro-

priate torque for the type of bolts.

3-1-618 Page 15

8. Maintaining a slight amount of upward
tension on the fluid end, check the gap
beneath the fluid end supports.

9. Select the proper number and
thickness of blocks and/or shims to fill
the gap under the supports.

10. With blocks and/or shims in place,
tighten the four bolts on the fluid end
supports using the appropriate torque.

POWER END LUBRICATION SYSTEM

Due to variety of applications and drive
arrangements, the power end lubrication
pump and applicable auxiliary hydraulic
equipment are not furnished with the triplex
pump. Therefore, the pump lubrication
system is designed and built by individual
customers for each particular application.

The lubrication system is very critical to the
triplex pump performance and therefore
should be professionally designed in
accordance with sound engineering
practices developed for similar systems,
known otherwise as hydraulic power units or
HPU. The following discussion will
reemphasize some of the good practices
used in designing similar systems in the
past and comment on the system’s critical
components.

Lube System Pump

A positive displacement pump must be
used. Gear type pumps have demonstrated
reliable performance for similar applications
in the past. The pump should have the
largest suction port available for the
selected pump size to minimize losses in
the suction piping.

Lube Pump Suction Piping Sizing and
Requirements

In the past, failure to meet these
requirements has lead to pump damage
because of restricted oil flow in the lube
pump inlet. Therefore, the following
guidelines, developed as a result of long
experience, should be adhered to closely.

1. The oil flow velocity through the suc-

tion piping should not exceed 2 ft/sec.

2. At maximum operating speed the
vacuum reading at the lube pump inlet
must be no more than 8" hg or 4 psi or

0.28 bar.

3. The suction strainer should be sized for
oil flow three (3) times larger than the
actual flow passing through the
strainer.

4. Power End lubrication system should
be filtered with a minimum 25 micron
filter or finer per API specification

2.9.1.5.

5. The suction pipe should be kept as

short as possible and free of bends.

6. Warning devices to monitor lube oil

pressure and temperatures are highly
recommended. The triplex pump
operates at very high rod loads and
pressures, and malfunction of the lube
system may result in serious damage
occurring in a very time. Therefore,
early warning devices are essential to
the successful operation and should be
set according to the following operating
limits:

NOTICE

Maximum lube system pressure
should be set at 135 psi (relief
valve setting).

Minimum lube oil operating
pressure is 40 psi (with hot oil).

Approximate lube pump design
flow should be 40 gpm.

Maximum lube system vacuum at
lube pump inlet 8 Hg or 4 psi or

0.28 bar.

FIGURE 3-1 indicates API-GL5 oil grades
recommended for use in the pump power
end and the gear reducer lube system.
Crankcase operating temperature ranges
and minimum startup temperatures for each

3-1-618 Page 16

listed grade of oil for various inlet or sump
temperature ranges.

FIGURE 3-1 Lubricant Recommendations

PLUNGER / PACKING LUBRICATION

The fluid end plungers are lubricated from a
separate lubrication pump through the
stuffing box. The lubrication pump, hosing,
and check valve to the stuffing box is not
provided with the unit.
See "Plunger Packing Lubrication
Recommendation Chart," page 20, for a list
of lubricants recommended for plunger
/packing lubrication.

STARTUP AND NEW PUMP RUN-IN
PROCEDURES

A centrifugal charge pump will be required
to charge the fluid end suction manifold.
The charge pump should be sized according
to the volume to be pumped by the triplex
pump so that there is no less than 40 psi

3-1-618 Page 17

charge when the triplex pump operates at its
maximum flow.

The first startup and several hours of the pump
run-in are performed at the factory during the
acceptance tests as a part of quality assurance
procedure. However, the new pump break-in
period process may continue for the first 80-100
hours of operation, and therefore it will be each
user’s responsibility to perform all the tasks
related to this critical period. As all moving
parts of the pump go through wearing-in
process, steel and bronze wear particles are
carried by the oil flow in the lubrication system.
The resulting contamination of the lubrication
system with the wear particles and especially
clogging of the strainer and the oil filter may
cause serious problems. To assist the user,

the following guidelines are presented for the
maintenance personnel to follow during the
critical startup and break-in period:

1. Fill the lube oil reservoir with
recommended grade of oil. See "Power
End Lubrication," and FIGURE 3-1,
page 16.

2. Fill the packing lube reservoir with

proper oil. See "Plunger/Packing
Lubrication Recommendation Chart,"
page 20.

3. Remove all inspection covers on the

top of the pump frame.

4. Start the engine at the lowest possible
RPM and triplex pump at zero (0)
pressure. Make sure that all roller
bearings, crossheads, knuckle joints,
and crankshaft bearings are properly
lubricated.

5. Increase the engine RPM to maximum
and check whether the vacuum reading
at the lube pump suction inlet is less
the 8" Hg or 4 psi or 0.28 bar.

6. Check whether the lube system
pressure reading is at least 100 psi or

7.0 bar. Temporary pressure gages
should also be checked at this time to
make sure that all components of the
lube system are working properly.

7. Check to see that oil flow back to the

reservoir is normal. (There should be
no accumulation in the power end.)

8. Start the plunger lube system and

check to see whether it is adjusted
properly.

9. Run at low speed to "work out" any
trapped air in the fluid cylinder with the
charge pump operating.

10. Run the pump at 80-90 strokes per

minute and 20% of its maximum
pressure rating for 30 minutes

11. During this time, observe the suction
vacuum gage reading, oil pressure and
temperature and check for leaks.

12. Run the pump at 80-90 strokes per min
at the following loads:
40% of full rated load 30 min
60% of full rated load 30 min
80% of full rated load 30 min
100% of full rated load 30 min

13. During the operation observe the oil

pressure and temperature, and inlet
suction vacuum gage reading, and
entire system for proper operation.

14. If the triplex pump is equipped with a

transmission, run the pump for 30 min
in each gear in the higher gear ranges
pulling full horsepower in each gear.
Observe closely oil pressures and
temperatures, and lube oil suction
vacuum.

15. Shut the pump down and let it cool
thoroughly before starting normal
operation of the pump.

16. During the shutdown, change the oil

filter elements and clean the suction
strainer.

17. Change the lube oil and clean the

reservoir to get rid of metal particles
and any other wear products now
present in lube oil system.

18. Change filter elements and clean

strainer every 10-15 hours, till it
becomes apparent that wear-in process
is finished.

19. Tighten all fluid cylinder attachment

nuts, procedure listed in "Fluid End
Removal and Installation,” page 21,
after 50-70 hours of pump operation.
See FIGURE 4-1, page 22.

20. Change the lube oil again, replace the
filter elements, and clean the strainer
after 80-100 hours of pump operation.

21. Follow the routine maintenance
schedule described in the next section
after completion of the wear-in period.

3-1-618 Page 18

PERIODIC ROUTINE MAINTENANCE
SCHEDULE

Performance of the periodic routine
maintenance tasks, described in this
section, will ensure long, economical, and
trouble free operation of this pump. It is
highly recommended that the customer set
up a maintenance program during the run-in
period. The periodic maintenance data
should be recorded and kept with other
pump documents. The following
recommendations, based on previous
experience, should serve as a guideline for
establishing a good maintenance program.
The periodic maintenance schedule is
divided into daily, monthly, and quarterly
tasks to be performed by the user after the
pump has gone through 100 hours of wear­in period. For the tasks performed during
the wear-in period, see "Startup and New
Pump Run-In Procedure," page 17.

Daily Routine Maintenance Tasks

1. Check the oil level in the lube oil
reservoir.

2. Periodically monitor lube oil operating
pressure and temperature. Minimum oil
operating pressure is 50 psi. The
maximum oil operating temperature
depends on a particular grade of oil
used in the pump lube system. (See
FIGURE 3-1, page 17).

3. Check the lube pump suction inlet
vacuum. A vacuum gage reading
higher than 8" Hg or 4 psi or 0.28 bar
indicates that the suction strainer
and/or oil filter element are clogged.
The strainer must be cleaned, and the
oil filter element replaced as
necessary as soon as the pump can be
shut down for a short period of time to
perform these tasks.

4. Listen for any abnormal noise or rough

operation, which may indicate the need
for fluid end maintenance such as
changing valves or valve seats. Due
to very high pressures in the triplex
pump fluid end, worn valves and seats
should be changed as soon as possible
to prevent washing them out with the
pumped fluid.

5. Check the plunger/packing lubrication
pump for proper operation. Insure
packing nut is tightened sufficiently into
stuffing box. Recheck tightness after
extended continuous operation.

Monthly (100 hour) Routine Maintenance
Tasks

1. Clean the strainer and replace the oil
filter element.

2. Check the entire lube system for leaks

and eliminate them.

3. Check all fluid end expendables such

as valves, packings, and valve seats
and replace them as necessary.

4. Check the extension rod seals and
replace them as necessary.

Quarterly (300 hour) Routine
Maintenance Tasks

1. Change the lube oil and clean the oil
reservoir thoroughly.

2. Clean the lube system strainer and
replace the oil filter elements.

3. Re-tighten the critical bolt joints
following torque specifications given in
Section 6.

4. Add grease to the tie rod sleeves to
prevent corrosion.

5. Clean or replace the breather cap filter
element.

6. Check all pressure, temperature, and
vacuum gages for proper operation
and replace as necessary.

7. Check all lube system warning and
alarm devices for proper operation and
replace if found defective.

8. Check supply of on hand expendables
such as packings, valves and seats,
maintenance items such as seals, O­rings, oil and breather filter elements,
and also maintenance tools. Order to
replenish supplies as necessary.

3-1-618 Page 19

PLUNGER PACKING

LUBRICATION RECOMMENDATION CHART

ROCK DRILL LUBRICANTS - NORMAL CONDITIONS

Source Type Pour Point Maximum

Amoco Amoco Rock Drill Oil - Light -20°F

Amoco Rock Drill Oil - Medium 0°F

Arco Air Drill #147 0°F

Arco Trueslide #150 15°F

Chevron Oil U.S.A. Vistac #68X 10°F

Vistac #100X 5°F

Vistac #150X 0°F
Conoco EP Rockdrill #49, #17, #78 5°F
Gulf Oil (Chevron) Rockdrill #100 -30°F

Rockdrill #32 -35°F
Exxon Arox EP #46 -20°F

Arox #150 -35°F
Mobil Oil Co. Almo #525 -20°F

Almo #527 -20°F

Almo #529 -10°F

Almo #532 0°F
Pacer Oil Rockdrill #150 -10°F

Rockdrill #600 0°F
Phillips Petroleum EP #500 (Summer) or EP #300 (Winter) -10°F
Shell Oil Co. Torcula Oil #32 -50°F

Torcula Oil #100 -20°F

Torcula Oil #150 -15°F

Torcula Oil #320 -10°F
Sun Oil Co. Rockdrill 500 (Light) 5°F

Rockdrill 1000 (Heavy) 5°F
Texaco Oil Co. Rockdrill Oil XL -40°F

Rockdrill Oil XM 0°F

Rockdrill Oil XH -10°F
Union Oil of Ca. Marok 150 ------

STEAM CYLINDER OILS - HIGH TEMPERATURE PUMPED FLUIDS

Source Type

Amoco Amoco Cylinder Oil 460
Arco Modco Cylinder Oil 125, 175
Conoco Inca Cylinder Oil
Exxon Cylesstic TK-460 or TK-1000
Gulf Oil (Chevron) Senate #375 Compound
Security #460 Non-Compound
Mobil Oil Co. Mobil Cylinder Oil 600W
Pacer Oil Com-Cyl Oil
Phillips Petroleum Hector Cylinder Oil
Shell Oil Co. Valvata J-460
Sun Oil Co. Occident
Gear Oil 7-X, Gear Oil 8-C
Texaco Oil Co. Pinnacle Cylinder Oil

3-1-618 Page 20

SECTION 4
SERVICE PROCEDURES

This section describes various assembly
and disassembly procedures necessary for
pump servicing or parts replacement. The
General Requirements and Safety Rules
section is a reminder for the maintenance
personnel of the critical importance of safety
rules and precautions while working on the
pump. Notes on dangers and notices
specifically related to service procedures
are repeated and placed in this section also.

The pump consists of three major modules:
the fluid end, the power end, and the gear
reduction unit. (See Section 2) The
description of service procedures follows the
modular concept. Due to many expendable
parts, fluid end servicing is rather common
in the field and is therefore presented in the
very beginning followed by power end and
gear reduction unit servicing procedures.

General Requirements and Safety Rules

DANGER

Before any attempt to work on pumps
is made, all safety rules and
precautions described in this manual
must be read and clearly understood.

DANGER

Only qualified and specially trained
personnel should be allowed to work
on this pump.

DANGER

Proper capacity hoist and lifting

devices should be used while
working on pump.

FLUID END SERVICE

This discussion starts with the description of
steps necessary for removal and installation
of the fluid cylinder assembly and proceeds
to the removal and replacement of
expendable parts such as valves, valve
seats, and packing.

Fluid End Removal and Installation

1. Disconnect suction manifold from unit
piping and discharge lines at the
discharge flanges on the fluid end,
plunger lubrication lines, and also any
accessories such as stroke counters,
pressure gages, etc. from the fluid end

2. Open the hinged stainless steel cover
on the top of the crosshead housing
and disconnect the plungers from the
extension rods by removing plunger
clamps.

3. Move the plungers inside the fluid
cylinder as far as possible.

4. Connect hoist to the fluid end and
tighten the slings until they are snug
only. Make sure that hoisting slings are
not too tight, because that may bend
the long tie rods and damage threads
in the pump frame.

5. Remove all eight (8) 2-1/4" tie rod nuts

from the fluid end using the HYTORC
Model T-240K hydraulic tensioning tool
and air pump. Setting the pressure on
the air pump at 5,000 psi will be more
than adequate to remove nuts.

6. Pull the fluid end assembly in
horizontal direction, straight away from
the power end until it is completely off
the tie rods.

7. Move the fluid end to the service area
for changing valves or other service.

3-1-618 Page 21

NOTICE

The procedure for fluid end
installation is presented separately
due to the special and critical nature
of the connection between the power
end and the fluid end.

To reinstall the fluid end proceed as follows:

1. Check all eight tie rods for thread
damage. If replacement is required,
refer to “Crosshead Guide and Tie
Rods,” page 25.

2. Remove tie rod sleeves and thoroughly
clean tie rods. Grease and reinstall
sleeves.

3. Position the fluid end on the tie rods
and slide the fluid end onto tie rods
until it bottoms on tie bolt sleeves.

4. Lubricate the tie rod threads and the
threads and splines of the HYTORC
inner and outer sleeve and washer with
Dow-Corning 1000 anti-seize or
equivalent. Install HYTORC nuts on tie
rods by hand.

5. Using the HYTORC T-240K tensioning
tool and the torquing sequence in Fig.
4-1, torque all eight nuts with a
pressure setting of 1500 psi. Repeat
this procedure using 3400 psi for a final
torque of 7000 ft-lbs. on each nut.

6. Reinstall the plunger clamps, piping
connections and auxiliary equipment.

Plunger and Packing Replacement

This service procedure can be performed
with the fluid cylinder in place on the pump,
and consists of the following steps:

1. Remove the suction cover retainer nut
with the appropriate male hex wrench.

2. Remove the suction cover with a
threaded "slide hammer type" puller.

3. Open the hinged cover on the top of
the crosshead housing to get access to
the plunger/extension rod area.

4. Remove both cap screws holding the
extension rod clamp, then remove the
clamp.

5. Loosen the packing nut to free the
plunger from packing pressure.

6. Remove the plunger through the
suction cover opening.

7. Remove the packing nut, lantern
gland, packing, header ring and
spacer.

8. Inspect the plunger, lantern gland,
packing, header ring and spacer for
excessive wear, nicks, burrs, or any
other defects. Replace expendable
parts as necessary.

9. Clean and oil the packing bore in the
stuffing box.

10. Install the spacer, header ring, packing
rings (2) and the lantern gland in the
stuffing box with the packing lips
toward the front of the fluid end. See
FIGURE 4-2.

FIGURE 4-1 Tightening Sequence for Fluid

End Nuts

3-1-618 Page 22

FIGURE 4-2 Packing Assembly

11. Install and hand tighten the packing nut
to align the packing in the bore.

12. Loosen the packing nut to allow for

installation of the plunger.

13. Insert the plunger through the suction

cover hole into the packing. It may be
necessary to bump the plunger through
the packing with a slide hammer.

14. Tighten the packing nut.

15. Inspect the clamp surfaces, plungers,
and extension rods for cleanliness.

16. Install the clamp and tighten the clamp
screws with 58 ft-lbs. torque.

17. Tighten the packing nut again.

18. Replace the seals on the suction cover.

19. Install the suction cover and tighten the
suction cover retainer nut.

20. Make sure that the plunger lube line is
in place before restarting the pump.

Stuffing Box Replacement

This procedure is to be performed if it is
determined that the plunger size must be
changed to meet job performance
requirements.

1. Follow steps 1 through 8 of the

“Plunger and Packing Replacement”
section on page 22.

2. Loosen and remove the plunger

lubrication lines from the stuffing box.

3. Support the stuffing box using a nylon

sling attached to a hoist. (The sling
should be loose, to prevent twisting,
while loosening the stuffing box.)

4. Loosen the stuffing box using the

stuffing box wrench.

5. Carefully remove the stuffing box from

the cradle area.

6. Clean and oil the packing bore in the

stuffing box.

7. Install the stuffing box seal, lubricating
with a light coat of grease.

8. Lubricate the stuffing box threads with
Dow-Corning 1000 anti-seize or
equivalent.

9. Install sling on stuffing box and position
to install in the fluid end.

10. Install and tighten the stuffing box in
the fluid end. (Note: The stuffing box
will “bottom out” in the fluid end bore
when tightened properly.)

11. Complete installation by following steps
10 through 20 of the “Plunger and
Packing Replacement” section on page

22.

12. Repeat this procedure for each
cylinder.

Valve and Seat Replacement

This procedure may be performed with the
fluid end on the pump.

WARNING

Never try to remove or cut a valve
seat with a torch. Severe damage to
the fluid end may occur.

Before starting, make sure that special tools
required for this procedure are available.
For part numbers of the tools see the Parts
Manual.

1. Remove the discharge cover retainer

nut with a 2” hex wrench.

2. Remove the discharge cover with a

threaded “slide hammer” type puller.

3. Remove the suction cover retainer nut

with a 2" hex wrench.

4. Remove the suction cover with a "slide

hammer type" puller.

3-1-618 Page 23

5. Remove the suction valve spring
retainer, suction valve and valve
spring.

6. Remove the suction valve seat or

discharge valve seat with a seat puller
and a seat puller jack. These tools are
available from Gardner Denver.

7. Clean the valve seat deck thoroughly.

8. Be sure the O-ring is installed on the

seat and snap the valve seat into the
taper by hand to fit tightly.

9. Place the winged valve on the top of

the valve seat.

10. Bump the seat into the taper 2-3 times

with a heavy bar to make the fit tight.

11. Reinstall the valve spring retainer and

suction valve spring.

12. Install new seals on the cover and

reinstall the suction valve cover and
retainer nut.

13. Install new seals on the discharge
cover and reinstall the discharge valve,
spring, cover and retainer nut.

14. Run the pump at maximum discharge
pressure to secure the valve seats into
the fluid end tapered holes.

POWER END SERVICE

DANGER

Before attempting to service the
power end of the pump, the following
safety precautions must be
observed:

1. Shift the pump transmission into
the neutral gear.

2. Shut off the pump engine and
remove the key from the ignition
to prevent starting the engine
inadvertently.

The power end service procedures deal first
with major assemblies, namely crosshead,
connecting rod, crankshaft, and knuckle
joints and then describe how to access all
individual parts.

Oil Stop Head Seal Retainer and
Crosshead Guide End Plate (FIGURE 2-2

and FIGURE 2-3)

1. Remove the fluid end following the
procedure described in "Fluid End
Removal and Installation,” page 21.

2. Remove the hinged crosshead cradle
inspection cover.

3. Remove the drip pan and stroke
counter bracket.

4. Remove the tie rod sleeves.

5. Remove the extension rods using a
3/4” drive x 2” six point socket.

6. Remove the extension rod seal
retainers and inspect seals and O-rings
for wear or damage.

7. Remove the crosshead guide end
plate.

Crosshead Assembly (FIGURE 4-3)

1. Remove the fluid end following the
procedure described in "Fluid End
Removal and Installation,” page 21.

2. Remove the oil stop head seal retainer
and crosshead guide end plate
following the procedure described in
“Oil Stop Head Seal Retainer and
Crosshead Guide End Plate,” page 24.

3. Remove the rear inspection covers
from power frame and inspect the
gaskets.

4. Remove rod cap bolts.

5. Install rod cap removal tool in rod cap.

6. Prior to removing rod cap, one person
should hold pressure against extension
rod to prevent the crosshead and rod
assembly from moving forward away
from the crank journal

3-1-618 Page 24

FIGURE 4-3 Crosshead Assembly

7. Remove journal bearings from the rod
and rod cap.

8. Slide crosshead and rod assembly

forward until journal end of rod is ready to
enter the crosshead guide bore.

9. Place heavy plastic or cardboard under

end of rod as it enters bore to prevent
scoring as the assembly is removed
through the crosshead guide.

10. Position sling through center of the wrist

pin to support the assembly as it is
removed from crosshead guide bore.

11. Place assembly on floor, standing on the

journal end of the connecting rod, with the
crosshead pointing upward.

12. Remove the four screws holding the front

and back half of the crosshead together.

13. Attach lifting device to the thread of the
crosshead front half and lift off.

14. Remove the thrust bearing.

15. Remove the snap rings from the wrist pin.

16. Remove the wrist pin while supporting the
crosshead back half.

17. Remove the crosshead back half from the
connecting rod.

18. Remove the crosshead wrist pin bushings
from the back half of the crosshead.

Crosshead Guide and Tie Rods

1. Remove the fluid end following the
procedure described in "Fluid End
Removal and Installation,” page 21.

2. Remove the oil stop head seal retainer
and crosshead guide end plate following
the procedure described in “Oil Stop
Head Seal Retainer and Crosshead Guide
End Plate,” page 24.

3. Remove the crosshead assembly as
described in “Crosshead Assembly,” page

24.

4. Remove the 8 bolts connecting the guide
to the frame.

5. Attach a lifting sling to the guide and
carefully slide the guide forward until it
clears the end of the tie rods.

3-1-618 Page 25

6. Using the tie rod wrench (refer to the
Special Tools section in the Parts
Manual) remove the tie rod. Note: the
tie rod should be supported either with
a hoist or another technician.

Gear Reduction Unit

NOTICE

This assembly requires factory
tooling for helical gear timing during
reassembly, and therefore should not
be disassembled in the field. If
repairs are needed, the gear reducer
should be returned to the factory.

1. Disconnect the gear reducer input shaft
from the transmission shaft.

2. Disconnect the gear reducer lube hose
and remove the oil drain hoses from
the offset parallel gear drive section
and the transition section.

3. Attach hoist with sling to gear reducer
lifting eyes.

4. Remove the 24 bolts connecting the
gear reducer to the pump frame

5 Pull the gear reducer horizontally away

from the joint to clear the splined
crankshaft gear coupling.

6. Cut the safety wire between the 18
bolts on the splined adapter and
remove the adapter from the
crankshaft.

7. Install crankshaft retainer in one of the
24 holes used to secure the gearbox to
the power frame. This will prevent the
crankshaft from disengaging with the
frame (see Special Tools section of
Parts Manual).

8. Move the gearbox and the splined
adapter to the service area.

Crankshaft Assembly

1. Remove the pump from the trailer and
move it to service area. The pump
service area must have a capability to
turn the pump frame on its side and
end.

2. Remove the fluid end as described in
"Fluid End Removal and Installation,"
page 21.

3. Remove the oil stop head seal retainer
and crosshead guide end plate as
described in “Oil Stop Head Seal
Retainer and Crosshead Guide End
Plate,” page 24.

4. Remove the crosshead assembly as
described in “Crosshead Assembly,”
page 24.

5. Remove the crosshead guide and tie
rods as described in “Crosshead Guide
and Tie Rods,” page 25.

6. Remove the gear reduction unit as
described in “Gear Reduction Unit,”
page 26.

7. Remove the lube inlet cover (4 bolts).

8. Remove the thrust bearing retainer
cover (12 bolts).

9. Remove the thrust bearing retainer (12

bolts).

10. Remove crankshaft bearing retainer
(12 bolts).

11. Remove the rotary union.

12. Position the entire power end assembly
on the gear reducer end with the hole
where the rotary union was removed,
facing up.

13. Install a lifting eye in the tapped hole of
the crankshaft, typically used for the
rotary union (refer to the Special Tools
Section in the Parts Manual).

3-1-618 Page 26

14. Lift the crankshaft until it is free of all
main bearings. Continue until bearing
faces of crankshaft reaches next
bearing. If crankshaft does not slip
through bearings freely, push rollers
into race. If bearings are extremely
loose and worn, it may be necessary to
install spiral lock pins (refer to Special
Tools section of the Parts Manual) to
hold rollers in place. Continue until
crankshaft is clear of all bearings.

15. Remove bearing retainers from the
frame.

16. Set power frame back on mounting feet
before removing main bearings.

NOTICE

As the two end bearings are 0.050”
larger than the center bearings, it is
advisable to remove the right end
bearing and center right bearing out
the right side of the frame and the left
end bearing and center left bearing
out the left side of the frame.

17. With bearing locks removed, bearings
may be driven out of bore with a
hammer and brass or aluminum blunt
nosed drift punch.

WARNING

When reassembling the crankshaft
assembly, make sure to follow these
steps:

1. Pack the bearings in dry ice
before assembling in the frame.

2. Slightly heat the inner bearing
races before installing on the
crankshaft.

3. Braze the retaining rings on the
crankshaft after installing the
inner bearing races. Avoid
direct contact with the inner race
or the crankshaft.

4. Reinstall the safety wire for the
bolts holding the splined
coupling to the crankshaft.

Failure to follow these directions may
result in serious damage to the
pump.

WARNING

Do not drive against rollers or
bearing cage. Drive only against the
bearing race, as severe damage to
the bearings could occur.

3-1-618 Page 27

SECTION 5
TROUBLE-SHOOTING

PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Pump Overloads Driver. 1. Excessive pump speed 1. Reduce pump speed and/or
and/or discharge pressure. pressure.

2. Blockage or closed 2. Clean or open valve.
valve in discharge line.

3. Incorrect plunger size. 3. Install the correct
plunger.

4. Improper bypass conditions. 4. See recommended system
layout, and correct error.

Fluid Not Delivered. 1. Pump not primed. 1. Prime pump.

2. Air or vapor pocket in 2. Remove pocket from line.
suction line.

3. Clogged suction line. 3. Clean out line.

4. Suction and/or discharge 4. Remove the obstruction.
valves propped open.

Low Discharge Pressure. 1. Worn or fluid cut valve. 1. Replace valve assembly.

2. Valve propped open. 2. Remove the obstruction.

3. Pump cavitating. 3. See Cavitation, Fluid Knock
or Hammer problem.

4. Fluid leakage. 4. Replace plungers/packing
and/or fluid end seals.

5. Erroneous gauge reading. 5. Recalibrate or replace
gauge(s).

Low Suction Pressure. 1. Low head (NPSH). 1. Raise fluid supply level.
Install charging pump.

2. Insufficient charging pump 2. Increase charging pump
capacity. speed or size.

3. Retarded fluid flow. 3. Remove restrictions
from suction line.

4. Erroneous gauge reading. 4. Recalibrate or replace
gauge(s).

3-1-618 Page 28

PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Cavitation, Fluid Knock 1. Improper suction system 1. See recommended system
or Hammer. layout. layout in manual.

2. Low suction pressure. 2. See Low Suction Pressure
problem.

3. Suction stabilizer and 3. Install suction stabilizer
pulsation damper not used. and pulsation damper.

4. Defective stabilizer or 4. Repair and recharge or
damper. replace.

5. High fluid temperature or 5. Reduce pump speed.

viscosity.

6. High fluid vapor pressure. 6. Increase NPSH.

7. High acceleration head. 7. Increase supply line size.

Decrease supply line length.

8. Suction valve spring too stiff. 8. Use weaker spring.
with low NPSH.

9. Air/Gas in pumped fluid. 9. Allow more settling

time in supply tank.
Reduce pump speed.

10. Air entering suction line. 10. Repair suction line.

11. Air entering charging pump. 11. Tighten or replace shaft

packing or seal.

12. Air entering or charge gas 12. Repair and recharge

escaping from suction stabilizer
stabilizer.

13. Multiple pumps operating in 13. Use a suction stabilizer

phase. on each pump. Separate
lines may also be needed.

Suction or Discharge Line 1. Line(s) not supported. 1. Install supports or
Vibration. hangers.

2. Pump cavitating. 2. See Cavitation, Fluid Knock

or Hammer problem.

High Crankcase Oil 1. High ambient temperature. 1. Use an oil heat exchanger
Temperature. with a circulating pump.

2. Improper type/grade oil used. 2. Use recommended oil.

3. Pump overloaded. 3. Reduce pump speed and/or

pressure.

4. Improper clearance in main 4. Check and adjust clearance.

or rod bearings, crossheads Replace parts as required.
or bushings.

3-1-618 Page 29

PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Knock In Power End. 1. Improper main bearing 1. Check and adjust
clearance. clearances.

2. Incorrect pump rotation. 2. Reverse rotation.

3. Loose plunger coupling. 3. Check and tighten. Replace

if damaged.

4. Loose bearing housings/ 4. Check and tighten.

covers. Replace if damaged.

5. Worn crosshead pin. 5. Replace.

6. Worn crosshead pin bushing. 6. Replace.

7. Worn connecting rod to 7. Replace.

journal bearing.

8. Worn crankshaft. 8. Replace.

9. Worn crosshead. 9. Replace.

10. Worn main bearing. 10. Replace.

11. Valve noise transmitted to 11. See Excessive Valve

power end. Noise problem.

12. Cavitation noise transmitted 12. See Cavitation, Fluid

to or causing shock loading in Knock or Hammer problem.
power end.

Excessive Valve Noise. 1. Pump cavitation. 1. See Cavitation, Fluid Knock
or Hammer problem.

2. Seal on inserted valve 2. Replaced seal or valve.

damaged or missing.

3. Broken/weak valve spring(s) 3. Replace spring(s).

Oil Leakage From 1. Worn, damaged or corroded. 1. Replace extension rod.
Stop Head. extension rod.

2. Worn oil stop head seal. 2. Replace seal.

3. Oil level too high. 3. Reduce oil level.

4. Excessive crosshead wear. 4. Replace crosshead.

5. Pressure in crankcase. 5. Clean or replace air breather.

6. Misalignment in front. 6. Loosen bolts and center.

crosshead guide cover

3-1-618 Page 30

PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Oil Seal Leakage. 1. Worn sealing lip. 1. Replace seal.

2. Damaged sealing lip. 2. Replace seal.

3. Outside diameter not seated. 3. Clean and polish bore of

oil seal housing.

4. Shaft rough at seal lip. 4. Clean and polish shaft or

replace wear sleeve.

5. Pressure in crankcase. 5. Clean or replace air breather.

Stuffing Box Leakage. 1. Short plunger/packing life. 1. See Short plunger/Packing
Life problem.

2. Worn packing rings/metal. 2. Replace packing rings/metal.

3. Seal leaking at fluid 3. Check seal, stuffing box

end. groove and sealing surface.

4. Corrosion due to wrong 4. Determine and install correct

stuffing box material stuffing box.

for pumped fluid.

5. Stuffing box bore worn. 5. Replace stuffing box.

Pumped Fluid In 1. Worn, damaged or corroded 1. Replace extension rod.
Crankcase. extension rod.

2. Worn oil stop head seal. 2. Replace seal.

3. Stuffing box leakage. 3. See Stuffing Box Leakage

problem.

Short Valve Life. 1. Abrasives in pumped fluid. 1. Filter pumped product.
Use severe duty valves
with insert.

2. Valve not sealing. 2. Broken valve spring - replace.

Worn valve guide - replace.
Worn valve/seat - replace.

3. Pump cavitating. 3. See Cavitation, Fluid Knock or

Hammer problem.

4. Corrosion. 4. Treat pumped fluid.

Use different materials
for valves/seats.
Install sacrificial anodes
in suction manifold.

3-1-618 Page 31

PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Short Plunger/Packing Life. 1. Abrasives in pumped fluid. 1. Consult Gardner Denver
Customer Service for plunger/
packing recommendation.
Filter pumped fluid.

2. Excessive plunger/packing 2. Lubricate with rock drill oil.

friction. Do not overtighten adjust­ able packing.
Use Gardner Denver plungers.

3. Metal parts or particles 3. Check stuffing box

wearing plunger. alignment.
Check gland alignment.
Check plunger alignment.
Check packing for foreign
particles.
Replace lantern ring.

4. Wrong plunger/packing for 4. Consult Gardner Denver

pumping conditions. Customer Service.

5. Wrong size packing. 5. Install correct size packing.

6. Improper packing installation. 6. Check installation procedure

and install correctly.

7. Excessive crosshead wear. 7. Replace crosshead.

8. Pump cavitating. 8. See Cavitation, Fluid Knock

or Hammer problem.

Catastrophic Failures: 1. Pump overloaded. 1. Reduce pump speed and/or
Broken Shafts, pressure.
Bent Rods, etc.

2. Start-up against closed 2. Insure valve is open

discharge valve. before starting.

3. Main bearing failure. 3. Repair or replace.

4. Plunger striking valve or 4. Check valve condition and

valve parts. installation procedure.

5. Plunger striking cylinder. 5. Check plunger for proper

length.

6. Frozen fluid in cylinder. 6. Do not start pump when

pumped fluid is below freezing
temperature.

7. Lube oil pump failure. 7. Replace oil pump.

3-1-618 Page 32

PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Catastrophic Failures: 8. Low oil level in sump. 8. Check oil level frequently,
Broken Shafts, and add oil as required.
Bent Rods, etc.
(continued). 9. Contaminated oil in sump. 9. Check oil condition
frequently.

10. Cavitation shock loading. 10. See Cavitation, Fluid Knock

or Hammer problem.

Stud Failures. 1. Catastrophic failures. 1. See Catastrophic Failures
problem.

2. Improper nut torquing. 2. Check torque specifications

and torque to correct values.

3. Stud bending due to uneven 3. Check nut seat surface for

nut seating. flatness. Rework or replace
as required.

4. Corrosive attack by pumped 4. Treat fluid or use corrosion

fluid. resistant studs.

5. Studs damaged before 5. Check condition before

installation. installation, and replace if
necessary.

6. Low strength studs. 6. Use Gardner Denver studs.

3-1-618 Page 33

SECTION 6
REBUILDING DATA, RECOMMENDED RUNNING CLEARANCES AND
TORQUES

REBUILDING DATA FOR GD 3000 PUMP (in.)

PUMP STROKE 11 Inches

Crankshaft Throw Diameter............................................... 7.7485/7.7500

Crankshaft Shaft Diameter at Main Bearings..................... 19.000/19.002

Distance Between Main Bearing Centers........................... 14.00

Bore in Frame for Inner Main Bearings.............................. 22.446/22.448

Bore in Frame for Outer Main Bearings ............................ 22.496/22.498

Connecting Rod Centers................................................... 14.0 0

Connecting Rod Bearing Bore (Assembled in

Journal Bearing Housing)............................................ 7.755/7.759

Crosshead Guide Bore (302TLS100)................................. 13.500/13.502

Babbitt Crosshead Guide Bore (303TLS100)..................... 13.557/13.562

Crosshead without Babbitt (302TLS005M)......................... 13.487/13.489

Crosshead with Babbitt (306TLS005) ................................ 13.535/13.540

Wrist Pin........................................................................... 4.494/4.496

Crosshead Wrist Pin Bushing Bore.................................... 5.028/5.029

RECOMMENDED RUNNING CLEARANCES – ACTUAL

New (in.) Maximum Allowable

Wear Limit (in.)

Connecting Rod Bearing to Crankshaft.............................. .005/.011.......................018

Main Bearing Installed Clearance*..................................... .0005/.012.....................019

Main Bearing Bench Clearance*........................................ .015/.018.......................N/A

Crosshead to Guide*......................................................... .011/.026.......................045

Crankshaft Endplay........................................................... .005/.015.......................060

* Feeler gauge clearances .001 inch less than actual values

3-1-618 Page 34

RECOMMENDED TORQUES VALUES FOR GD-3000

_ FOOT POUNDS_________
DESCRIPTION FASTENER WITH LOCTITE WITH ANTISEIZE

Plunger Clamp Bolts……………………………….. 1/2”-13 58

Main Bearing Retainer Bolts............................... ½”-13 58

Thrust Bearing Retainer..................................... 5/8”-11 115

Crosshead Guide to Pump Frame...................... 3/4”-10 200

Crankshaft Bearing to Pump Frame................... 3/4”-10 290

Suction Manifold to Fluid End............................. 7/8” – 9 320

Discharge Flange to Fluid Cylinder Nuts............. 1-1/8” - 12 1080

Gear Reducer to Pump Frame........................... ¾”-10 290

Crosshead (Front to Back Half) .......................... 1”- 14 750

Rod Cap to Rod Fasteners................................. 1”- 14 750

Gearbox Splined Adaptor................................... 1”- 14 750

Stay Rods into Frame ........................................ 2-1/4”-8 200

Cover Lock Hex, Left Hand Bolt......................... 1-1/8”- 7 900

Extension Rod to Crosshead.............................. 3-1/4”-8 1200

3-1-618 Page 35

Product Warranty

BE-13 R 02/2003, Copyright © 2003 Gardner Denver, Inc.

GENERAL PROVISIONS AND LIMITATIONS

Gardner Denver (the "Company") warrants to each original retail purchaser ("Purchaser") of
its new products, assemblies or parts from the Company or its authorized distributors that such
products are, at the time of delivery to the Purchaser, made with good material and
workmanship. No warranty is made with respect to:

1. Any product which has been repaired or altered in such a way, in the Company's
judgment, as to affect the product adversely.

2. Any product which has, in the Company's judgment, been subject to negligence,
accident, or improper storage, improper installation, operation or application. (Examples:
over-pressure, sand-outs, cavitation, corrosion, erosion or degradation).

3. Any product which has not been operated or maintained in accordance with the
recommendations of the Company.

4. Components or accessories manufactured, warranted and serviced by others.

5. Any reconditioned or prior owned product.

Claims for items described in (4) above should be submitted directly to the manufacturer.

WARRANTY PERIOD

The Company's obligation under this warranty is limited to repairing or, at its option,
replacing, during normal business hours at an authorized service facility of the Company, any
part or assembly which in the Company’s judgment proved to have unsatisfactory material or
workmanship within the applicable Warranty Period as follows.

Except for the products or components listed below, and subject to the limitations and
restrictions set forth in the “Disclaimer” section set forth below, the Warranty Period for all
products is 1,250 hours of operation or three (3) months after start-up, not to exceed 120 days
after delivery to Purchaser, whichever occurs first. The exceptions are as follows:

1. Power end is warranted for twelve (12) months from date of start-up or eighteen (18)
months from date of delivery to the Purchaser, whichever occurs first.

2. Forged steel fluid cylinders are warranted for materials and workmanship for 6 months
from the date of installation or 18 months from the date of delivery to the purchaser,
which ever occurs first.

3. Repairs are warranted for 90 days from the date of delivery, for the workmanship and
materials of the new parts installed.

4. Weld repaired fluid ends and weld repaired components are not warranted.

5. Expendable fluid end parts, including, but not limited to, valves, valve parts, packing,
liners and pistons, are not covered by this warranty due to variable abrasive nature of
material pumped.

PRESERVATION ASSEMBLIES DESTINED FOR STORAGE

In order for warranty acceptance any pump assembly not immediately installed or destined to

be in storage or in transit for extended periods of time must be prepared for storage as

defined in

the Company’s Long Term Storage Procedure. This includes but is not limited to:

 Drain and thoroughly clean inside power end crankcase.
 Spray rust inhibiting oil on all bearing, machined and inside surfaces of the power end.
 Induce clean gear oil into any circulating pump, filter, heat exchanger and piping.
 Remove valves, seats and plungers from the fluid end. Thoroughly clean and dry these parts

and all internal surfaces. Coat all cylinder bores, valve covers and reusable expendable parts
with rust preventative.

 Flush all water, and contaminants from pump, tanks, hoses and spray nozzles. Spray all

components with a rust inhibiting oil.

 Rotate pump every 30 days to insure bearings are oiled.
 At the expense of the Purchaser, any product properly preserved must be inspected by an

authorized agent of the Company, prior to the Company, granting any extended warranty
beyond that stated in this warranty.

3-1-618 Page 36

LABOR TRANSPORTATION AND INSPECTION

The Company will provide labor, by Company representative or authorized service personnel, for
repair or replacement of any product or part thereof which in the Company's judgment is proved not to
be as warranted. Labor shall be limited to the amount specified in the Company's labor rate schedule.
Labor costs in excess of the Company rate schedules caused by, but not limited to, location or
inaccessibility of the equipment, or labor provided by unauthorized service personnel is not provided
for by this warranty.

All costs of transportation of product or parts claimed not to be as warranted and, of repaired or
replacement parts to or from such service facility shall be borne by the Purchaser. The Company may
require the return of any part claimed not to be as warranted to one of its facilities as designated by the
Company, transportation prepaid by the Purchaser, to establish a claim under this warranty.

Replacement parts provided under the terms of this warranty are warranted for the remainder of the
Warranty Period of the product upon which installed to the same extent as if such parts were original
components.

The Company may request a root cause analysis be performed in-order to identify if a
request for warranty claim meets the requirements of this warranty.

DISCLAIMER

Except as to title, the foregoing warranty is the sole and exclusive warranty of the Company. The
Company hereby extends other manufactures’ warranty or guaranties, if any given to Company by
such manufacturer, but only to the extent the Company is able to enforce such warranty or guaranties.
The Company has not authorized any party to make any representation or warranty other than as
expressly set forthherein. SELLER HEREBY DISCLAIMS AND EXCLUDES ANY OTHER
EXPRESS, IMPLIED OR STATUTORY WARRANTIES, ARISING BY OPERATION OF LAW OR
OTHERWISE, INCLUDING, WITHOUT LIMITATION, ANY WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. COMPANY MAKES NO
WARRANTIES OR REPRESENTATIONS OF ANY KIND WHATSOEVER (EXPRESS, IMPLIED OR
STATUTORY), OF LAW OR OTHERWISE, ON ANY EQUIPMENT, COMPONENT PARTS OR
ACCESSORIES SOLD HEREUNDER WHICH, ARE NOT MANUFACTURED BY COMPANY.

NOTWITHSTANDING ANYTHING HEREIN TO THE CONTRARY, THE FOREGOING
WARRANTY SHALL BE THE SOLE AND EXCLUSIVE REMEDY AVAILABLE TO THE
PURCHASER. UNDER NO CIRCUMSTANCES, WHETHER IN CONTRACT, TORT OR
OTHERWISE, SHALL THE COMPANY’S TOTAL LIABILITY ARISING IN CONNECTION WITH
ANY PURCHASE ORDER EXCEED THE AMOUNT OF ANY SALES OR OTHER PROCEEDS
RECEIVED PURSUANT THERETO. IN ADDITION, UNDER NO CIRCUMSTANCES, WHETHER
IN CONTRACT, TORT OR OTHERWISE, SHALL THE COMPANY BE LIABLE FOR
LIQUIDATED, SPECIAL, INDIRECT, INCIDENTAL, EXEMPLARY, OR CONSEQUENTIAL
DAMAGES, EXPENSES OR COSTS, INCLUDING, WITHOUT LIMITATION, LOST PROFITS OR
FACILITY DOWNTIME, HOWEVER CAUSED AND EVEN IF THE POTENTIAL OF SUCH
DAMAGES WAS DISCLOSED AND/OR KNOWN.

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No statement, representation, agreement, or understanding, oral or written, made by any agent,
distributor, representative, or employee of the Company which is not contained in this Warranty will be
binding upon the Company unless made in writing and executed by an officer of the Company.

This warranty shall not be effective as to any claim which is not presented within 30 days
after the date upon which the product is claimed not to have been as warranted. Any action for
breach of this warranty must be commenced within one year after the date upon which the cause
of action occurred.

Any adjustment made pursuant to this warranty shall not be construed as an admission by the
Company that any product was not as warranted.

WARRANTY REQUESTS
Products to be returned for warranty analysis shall be approved for return in writing by the

Company prior to shipment. All requests for product return shall be submitted by email.
Facsimile or letter to:

Warranty Department c/o
Gardner Denver Petroleum Pumps
4747 South 83rd East Avenue
Tulsa, Oklahoma 74145

Email:

[e-mail]

Facsimile: [phone]

BE-13 R 02/2003, Copyright © 2003 Gardner Denver, Inc.

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