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: (918) 664-1151 (800) 637-8099
Fax: (918) 664-6225 Fax: (432) 363-9940 Fax: (817) 249-6401
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: (432) 366-5433 (800) 368-1134
Service Center (Ft. Worth)
Geoquip 7533 Kathy Lane Ft. Worth, Texas 76126
Phone: (817) 249-6400 (800) 824-0271
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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.
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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
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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
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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
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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.
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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
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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
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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.
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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.
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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.
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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.
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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,
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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.
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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
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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.
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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.
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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
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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
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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.
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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
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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.
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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.
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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
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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.
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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
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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.
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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
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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.
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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).
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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.
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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).
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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.
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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
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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.
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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.
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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
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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.
3-1-618 Page 37
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:
CCR.QAR@gardnerdenver.com
Facsimile: (918) 664-6225
BE-13 R 02/2003, Copyright © 2003 Gardner Denver, Inc.
3-1-618 Page 38
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